Jaguar X 350 Workshop Manual

Workshop Manual
JagDocs.com
X350 – XJ
2003 to 2009MY
VIN G00442 to VIN H99999
Version 1.7
May 2014
TABLE OF CONTENTS
1 : General Information
100 : Service Information
100-00 : General Information

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Description and Operation

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

Identification Codes - VIN Range: G00442->G45703
Identification Codes - VIN Range: G45704->G99999
100-02 : Jacking and Lifting

Jacking
Jacking - Armoured Vehicles
Lifting
100-04 : Noise, Vibration and Harshness
General Procedures
Exhaust System Neutralizing
Noise, Vibration and Harshness (NVH)
Diagnosis and Testing
2 : Chassis
204 : Suspension
204-00 : Suspension System - General Information
Specifications
Specifications
General Procedures
Camber and Caster Adjustment
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
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Wheel Bearing Inspection

Wheel Alignment Angles
Suspension System
204-01 : Front Suspension
Specifications
Specifications
Front Suspension
Front Suspension - Armoured Vehicles
Front Suspension
Removal and Installation
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 - 3.0L NA V6 - AJ27 (60.10.01)
Front Stabilizer Bar - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (60.10.01)
Front Stabilizer Bar - 2.7L V6 - TdV6 (60.10.01)
Front Stabilizer Bar Link (60.10.02)
Stabilizer Bar Link Bushing (60.10.03)
Upper Arm LH (60.35.41)
Upper Arm RH (60.35.42)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
204-02 : Rear Suspension
Specifications
Specifications
Rear Suspension
Rear Suspension - Armoured Vehicles
Rear Suspension
Lower Arm (64.35.43)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Upper Arm (64.25.31)
Rear Wheel Bearing (64.15.14)
204-04 : Wheels and Tires
Specifications
Specifications
Specifications
Specifications
Wheels and Tires - VIN Range: G00442->G45703
Wheels and Tires - VIN Range: G45704->H18679
Wheels and Tires - VIN Range: H18680->H99999
Wheels and Tires - VIN Range: Armoured Vehicles
Tire Low Pressure Sensor
Tire Pressure Monitoring System (TPMS) Front Antenna
Tire Pressure Monitoring System (TPMS) Module
Tire Pressure Monitoring System (TPMS) Rear Antenna
Wheel and Tire (74.20.05)
Wheel and Tire - Armoured Vehicles (74.20.05)
204-05 : Vehicle Dynamic Suspension
Specifications
Specifications
General Procedures
Air Leaks
Ride Height Adjustments
Vehicle Dynamic Suspension
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Air Suspension Compressor
Air Suspension Control Module (60.32.03)
Air Suspension Reservoir
Air Suspension Solenoid Valve Block
Front Air Spring (60.32.08)
Front Vertical Accelerometer (86.56.53)
Rear Air Spring - VIN Range: G00442->G45703 (60.32.10)
Rear Air Spring - VIN Range: G45704->G99999 (60.32.10)
Rear Air Spring Lower Bushing (64.32.03)
Rear Vertical Accelerometer (86.56.55)
Suspension Height Sensor (60.32.05)
205 : Driveline
205-00 : Driveline System - General Information
General Procedures
Driveline Angle Inspection
Driveline System
Driveline System
205-01 : Driveshaft
Specifications
Specifications
General Procedures
Driveshaft Runout and Balancing
Driveshaft
Driveshaft
Driveshaft (47.15.01)
205-02 : Rear Drive Axle/Differential
Specifications
Specifications
Rear Drive Axle and Differential
Axle Assembly - Vehicles Without: Differential Drain Plug (51.25.13)
Axle Assembly - Vehicles With: Differential Drain Plug (51.25.13)
Axle Housing Bushing (64.25.30)
In Vehicle Repair
Drive Pinion Seal (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

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Specifications
Specifications
Specifications - Armoured Vehicles
General Procedures
Brake Disc Runout Check
Brake System Bleeding - VIN Range: G00442->G45703 (70.25.03)
Brake System Bleeding - VIN Range: G45704->H99999 (70.25.03)
Brake System Bleeding - Armoured Vehicles (70.25.03)
Brake System - VIN Range: G00442->G45703
Brake System - VIN Range: G45704->G99999
Brake System
206-03 : Front Disc Brake
Specifications
Specifications
Specifications
Front Disc Brake - VIN Range: G00442->G45703
Front Disc Brake - VIN Range: G45704->G99999
Front Disc Brake
Front Disc Brake - Armoured Vehicles
Front Disc Brake
Brake Caliper - Vehicles With: Standard Brakes, VIN Range: G00442-
>G45703 (70.55.02)
>G99999 (70.55.02)
Brake Caliper - Vehicles With: High Performance Brakes, VIN Range:
G00442->G45704 (70.55.02)
G45704->G99999 (70.55.02)
Brake Caliper - Armoured Vehicles
Brake Disc - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.10.10)
(70.10.10)
Brake Disc - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.10.10)
>G99999 (70.10.10)
Brake Disc - Armoured Vehicles
Brake Disc Shield - Vehicles With: Standard Brakes (70.10.18)
Brake Disc Shield - Vehicles With: High Performance Brakes (70.10.18)
Brake Pads - Vehicles With: Standard Brakes, VIN Range: G00442->G45703
(70.40.02)
(70.40.02)
Brake Pads - Vehicles With: High Performance Brakes, VIN Range: G00442-
>G45703 (70.40.02)
>G99999 (70.40.02)
Brake Pads - Armoured Vehicles
206-04 : Rear Disc Brake
Specifications
Specifications
Specifications
Rear Disc Brake - VIN Range: G00442->G45703
Rear Disc Brake - VIN Range: G45704->G99999
Rear Disc Brake
Rear Disc Brake - Armoured Vehicles
Rear Disc Brake
>G45703 (70.55.03)
G00442->G45703 (70.55.03)
Brake Caliper - VIN Range: G45704->G99999 (70.55.03)
Brake Caliper - Armoured Vehicles
(70.10.11)
>G45703 (70.10.11)
Brake Disc - VIN Range: G45704->G99999 (70.10.11)
Brake Disc - Armoured Vehicles (70.10.11)
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(70.40.03)
>G45703 (70.40.03)
Brake Pads - VIN Range: G45704->G99999 (70.40.03)
Brake Pads - Armoured Vehicles (70.40.03)
206-05 : Parking Brake and Actuation
Specifications
Specifications
Specifications
General Procedures
Parking Brake Cable Tension Release - VIN Range: G00442->G45703
Parking Brake Cable Tension Release - VIN Range: G45704->G99999
Parking Brake - VIN Range: G00442->G45703
Parking Brake Module - VIN Range: G00442->G45703 (70.35.47)
Parking Brake Module - VIN Range: G45704->G99999 (70.35.47)
Parking Brake Pads - Vehicles With: High Performance Brakes (70.40.04)
Parking Brake Rear Cables
Parking Brake Release Actuator - VIN Range: G00001->G03445 (70.35.45)
Parking Brake Release Actuator - VIN Range: G03446->H99999 (70.35.45)
Parking Brake Switch (70.35.46)
206-06 : Hydraulic Brake Actuation
Specifications
Specifications
Hydraulic Brake Actuation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (70.30.08)
Brake Master Cylinder - 2.7L V6 - TdV6 (70.30.08)
206-07 : Power Brake Actuation
Specifications
Specifications
Brake Booster
Brake Booster
Power Brake System
Brake Booster (70.50.17)
Brake Vacuum Pump
205-05 : Rear Drive Halfshafts
Specifications
Specifications
Anti-Lock Control - Stability Assist - VIN Range: G00442->G45703
Anti-Lock Control - Stability Assist
Anti-Lock Brake System (ABS) Module (70.60.02)
Brake Master Cylinder Pressure Transducer
Brake Pedal Travel Sensor - VIN Range: G00442->G49700
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) - VIN Range: G00442->G45703 (70.60.18)
Hydraulic Control Unit (HCU) - VIN Range: G45704->G99999 (70.60.18)
Rear Wheel Speed Sensor (70.60.04)
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Steering Wheel Rotation Sensor (86.56.58)

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 )
Steering Column Lower Shaft Setting
Power Steering System Flushing (57.15.08)
Steering System
Steering System
211-02 : Power Steering
Specifications
Specifications
Power Steering
Power Steering
Power Steering Control Valve Actuator (57.10.32)
Power Steering Fluid Cooler (57.15.11)
Power Steering Fluid Reservoir - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8 (57.15.08)
Power Steering Fluid Reservoir - 2.7L V6 - TdV6 (57.15.08)
Power Steering Pump - 3.0L NA V6 - AJ27 (57.20.14)
Power Steering Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (57.20.14)
Power Steering Pump - 2.7L V6 - TdV6 (57.20.14)
Steering Gear Bushing (57.10.30)
211-03 : Steering Linkage
Specifications
Specifications
Steering Linkage
Steering Linkage
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.02)
211-04 : Steering Column
Specifications
Specifications
Steering Column
Steering Column
Ignition Switch Lock Cylinder (57.40.29)
Steering Column (57.40.01)
Steering Column Lower Shaft (57.40.05)
Steering Wheel (57.60.01)
Assembly & Disassembly
Steering Column
211-05 : Steering Column Switches

Steering Column Switches
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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 - 3.0L NA V6 - AJ27
Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8/3.5L NA V8 - AJV8
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
Engine
Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA
V8 - AJV8
Engine - 2.7L V6 - TdV6
303-01A : Engine - 3.0L NA V6 - AJ27
Specifications
Specifications
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
Engine
Engine
Removal
Engine (12.41.01)
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Installation
Engine (12.41.01)
In Vehicle Repair
Camshafts LH (12.13.19)
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head (12.29.01)
Engine Front Cover (12.65.01)
Engine Mount (12.45.13)
Exhaust Manifold LH - VIN Range: G004442->G45703 (30.15.55)
Exhaust Manifold LH - VIN Range: G45704->G99999 (30.15.55)
Flexplate (12.53.13)
Intake Manifold (30.15.01)
Lower Intake Manifold (30.15.61)
Oil Cooler (12.60.68)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Disassembly
Engine
Disassembly/Assembly of subassemblies
Piston (12.17.02)
Assembly
Engine
303-01B : Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
Specifications
Specifications
General Procedures
Engine
Engine
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshafts RH - VIN Range: G00442->G45703 (12.13.18)
Camshafts RH - VIN Range: G45704->G99999 (12.13.18)
Crankshaft Front Seal - VIN Range: G00442->G45703 (12.21.14)
Crankshaft Front Seal - VIN Range: G45704->G99999 (12.21.14)
Cylinder Head LH - VIN Range: G00442->G45703 (12.29.02)
Cylinder Head LH - VIN Range: G45704->G99999 (12.29.02)
Engine Front Cover - VIN Range: G00442->G45703 (12.65.01)
Engine Front Cover - VIN Range: G45704->G99999 (12.65.01)
Engine Mount LH (12.45.01)
Engine Mount RH (12.45.03)
Exhaust Manifold RH - VIN Range: G00442->G45703 (30.15.56)
Exhaust Manifold RH - VIN Range: G45704->G99999 (30.15.56)
Intake Manifold - VIN Range: G00442->G45703 (30.15.01)
Intake Manifold - VIN Range: G45704->G99999 (30.15.01)
Oil Cooler - Vehicles With: Supercharger (12.60.68)
Oil Cooler - Vehicles Without: Supercharger (12.60.68)
Oil Pan (12.60.44)
Oil Pan Extension (12.60.48)
Oil Pump - VIN Range: G00442->G45703 (12.60.26)
Oil Pump - VIN Range: G45704->G99999 (12.60.26)
Secondary Timing Chain Tensioner
Timing Drive Components - VIN Range: G00442->G45703 (12.65.13)
Timing Drive Components - VIN Range: G45704->G99999 (12.65.13)
Valve Cover LH - VIN Range: G00442->G45703 (12.29.43)
Valve Cover LH - VIN Range: G45704->G99999 (12.29.43)
Valve Cover RH - VIN Range: G00442->G45703 (12.29.44)
Valve Cover RH - VIN Range: G45704->G99999 (12.29.44)
Disassembly
Engine
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Assembly
Engine
303-01C : Engine - 2.7L V6 - TdV6
Specifications
Specifications
Engine
Engine
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshaft Front Seal
Camshaft Rear Seal
Crankshaft Vibration Damper (12.21.09)
Cylinder Head LH (12.29.02)
Exhaust Manifold LH (30.15.55)
Exhaust Manifold RH (30.15.56)
Oil Filter Element (12.60.02)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Belt
Timing Belt Cover
303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -

AJ27/3.5L NA V8 - AJV8
Specifications
Specifications
General Procedures
Cooling System Backflushing
Cooling System Draining, Filling and Bleeding
Cooling System Draining and Vacuum Filling
Cooling System Flushing
Engine Cooling
Engine Cooling
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud (26.25.25)
Radiator (26.40.01)
Thermostat - 3.0L NA V6 - AJ27 (26.45.07)
Thermostat - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8 (26.45.07)
Thermostat - 4.2L SC V8 - AJV8 (26.45.07)
Water Pump - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703 (26.50.01)
Water Pump - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999 (26.50.01)
Water Pump - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8 (26.50.01)
Water Pump - 4.2L SC V8 - AJV8 (26.50.01)
303-03B : Supercharger Cooling
Specifications
Specifications
General Procedures
Supercharger Cooling System Draining, Filling and Bleeding
Supercharger Cooling
Radiator
Water Pump
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303-03C : Engine Cooling - 2.7L V6 - TdV6
Specifications
Specifications
General Procedures
Cooling System Draining and Vacuum Filling
Engine Cooling
Engine Cooling
Radiator (26.40.01)
Thermostat (26.45.07)
Water Pump (26.50.01)
303-04A : Fuel Charging and Controls - 3.0L NA V6 - AJ27
Specifications
Specifications
Fuel Charging and Controls
Fuel Charging and Controls - VIN Range: G00442->G45703
Fuel Charging Wiring Harness (86.70.22)
Fuel Injectors (18.10.02)
Fuel Injection Supply Manifold (19.60.13)
Throttle Body - VIN Range: G00442->G45703 (19.70.04)
Throttle Body - VIN Range: G45704->G99999 (19.70.04)
303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L

NA V8 - AJV8
Specifications
Specifications
Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G00442->G45703 (19.70.04)
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G00442-
>G45703 (19.70.04)
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G45704-
>G99999 (19.70.04)
303-04C : Fuel Charging and Controls - 2.7L V6 - TdV6
Specifications
General Procedures
Fuel Injection Component Cleaning
Fuel Diverter Rail
Fuel Injection Pump
Fuel Injector (18.10.01)
Fuel Rail
Intake Air Shutoff Throttle
Swirl Plate Actuator Diaphragm
303-04D : Fuel Charging and Controls - Turbocharger - 2.7L V6 - TdV6

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Specifications
Specifications
Turbocharger
Turbocharger
Turbocharger LH
Turbocharger RH
303-05 : Accessory Drive
Specifications
Specifications
Accessory Drive
Accessory Drive - 3.0L/3.5L/4.2L
Accessory Drive - 2.7L Diesel
Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G00442->G45703
(12.10.40)
Accessory Drive Belt - 3.0L NA V6 - AJ27, VIN Range: G45704->G99999
(12.10.40)
Accessory Drive Belt - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -
AJV8 (12.10.40)
Accessory Drive Belt - 2.7L V6 - TdV6 (12.10.40)
Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G00442-
>G45703 (12.10.43)
Accessory Drive Belt Idler Pulley - 3.0L NA V6 - AJ27, VIN Range: G45704-
>G99999 (12.10.43)
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (12.10.43)
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8/4.2L SC V8 -
Accessory Drive Belt Idler Pulley - 2.7L V6 - TdV6 (12.10.43)
Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G00442-
>G45703 (12.10.41)
Accessory Drive Belt Tensioner - 3.0L NA V6 - AJ27, VIN Range: G45704-
>G99999 (12.10.41)
Accessory Drive Belt Tensioner - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (12.10.41)
Accessory Drive Belt Tensioner - 2.7L V6 - TdV6 (12.10.41)
Fuel Injection Pump Belt
Fuel Injection Pump Pulley
Supercharger Belt - VIN Range: G00442->G45703 (18.50.08)
Supercharger Belt - VIN Range: G45704->G99999 (18.50.08)
Supercharger Belt Idler Pulley - VIN Range: G04422->G45703 (18.50.09)
Supercharger Belt Idler Pulley - VIN Range: G45704->G99999 (18.50.09)
Supercharger Belt Tensioner - VIN Range: G00442->G99999 (18.50.24)
303-06 : Starting System
Specifications
Specifications
Starting System
Starting System
Starter Motor - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (86.60.01)
Starter Motor - 2.7L V6 - TdV6 (86.60.01)
303-07A : Engine Ignition - 3.0L NA V6 - AJ27
Specifications
Specifications
Engine Ignition
Engine Ignition - VIN Range: G00442->G45703
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Ignition Coil-On-Plug LH (18.20.44)
Ignition Coil-On-Plug RH (18.20.43)
303-07B : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -

AJV8
Specifications
Specifications
Engine Ignition
Ignition Coil-On-Plug (18.20.40)
303-07C : Glow Plug System
Specifications
Specifications
Glow Plug System
Glow Plug System
Glow Plugs
303-08A : Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L

NA V6 - AJ27/3.5L NA V8 - AJV8
Specifications
Specifications
Specifications
Engine Emission Control - VIN Range: G00442->G45703
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
(17.45.11)
Secondary Air Injection (AIR) Control Valve - 3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve - 4.2L NA V8 - AJV8/3.5L NA V8
- AJV8
Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 - AJV8
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube LH -
3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube RH -
3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -
4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, 4.2L
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube -
4.2L SC V8 - AJV8, 4.2L
Secondary Air Injection (AIR) Pump
303-08B : Engine Emission Control - 2.7L V6 - TdV6
Specifications
Specifications
Engine Emission Control
Crankcase Vent Oil Separator
Exhaust Gas Recirculation (EGR) Valve LH
Exhaust Gas Recirculation (EGR) Valve Outlet Tube (17.45.11)
Exhaust Gas Recirculation (EGR) Valve RH
303-12A : Intake Air Distribution and Filtering - 3.0L NA V6 - AJ27

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Specifications
Specifications
Intake Air Distribution and Filtering
Intake Air Distribution and Filtering - VIN Range: G00442->G45703
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8/4.2L SC V8 -

AJV8/3.5L NA V8 - AJV8
Specifications
Specifications
Charge Air Cooler
Supercharger - VIN Range: G00442->G45703 (18.50.15)
Supercharger - VIN Range: G45704->G99999 (18.50.15)
Supercharger Outlet Pipe (18.50.16)
303-12C : Intake Air Distribution and Filtering - 2.7L V6 - TdV6
Specifications
Specifications
Charge Air Cooler
303-13 : Evaporative Emissions
Specifications
Specifications
Evaporative Emissions - VIN Range: G00442->G45703
Evaporative Emission Canister - VIN Range: G00442->G45703 (17.15.13)
Evaporative Emission Canister - VIN Range: G45704->G99999 (17.15.13)
Evaporative Emission Canister Purge Valve - VIN Range: G00442->G45703
(17.15.30)
Evaporative Emission Canister Purge Valve - 3.0L NA V6 - AJ27, VIN Range:
G45704->G99999 (17.15.30)
Evaporative Emission Canister Purge Valve - 4.2L SC V8 - AJV8/3.5L NA V8
- AJV8, VIN Range: G45171->G99999 (17.15.30)
Evaporative Emission Canister Purge Valve - 4.2L NA V8 - AJV8/3.5L NA V8
- AJV8, VIN Range: G45171->G99999 (17.15.30)
Evaporative Emission Canister Vent Solenoid (17.15.45)
Fuel Tank Pressure Sensor (19.55.31)
303-14A : Electronic Engine Controls - 3.0L NA V6 - AJ27
Specifications
Specifications
General Procedures
Brake Pedal Position (BPP) Switch Adjustment
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Electronic Engine Controls

Electronic Engine Controls - VIN Range: G00442->G45703
Brake Pedal Position (BPP) Switch
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 - VIN Range: G00442->G45703
(18.30.10)
Engine Coolant Temperature (ECT) Sensor - VIN Range: G45704->G99999
(18.30.10)
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Intake Manifold Tuning (IMT) Valve LH (19.70.30)
Knock Sensor (KS) LH (18.30.92)
Knock Sensor (KS) RH (18.30.93)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14B : Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
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)
Engine Coolant Temperature (ECT) Sensor - 4.2L SC V8 - AJV8 (18.30.10)
Engine Coolant Temperature (ECT) Sensor - 4.2L NA V8 - AJV8 (18.30.10)
Intake Air Temperature (IAT) Sensor - 4.2L SC V8 - AJV8 (18.30.52)
Manifold Absolute Pressure (MAP) Sensor - 4.2L SC V8 - AJV8 (18.30.86)
Manifold Absolute Pressure (MAP) Sensor - 4.2L NA V8 - AJV8 (18.30.86)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14C : Electronic Engine Controls - 2.7L V6 - TdV6
Specifications
Specifications
General Procedures
Camshaft Position (CMP) Sensor (18.30.63)
Crankshaft Position (CKP) Sensor Ring
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Exhaust Gas Temperature Sensor
Engine Oil Pressure (EOP) Sensor
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Intake Air Temperature (IAT) Sensor (18.30.52)
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 - 3.0L NA V6 - AJ27 (44.20.01)
Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(44.20.01)
Transmission - 2.7L V6 - TdV6 (44.20.01)
Installation
Transmission - 3.0L NA V6 - AJ27 (44.20.01)
Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(44.20.01)
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
Input Shaft Seal (44.32.07)
307-02 : Transmission/Transaxle Cooling
Specifications
Specifications
Transmission Cooling
Transmission Fluid Cooler - 2.7L V6 - TdV6 (44.24.10)
Transmission Fluid Cooler Tubes - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8 (44.24.19)
Transmission Fluid Cooler Tubes - 2.7L V6 - TdV6 (44.24.19)
307-05 : Automatic Transmission/Transaxle External Controls
Specifications
Specifications
General Procedures
Selector Lever Cable Adjustment (44.15.07)
External Controls
External Controls
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Assembly (44.15.04)
309 : Exhaust System
309-00 : Exhaust System
Specifications
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Specifications
Exhaust System
Exhaust System
Catalytic Converter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (17.50.05)
Catalytic Converter - 2.7L V6 - TdV6 (17.50.05)
Diesel Particulate Filter (DPF)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Exhaust System - 2.7L V6 - TdV6
Front Muffler - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (30.10.18)
Front Muffler - 2.7L V6 - TdV6 (30.10.18)
Muffler and Tailpipe (30.10.52)
310 : Fuel System
310-00 : Fuel System - General Information
Specifications
Specifications
General Procedures
Fuel System Pressure Check
Fuel System Pressure Release - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8 (19.50.02)
Fuel System Pressure Release - 2.7L V6 - TdV6 (19.50.02)
Fuel Tank Draining - VIN Range: G00442->G45703
Fuel Tank Draining - VIN Range: G45704->G99999
High-Pressure Fuel System Bleeding - 2.7L V6 - TdV6
Low-Pressure Fuel System Bleeding - 2.7L V6 - TdV6
Quick Release Coupling
Quick Release Coupling - Push Connect
Spring Lock Couplings
Fuel System - VIN Range: G00442->G45703
Fuel System - VIN Range: G45704->G99999
310-01 : Fuel Tank and Lines
Specifications
Specifications
Fuel Tank and Lines - VIN Range: G00442->G45703
Fuel Tank and Lines - VIN Range: G45704->G99999
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Tank and Lines - 2.7L V6 - TdV6
Fuel Filter - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L
NA V8 - AJV8 (19.25.02)
Fuel Filter - 2.7L V6 - TdV6 (19.25.02)
Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Level Sender LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Level Sender LH - 2.7L V6 - TdV6
Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Level Sender RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Level Sender RH - 2.7L V6 - TdV6
Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (19.45.08)
Fuel Pump Module - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Pump Module - 2.7L V6 - TdV6 (19.45.08)
Fuel Tank - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA
V8 - AJV8 (19.55.01)
Fuel Tank - 2.7L V6 - TdV6 (19.55.01)
Fuel Tank Filler Pipe (19.55.33)
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Fuel Transfer Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -

Fuel Transfer Unit - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel Transfer Unit - 2.7L V6 - TdV6
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
310-02 : Acceleration Control
Specifications
Specifications
Acceleration Control
Acceleration Control
Accelerator Pedal (19.20.01)
310-03 : Speed Control
Specifications
Specifications
General Procedures
Speed Control Module Alignment - VIN Range: G00442->H18679
Speed Control Module Alignment - VIN Range: H18680->H99999
Speed Control - VIN Range: G00442->G45703
Speed Control Deactivator Switch (19.75.20)
Speed Control Module (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)
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Contaminated Refrigerant Handling

Electronic Leak Detection
Fluorescent Dye Leak Detection
Inspection and Assembly Requirements
Manifold Gauge Set Connection
Refrigerant Oil Adding
Refrigerant System Tests
Climate Control System
Climate Control System
412-01 : Air Distribution and Filtering
Specifications
Specifications
Air Distribution and Filtering
Air Distribution and Filtering
Cabin Air Filter (76.10.09)
Center Registers (82.20.38)
Driver Side Register (82.20.39)
Floor Console Register Duct (82.20.37)
Front Footwell Duct LH (82.20.91)
Front Footwell Duct RH (82.20.92)
Passenger Side Register (82.20.40)
Rear Footwell Duct (82.20.96)
412-02A : Heating and Ventilation
Specifications
Specifications
Heating and Ventilation
Heating and Ventilation
Auxiliary Coolant Flow Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (82.25.59)
Auxiliary Coolant Flow Pump - 2.7L V6 - TdV6 (82.25.59)
Blower Motor (82.25.66)
Heater Core (80.20.29)
Heater Core and Evaporator Core Housing (82.25.21)
Heater Hose (80.25.01)
412-02B : Auxiliary Heating
Specifications
Specifications
Fuel Fired Booster Heater
412-03A : Air Conditioning
Specifications
Specifications
Air Conditioning
Air Conditioning
Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:
G00442->G45703 (82.10.20)
Air Conditioning (A/C) Compressor - 3.0L NA V6 - AJ27, VIN Range:
G45704->G99999 (82.10.20)
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8/4.2L SC V8 -
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Air Conditioning (A/C) Compressor - 2.7L V6 - TdV6 (82.10.20)
Condenser Core - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.15.07)
Condenser Core - 2.7L V6 - TdV6 (82.15.07)
Desiccant Bag - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.17.03)
Desiccant Bag - 2.7L V6 - TdV6 (82.17.03)
Pressure Cutoff Switch - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (82.10.32)
Pressure Cutoff Switch - 2.7L V6 - TdV6 (82.10.32)
412-03B : Auxiliary Climate Control
Specifications
Specifications
Auxiliary Climate Control
Auxiliary Climate Control - Armoured Vehicles
Auxiliary Climate Control
Auxiliary Climate Control Assembly
Auxiliary Evaporator Outlet and Inlet Line
Auxiliary Footwell Vent/Duct Blend Door Actuator
Auxiliary Heater Core and Evaporator Core Housing
Auxiliary Temperature Blend Door Actuator
Auxiliary Blower Motor
Auxiliary Blower Motor Resistor
Evaporator Core
Heater Core
Register
412-04 : Control Components
Specifications
Specifications
Control Components
Control Components - VIN Range: H18680->H99999
Control Components
Air Discharge Temperature Sensor (82.20.64)
Ambient Air Temperature Sensor (82.20.02)
Climate Control Assembly (82.20.07)
Cold Air Bypass Blend Door Actuator LH
Cold Air Bypass Blend Door Actuator RH
Defrost Vent/Register Blend Door Actuator LH
Defrost Vent/Register Blend Door Actuator RH
Footwell Vent/Duct Blend Door Actuator LH
Footwell Vent/Duct Blend Door Actuator RH
In-Vehicle Temperature Sensor (82.20.03)
Recirculation Blend Door Actuator (82.20.67)
Sunload Sensor (82.20.70)
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
Indicator Bulb (86.45.61)
Instrument Cluster (88.20.01)
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Instrument Cluster Lens (88.20.28)
413-06 : Horn
Specifications
Specifications
Horn
Horn
Horn (86.30.02)
Horn Switch (86.30.01)
413-07 : Clock

Clock
Clock
Clock (88.15.07)
413-08 : Information and Message Center

Information and Message Center
Information and Message Center
Message Center Switch (86.66.11)
413-09A : Warning Devices
General Procedures
Oil Change Indicator Reset
Warning Devices
Warning Devices - Armoured Vehicles
Engine Protection System - Armoured Vehicles
Warning Devices
413-13 : Parking Aid

Parking Aid
Parking Aid
Front Parking Aid Speaker (86.54.18)
Parking Aid Module - VIN Range: G00442->G45703 (86.80.39)
Parking Aid Module - VIN Range: G45704->G99999 (86.80.39)
Parking Aid Sensor (86.62.01)
Rear Parking Aid Speaker (86.54.19)
414 : Battery and Charging System
414-00 : Charging System - General Information
General Procedures
Battery Charging
Charging System
Charging System
Charging System - 2.7L V6 - TdV6
414-01 : Battery, Mounting and Cables

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Specifications
Specifications
General Procedures
Battery Connect (86.15.15)
Battery Disconnect and Connect
Battery and Cables
Battery
Battery (86.15.01)
Battery Ground Cable (86.15.19)
Battery Tray (86.15.11)
414-02 : Generator and Regulator
Specifications
Specifications
Generator
Generator
Generator - 3.0L NA V6 - AJ27 (86.10.02)
Generator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(86.10.02)
Generator - 2.7L V6 - TdV6 (86.10.02)
415 : Information and Entertainment Systems
415-00 : Information and Entertainment System - General Information [page

403]
General Procedures
Cassette Player Cleaning
Audio System
415-01 : Audio Unit
Specifications
Specifications
Audio System
Audio System - VIN Range: H18680->H99999
Audio System
Audio System
Amplifier (86.50.10)
Audio Unit (86.50.03)
Compact Disc (CD) Changer (86.50.06)
Steering Wheel Audio Controls (86.50.42)
415-02 : Antenna
Antenna
Antenna
Antenna Isolator Module (86.51.08)
415-03 : Speakers

Speakers
Speakers
Speakers
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Front Door Speaker (86.50.13)

Front Door Tweeter Speaker (86.50.63)
Instrument Panel Speaker
Rear Door Speaker (86.50.14)
Rear Door Tweeter Speaker (86.50.62)
Subwoofer Speaker (86.51.05)
415-07 : Video System
Specifications
Specifications
Video System
Video System
Digital Versatile Disc (DVD) Player
Rear Passenger Entertainment Control Panel
Video Display
Video System Module
417 : Lighting
417-01 : Exterior Lighting
Specifications
Specifications
General Procedures
Headlamp Adjustment (86.40.18)
Exterior Lighting
Exterior Lighting - VIN Range: H18680->H99999
Exterior Lighting - Armoured Vehicles
Headlamps
Approach Lamp - VIN Range: G00442->H18679
Approach Lamp - VIN Range: H18680->H99999
Ballast - Vehicles With: High Intensity Discharge Headlamps (86.41.52)
Front Fog Lamp - VIN Range: G00442->H18679 (86.40.96)
Fog Lamp - VIN Range: H18680->H99999
Headlamp Assembly (86.41.33)
Headlamp Bulb - Vehicles With: High Intensity Discharge Headlamps
(86.42.14)
Headlamp Leveling Motor (86.42.04)
Headlamp Leveling Sensor (86.42.15)
High Mounted Stoplamp (86.41.01)
Stoplamp Switch
Rear Lamp Assembly (86.40.70)
417-02 : Interior Lighting

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

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

Communications Network
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418-01 : Module Configuration

Module Configuration
419 : Electronic Feature Group
419-01A : Anti-Theft - Active

Anti-Theft - Active
Anti-Theft - Active
Anti-Theft Alarm Horn (86.52.03)
419-01B : Anti-Theft - Passive
General Procedures
Anti-Theft Security Access
Key Programming Using Diagnostic Equipment
Key Programming Using Two Programmed Keys
Anti-Theft - Passive
Anti-Theft - Passive
Passive Anti-Theft System (PATS) Transceiver (86.52.30)
419-02 : Remote Convenience
General Procedures
Universal Transmitter Programming
Universal Transmitter
Universal Transmitter
419-07 : Navigation System

Navigation System
Navigation System
Navigation System Antenna - VIN Range: G00442->H18679 (86.62.06)
Navigation System Antenna - VIN Range: H18680->H99999 (86.62.06)
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05)
419-08 : Cellular Phone

Cellular Phone - VIN Range: G00442->G45703
Cellular Phone - VIN Range: G45704->H18679
Cellular Phone - VIN Range: H18680->H99999
Cellular Phone
Cellular Phone - Vehicles With: Bluetooth
Bluetooth Module
Cellular Phone Antenna - Vehicles With: Corded Cellular Phone, VIN
Range: G00442->H18679 (86.51.17)
Cellular Phone Antenna - Vehicles With: Cordless Cellular Phone, VIN
Range: G00442->H18679 (86.51.17)
Cellular Phone Antenna - VIN Range: H18680->H99999 (86.51.17)
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Front Handset Holder

Transceiver Module
419-10 : Multifunction Electronic Modules
Specifications
Specifications
Module Controlled Functions
Multifunction Electronic Module
Driver Door Module (DDM) (86.80.29)
Driver Seat Module (DSM) (86.75.28)
Front Electronic Module (FEM) (86.80.41)
Multifunction Voice Activated Module (86.53.13)
Rear Electronic Module (REM) (86.80.37)
Rear Seat Module (RSM) (86.75.40)
5 : Body and Paint
501 : Body and Paint
501-02 : Front End Body Panels

Front End Body Panels
Air Deflector (76.11.41)
Cowl Vent Screen (76.10.01)
Fender Splash Shield (76.10.90)
Radiator Grille Opening Panel (76.10.06)
Radiator Splash Shield (76.22.90)
Secondary Bulkhead Center Panel
501-03 : Body Closures
Specifications
Specifications
General Procedures
Hood Alignment (76.16.02)
Luggage Compartment Lid Alignment (76.19.03)
Rear Door Alignment (76.28.08)
Body Closures
Front Door Opening Weatherstrip (76.40.01)
Hood (76.16.01)
Door Check Arm - Armoured Vehicle
501-05 : Interior Trim and Ornamentation
Specifications
Specifications
Interior Trim
A-Pillar Trim Panel (76.13.31)
B-Pillar Lower Trim Panel (76.13.29)
B-Pillar Upper Trim Panel (76.13.28)
Cowl Side Trim Panel (76.13.30)
C-Pillar Lower Trim Panel
C-Pillar Upper Trim Panel
Folding Tray (76.47.31)
Front Door Trim Panel (76.34.01)
Front Door Trim Panel - Armoured Vehicles (76.34.01)
Headliner (76.64.01)
Parcel Shelf (76.67.06)
Rear Door Quarter Window Blind
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Rear Door Trim Panel (76.34.04)

Rear Door Trim Panel - Armoured Vehicles (76.34.04)
Rear Door Window Blind
Rear Window Blind (76.14.04)
Rear Window Blind Arm
Rear Window Blind Motor
Scuff Plate Trim Panel (76.13.81)
Sun Visor (76.10.48)
501-08 : Exterior Trim and Ornamentation

Exterior Trim
Door Moulding (76.43.72)
Luggage Compartment Lid Moulding - VIN Range: G00442->H18679
(76.43.79)
Luggage Compartment Lid Moulding - VIN Range: H18680->H99999
(76.43.79)
Radiator Grille (76.55.03)
Rocker Panel Moulding (76.11.36)
Window Moulding (76.43.20)
501-09 : Rear View Mirrors
Specifications
Specifications
Rear View Mirrors
Rear View Mirrors - VIN Range: H18680->H99999
Rear View Mirrors
Auto-Dimming Interior Mirror (76.10.56)
Exterior Mirror (76.10.52)
Exterior Mirror Cover (76.10.55)
Exterior Mirror Glass (76.10.53)
Exterior Mirror Motor - VIN Range: G00442->H18679 (76.10.57)
Exterior Mirror Motor - VIN Range: H18680->H99999 (76.10.57)
501-10 : Seating
Specifications
Specifications
Seats - VIN Range: G00442->H18679
Seats - VIN Range: H18680->H99999
Seats - VIN Range: G00442->H18679
Seats - VIN Range: H18680->H99999
Front Seat (76.70.01)
Front Seat Backrest - VIN Range: G00442->H18679 (76.70.06)
Front Seat Backrest - VIN Range: H18680->H99999 (76.70.06)
Front Seat Backrest Cover - VIN Range: G00442->H18679 (76.70.15)
Front Seat Backrest Cover - VIN Range: H18680->H99999 (76.70.15)
Front Seat Backrest Heater and Blower Assembly
Front Seat Backrest Rear Cover - VIN Range: G00442->H18679 (76.70.03)
Front Seat Backrest Rear Cover - VIN Range: H18680->H99999 (76.70.03)
Front Seat Control Switch (86.75.46)
Front Seat Cushion Cover - VIN Range: G00442->H18679 (76.70.33)
Front Seat Cushion Cover - VIN Range: H18680->H99999 (76.70.33)
Front Seat Cushion Heater and Blower Assembly
Front Seat Head Restraint - Vehicles With: Head Restraint Video Display,
VIN Range: G00442->H18679 (76.70.14)
Front Seat Head Restraint - Vehicles With: Head Restraint Video Display,
VIN Range: H18680->H99999 (76.70.14)
Front Seat Head Restraint Motor - VIN Range: G00442->H18679
(86.75.17)
Front Seat Head Restraint Motor - VIN Range: H18680->H99999
(86.75.17)
Front Seat Height Adjustment Motor (86.75.29)
Front Seat Lumbar Motor (86.75.44)
Front Seat Rear Height Adjustment Motor (86.75.32)
Front Seat Recliner Motor - VIN Range: G00442->H18679 (86.75.04)
Front Seat Recliner Motor - VIN Range: H18680->H99999 (86.75.04)
Front Seat Track Motor (86.75.33)
Lumbar Assembly (86.75.12)
Memory Seat Position Switch
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Rear Outer Seat Backrest (76.70.76)

Rear Outer Seat Backrest Cover (76.70.51)
Rear Outer Seat Cushion (76.70.44)
Rear Seat Armrest (76.70.39)
Rear Seat Backrest (76.70.38)
Rear Seat Backrest Cover (76.70.48)
Rear Seat Control Switch (86.75.42)
Rear Seat Cushion (76.70.37)
Rear Seat Cushion Cover (76.70.47)
Rear Seat Head Restraint Motor (86.75.41)
Rear Seat Lumbar Motor (86.75.43)
Seat Armrest (76.70.97)
Seat Base (76.70.08)
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
Glass, Frames and Mechanisms
Glass, Frames and Mechanisms - Armoured Vehicles
Glass, Frames and Mechanisms
Front Door Window Glass (76.31.01)
Front Door Window Regulator and Motor (86.25.04)
Front Door Window Regulator and Motor - Armoured Vehicles (86.25.04)
Rear Door Fixed Window Glass
Rear Door Window Glass (76.31.02)
Rear Door Window Glass - Armoured Vehicles (76.31.02)
Rear Door Window Regulator and Motor (86.25.09)
Rear Window Glass (76.81.11)
Rear Window Glass - Armoured Vehicles (76.81.11)
Window Control Switch (86.25.08)
Windshield Glass (76.81.40)
Windshield Glass - Armoured Vehicles (76.81.40)
501-12 : Instrument Panel and Console
Specifications
Specifications
Instrument Panel
Floor Console - Vehicles With: Auxiliary Climate Control (76.25.01)
Floor Console - Vehicles Without: Auxiliary Climate Control (76.25.01)
Glove Compartment (76.52.03)
Instrument Panel (76.46.01)
Instrument Panel Console (88.20.34)
Overhead Console (76.13.69)
501-14 : Handles, Locks, Latches and Entry Systems
Specifications
Specifications
General Procedures
Remote Transmitter Programming
Handles, Locks, Latches and Entry Systems
Locks, Latches and Entry Systems
Exterior Door Handle (76.58.07)
Front Door Lock Actuator (76.37.74)
Front Door Lock Cylinder (76.37.71)
Interior Door Handle (76.37.31)
Luggage Compartment Lid Latch Actuator - VIN Range: G00442->H18679
(76.19.25)
Luggage Compartment Lid Latch Actuator - VIN Range: H18680->H99999
(76.19.25)
Luggage Compartment Lid Lock Cylinder - VIN Range: G00442->H18679
(76.19.19)
Luggage Compartment Lid Lock Cylinder - VIN Range: H18680->H99999
(76.19.19)
Rear Door Lock Actuator (76.37.09)
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501-16 : Wipers and Washers
Specifications
Specifications
Specifications
Wipers and Washers - VIN Range: G00442->G45703
Wipers and Washers - VIN Range: G45704->G99999
Wipers and Washers
Headlamp Washer Jet (84.20.08)
Headlamp Washer Pump - VIN Range: G00442->G45703 (84.20.21)
Headlamp Washer Pump - VIN Range: G45704->G99999 (84.20.21)
Rain Sensor (84.12.10)
Windshield Washer Pump - VIN Range: G00442->G45703 (84.10.21)
Windshield Washer Pump - VIN Range: G45704->G99999 (84.10.21)
Windshield Washer Reservoir - VIN Range: G00442->G45703 (84.10.01)
Windshield Washer Reservoir - VIN Range: G45704->G99999 (84.10.01)
Windshield Wiper Motor (84.15.13)
Wiper Mounting Arm and Pivot Shaft (84.15.24)
Wiper Pivot Arm (84.15.03)
501-17 : Roof Opening Panel
Specifications
Specifications
General Procedures
Motor Synchronization (76.82.48)
Roof Opening Panel Alignment
Roof Opening Panel
Roof Opening Panel
Roof Opening Panel Frame (76.82.01)
Roof Opening Panel Front Drain Hose (76.82.21)
Roof Opening Panel Glass (76.82.05)
Roof Opening Panel Motor (86.76.01)
Roof Opening Panel Weatherstrip (76.82.15)
Trough Assembly (76.82.58)
501-19 : Bumpers
Specifications
Specifications
Bumpers
Front Bumper (76.22.08)
Front Bumper Cover - VIN Range: G00442->H18679 (76.22.78)
Front Bumper Cover - VIN Range: H18680->H99999 (76.22.78)
Front Bumper Cover Insert (76.22.73)
Rear Bumper (76.22.27)
Rear Bumper Cover - VIN Range: G00442->H18679 (76.22.74)
Rear Bumper Cover - VIN Range: H18680->H99999 (76.22.74)
Rear Bumper Cover Insert (76.22.75)
501-20A : Safety Belt System
Specifications
Specifications
Safety Belt System
Safety Belt System
Front Safety Belt Buckle (76.73.49)
Front Safety Belt Retractor (76.73.10)
Front Safety Belt Shoulder Height Adjuster (76.73.12)
Rear Center Safety Belt Retractor (76.73.20)
Rear Safety Belt Buckle (76.73.50)
Rear Safety Belt Retractor (76.73.18)
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501-20B : Supplemental Restraint System
Specifications
Specifications
General Procedures
Air Bag Disposal
Air Bag Supplemental Restraint System (SRS)
Air Bag Supplemental Restraint System (SRS)
B-Pillar Side Impact Sensor (76.73.68)
Clockspring (86.65.92)
C-Pillar Side Impact Sensor (76.73.69)
Crash Sensor (76.73.55)
Driver Air Bag Module (76.73.39)
Front Passenger Seat Occupant Classification Sensor (76.73.60)
Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)
Passenger Air Bag Module (76.73.37)
Restraints Control Module (RCM) (76.73.48)
Seat Position Sensor (76.73.62)
Side Air Bag Module (76.73.47)
Side Air Curtain Module (76.73.64)
502 : Frame and Mounting
502-00 : Uni-Body, Subframe and Mounting System
Specifications
Specifications
Frame Assembly
Front Subframe - 3.0L NA V6 - AJ27 (76.10.05)
Front Subframe - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(76.10.05)
Front Subframe - 2.7L V6 - TdV6 (76.10.05)
Front Subframe Front Bushing (60.35.51)
Front Subframe Rear Bushing (60.35.26)
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
About This Manual

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Notes, Cautions and Warnings

Throughout this manual, important information is highlighted by the use of notes, cautions
and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are
given to prevent damage to the vehicle, and WARNINGS are given to prevent personal
injury.
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 fitting of replacement parts
and accessories:
• Safety features embodied in the vehicle may be impaired if other than genuine parts are
fitted. In certain territories, legislation prohibits the fitting 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 fitted. 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 fitted location on the vehicle conform to mandatory requirements existing in their
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country of origin.
• The vehicle warranty may be invalidated by the fitting 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). It is not necessary to disconnect or remove
electronic control modules.
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. 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.
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Restart the clock (where fitted) and set it to the correct time.
Re - 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 may cause a driveability concern if the procedure is
not carried out. This will allow the ECM to relearn idle values.
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 flat 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 normal 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 from the vehicle that had the discharged battery, 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 alternator to restore a discharged battery. For an alternator 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
•
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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 fitted. 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 make sure that
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 oilways, 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, oilways and fluid
passages with compressed air. 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 refitted 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 part may be refitted 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 which 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.
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The manual covers the following OBD topics:
• General Information
• Engine Management System
• Automatic Transmission
• Anti-lock Braking System
Each section comprises one or more of the following sub-sections as required.
The Description and Operation sub-section includes:
• A general illustration and parts list to help the identification of the particular system or
component.
• A brief description of the system operating characteristics and monitoring procedure
accompanied by a component illustration.
• Additional information, where appropriate, is provided in the form of component
calibrations, characteristics and cross sectional views.
• A localized circuit diagram is included to provide circuit identification, connectors, splices,
fuses, wire gauge and colors. See Circuit Diagrams.
The Diagnosis and Testing sub-section is dedicated to fault analysis and rectification, and includes:
• Recommended special tools.

• Symptom chart; a chart containing all relevant Diagnostic Trouble Codes (DTC), their possible
causes and an indication of the appropriate test.
• Specific pinpoint test(s), designed so that fault diagnosis can be carried out in a logical and
efficient manner.
The Removal and Installation sub-section covers:
• Removal procedure(s), formatted in the recommended sequence.

• Illustrated guide to the use of special tools.
• Illustrations to support the relevant text.
• Installation procedure as above and including special recommendations for processes,
lubricants and tightening torques.
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 Definition

/ Abbreviation
Accelerator Pedal AP
Is a multitrack sensor which inputs the

Accelerator Pedal
APP drivers demand into the engine control
Position Sensor
module (ECM)
After Bottom Dead

ABDC Event occurring after BDC
Center
After Top Dead

ATDC Event occurring after TDC
Center
Airbag /
Airbag restraint system for driver and
Supplementary Airbag, SRS
front seat passenger
Restraint System
Air Cleaner ACL

Air Conditioning A/C
Air Conditioning Module controlling air conditioning,

A/CCM
Control Module heating and ventilation
Air conditioning compressor clutch

Air Conditioning operation is signalled to the ECM which
ACS
Signal induces idle speed corrections to
compensate for engine load changes
Alternating current ac
Air Fuel Ratio AFR Nominally 14.7 parts air to one part fuel
Ampere A SI unit of current
Ampere hour Ah
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System which prevents wheel lock-up

ABS Control under braking by sensing lack of
ABS CM
Module rotation of a wheel(s) and diverting fluid
pressure away from it (them)
System which prevents wheel lock-up

ABS / Traction
under braking by sensing lack of
Control Control ABS/TCCM
rotation of a wheel(s) and diverting fluid
Module
pressure away from it (them)
Atmosphere atm Unit of pressure (1.01325 bar)
Barometric Sensor measuring the pressure of

Absolute Pressure BARO Sensor surrounding air at any given
Sensor temperature and altitude
Battery positive The positive voltage from a battery or

B+
voltage any circuit connected directly to it
Before Bottom
BBDC Event occurring before BDC
Dead Center
Before Top Dead BTDC Event (usually ignition) occurring before

Center TDC
Device which supplies a current of air at

Blower BLR moderate pressure, e.g. heater or A/C
blower
Control module for body electrical

Body Processor
BPM systems, e.g. interior lamps, windshield
Module
wash / wipe control
Bottom Dead Lowest point of piston travel in a

BDC
Center reciprocating engine
Effective horsepower developed by an

Brake horsepower BHP engine or motor, as measured by a
brake applied to its output shaft
The part of the effective pressure

Brake Mean developed in a cylinder that would result
BMEP
Effective Pressure in a cylinder output equal to the bhp of
the engine
Brake On/Off BOO Indicates the position of the brake pedal
Standard specification issued by the

British Standard BS
British Standards Institution
British Standard
BSau
Automotive
Topology of a
Bus communication
network
Bypass Air BPA Mechanical control of throttle bypass air
Camshaft Position
CMP Sensor Indicates camshaft position
Sensor
Canadian Motor CMVSS

Vehicle Safety
Standard
Canister Purge CANP Controls purging of the EVAP canister
Colorless gas with a density of

Carbon dioxide CO2
approximately 1.5 times that of air
Poisonous gas produced as the result

Carbon monoxide CO
of incomplete combustion
Case Ground CSE GND Control module casing ground
In-line exhaust system device used to

Catalytic converter reduce the level of engine exhaust
emissions
SI term for the Centigrade scale, with

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Celsius C freezing point at zero and boiling point

at 100 degrees
The section of a computer that contains

the arithmetic, logic and control circuits.
Central Processor It performs arithmetic operations,
CPU
Unit controls instruction processing, and
provides timing signals and other
housekeeping operations
Cylinder Head
A sensor for measuring the temperature
Temperature CHT Sensor
of the cylinder head
Sensor
Closed Loop CL
Closed Loop Control system with one or more

CL System
System feedback loops
A self-contained group of electrical

Column/Mirror /electronic components, designed as a
C/MCM
Control Module single replaceable unit, and controlling
one or more processes
Controller Area A communication system which allows
CAN
Network control modules to be linked together.
Generates crankshaft position

Crankshaft Position information in conjunction with the
CKP Sensor
Sensor CKPTR (also generates speed
information in certain applications)
System which scavenges camshaft

Crankcase
CV cover and crankcase emissions and
Ventilation System
feeds them into the inlet manifold
Cubic centimeter cm³
Weight of vehicle with fuel, lubricants

Curb weight and coolant, but excluding driver,
passengers or payload
Connector providing access and/or

Data Link control of the vehicle information,
DLC
Connector operating conditions, and diagnostic
information
Circuit that sends certain information

Data Output Line DOL
from the ECM to the instrument cluster
Degree deg, ° Angle or temperature
Department of Which is a fibre optic ring network, can

Transportation DOT be diagnosed through the SCP network,
(US) and with the optical bus tester.
Deutsche Institut
DIN German standards regulation body
fur Normung
Supplemental Restraint System (non -

Diagnostic Module DM controlling) module for diagnostics
overview
Diagnostic Test A level of capability in an OBD system.

DTM May include different functional states
Mode
to observe signals, a base level to read
DTCs, a monitor level which includes
information on signal levels, bi-
directional control with on/off board
aids, and the ability to interface with
remote diagnosis
An alpha/numeric identifier for a fault

Diagnostic Trouble
DTC condition identified by the On-Board
Code
Diagnostic (OBD) system
Pressure difference between two

Differential
regions e.g. between intake manifold
pressure
and atmospheric pressures
Differential An EGR system that monitors

Pressure Feedback DPFE differential EGR pressure across a
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EGR remote orifice to control EGR flow
Current which flows in one direction

Direct current dc only, though it may have appreciable
pulsations in its magnitude
Domestic Data Bus D2B
Exhaust Gas
Recirculation Sensing EGR function based on
EGRT
Temperature temperature change
Sensor
The engine management system

Engine conditions and reads inputs, supplies
Management EMS processing capability, and provides
System output drivers to control actuators as
directed by software and calibration
Engine Oil
EOP
Pressure
EGR Vacuum Controls EGR flow by changing vacuum

EVR
Regulator to the EGR valve
EGR Valve An EGR system that directly monitors
EVP
Position EGR valve position to control EGR flow
Electrically
Erasable
EEPROM
Programmable
Read-Only Memory
Electrically
Programmable EPROM
Read-Only memory
Electronic
A pump-driven system for providing
Secondary Air EAIR
secondary air using an electric air pump
Injection
Engine Control
ECM
Module
Engine Coolant
ECL
Level
Engine Coolant
ECT
Temperature
Thermistor which provides engine

coolant temperature signal to the ECM
ECT Sensor ECTS to trigger enrichment circuits which
increase injector 'on' time for cold start
and warm-up
Engine speed RPM
Environmental
EPA
Protection Agency
System designed to prevent fuel vapor

Evaporative from escaping into the atmosphere.
EVAP
Emission Typically includes a charcoal filled
canister to absorb fuel vapor
Evaporative
Emission Control EVAPP
Valve
System which reduces NOx emissions

Exhaust Gas
EGR by adding exhaust gases to the
Recirculation
incoming fuel/air charge
Exhaust Gas
Recirculation
EGRS
Solenoid Vacuum
Valve
Exhaust Gas
Recirculation
EGRT Sensor
Temperature
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Sensor
Exhaust Gas
EGR Valve
Recirculation Valve
Fan Control FC Engine cooling fan control
Federal Motor
Vehicle Safety FMVSS
Standard (US)
Figure Fig. Illustration reference
Flash Electrically
Erasable
FEEPROM
Programmable
Read-Only Memory
Flash Erasable
Programmable FEPROM
Read-Only Memory
Sensor mounted so as to be triggered

Flywheel Sensor CKFS by each flywheel ring gear tooth to give
an engine speed signal
Solenoid operated devices that spray a
Fuel Injection FI metered quantity of fuel into the inlet
ports
Controls fuel pressure regulator; used

Fuel Pressure
FPRC primarily to give extra fuel at cold start-
Regulator Control
up
Pumps fuel from the fuel tank to the fuel

Fuel Pump FP
injection system
Fuel Pump Monitor FP Module Monitors operation of fuel pump
Relay which controls electrical current

Fuel Pump Relay FP Relay
to fuel pump
Qualitative evaluation of air/fuel ratio

Fuel rich/lean based on a ratio known as
stoichiometry,or 14.7:1 (Lambda)
Generic Electronic
GEM
Module
Rotating machine which converts

Generator GEN mechanical energy into electrical
energy
Gramme
gcm
centimeter
Gramme (force) gf
Gramme (mass) g
Electrical conductor used as a common

Ground GND return for an electrical circuit or circuits,
and with a relative zero potential
Hard fault A fault currently present in the system
Headlamp HL
Heated Oxygen Electrically heated oxygen sensor which
HO2S
Sensor induces fueling corrections
Hertz (frequency) Hz Frequency, one cycle per second
High Mounted
HMSL
Stoplamp
High tension HT
Hour hour
Hydrocarbon HC
Stepper motor driven device which

varies the volume of air by-passing the
Idle Air Control IAC
throttle to maintain the programmed idle
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speed
Device which amplifies the ignition

Ignition amplifier IA
system output
Ignition ground IGN GND
Injection Pressure
IPS
Sensor
An inertia system that shuts off the fuel

Inertia Fuel Shut- supply when activated by pre-
IFS
off determined force limits brought about
by (e.g.) collision
Inertia Fuel Shut- Shuts down fuel and ignition systems in

IFS Switch
off Switch the event of a vehicle impact
Air drawn through a cleaner and

Intake air distributed to each cylinder for use in
combustion
Intake Air
IAT Temperature of intake air
Temperature
Intake Air
Temperature IAT Sensor Device used to measure IAT
Sensor
Intake Air Thermistor which signals the ECM to

IAT Sensor
Temperature retard the ignition timing in response to
Ignition
Sensor Ignition high inlet air temperatures
Intake Air
IAT Sensor Thermistor which inputs air density
Temperature
Injection information to the ECM
Sensor Injection
Internal diameter i.dia
International
Standards ISO
Organisation
Kilogramme (mass) kg
Kilogramme (force) kgf
Kilogramme force
per square kgf/cm²
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
Left-hand LH
Left-hand drive LHD

vehicle
Left-hand thread LHthd
Optical digital display system, applied

Liquid Crystal voltage to which varies the way the
LCD
Display crystals reflect light, thereby modifying
the display
Litre L
Primary circuit of the ignition system,

Low Tension LT linking the battery to the primary
winding in the ignition coil
A required on-board indicator to alert

Malfunction
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MIL the driver of an emission related

Indicator Lamp
malfunction
Manifold Absolute Absolute pressure of the intake

MAP
Pressure manifold air
Manifold Absolute Sensor located in the ECM and ported

MAP Sensor
Pressure Sensor to the intake manifold
Manifold Surface
MST
Temperature
System which provides information on

Mass Air Flow MAF the mass flow rate of the intake air to
the engine
Hot-wire sensor which monitors air flow

Mass Air Flow
MAF Sensor into the intake manifold for fueling and
Sensor
ignition control
Maximum max.
Meter
m
(measurement)
Metric (screw
M
thread, e.g. M8)
Unit of electrical capacitance, one

Microfarad MFD
millionth of a farad
Millimeter mm
Millimeter of
mmHg
mercury
Millisecond ms
Minimum min.
Minute minute
Model year MY
Device which constantly samples cabin

temperature by passing air over a
Motorized In-Car
MIA sensor, and communicates with the
Aspirator
A/CCM to modify A/C system
performance to suit
Multi Protocol An interpreter for the various data

MPA
Adapter languages present on a vehicle
National Institute of
Occupational
NIOSH
Safety and Health
(US)
SI unit of force. 1 N = 0.2248 pounds

Newton N
force
SI unit of torque. Must not be confused

Newton Meter Nm
with nm (nanometer)
Nox Compounds of nitrogen and oxygen

formed at high temperatures. Major
source of exhaust-gas air pollution
Non-Volatile
RAM which retains memory even if
Random Access NVRAM
power supply is interrupted
Memory
Fueling system using intake air at

Normally aspirated N/A atmospheric pressure; not
supercharged or turbocharged
Normally Closed NC
Normally Open NO
North American Vehicles for sale in the USA and

NAS
Specification Canadian markets
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Number No.
Occupational
Safety and Health OSHA
Administration (US)
A system that monitors some or all

computer input and output control
On-Board
OBD signals. Signal(s) outside the pre-
Diagnostic
determined limits imply a fault in the
system or a related system
Original Equipment
OEM
Manufacturer
Outside Diameter o. dia
Oxides of nitrogen Nox
A sensor which detects oxygen content

Oxygen Sensor O2S
in the exhaust gases
Parameter An index number referring to a

PID
Identification parameter within a module without
knowledge of its storage location
Park Neutral
PNP
Position
Park Neutral Indicates the selected non-drive modes

PNP Switch
Position Switch of the (automatic) transmission
Part number part no.
Pulse Width
PWM
Modulated
Process whereby a common ECM is

Programmable
programmed on the production line to
Electronic Control PECUS
suit the market requirements of a
Units System
particular vehicle
Programmable ROM with some provision for setting the

PROM
Read-only Memory stored data after manufacture
Random Access Fast access memory store which is

RAM
Memory accessible for entry or extraction of data
Fast access memory in which data is

Read-Only Memory ROM
fixed and may not be changed
Container, usually for oils, coolants or

Reservoir RES
hydraulic fluids
Rest Of The World ROW
Return RTN A dedicated sensor ground circuit
Revolutions Per Shaft speed of a device, usually an

RPM
Minute engine or motor
Right-hand RH
Right-hand drive RHD
Scan Tool ST Device that interfaces with and

communicates information on a data
link
Module controlling the seat motor

Seat Control
SCM systems (not electric raise/lower-only
Module
seats)
Secondary Air Air provided to the exhaust system
System used for a period of time each

time the engine is started, unless
certain temperature criteria are met.
Pumps air directly into the exhaust
Secondary Air AIR
system which generates extra heat and
reduces the time taken for the catalytic
converters to reach operating
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temperature
Secondary Air
AIR Bypass Vents secondary air to atmosphere
Injection Bypass
Secondary Air Valve which prevents back-flow of

Injection Check AIR Check Valve exhaust gas to the AIR system when
Valve the system is inoperative
Secondary Air Diverts secondary air to either the

AIR Diverter
Injection Diverter catalyst or exhaust manifold
Secondary Air
Injection Magnetic AIR Clutch Clutch mounted on the AIRP drive shaft
Clutch
Secondary Air Mechanically driven rotary vane pump,

AIR Pump
Injection Pump driven through the AIRPC
Secondary Air Controls the injection of air into the

AIR Relay
Injection Relay exhaust system
Secondary Air
AIR Switching Vacuum operated valve backing-up the
Injection Switching
Valve AIRC
Valve
Security & Locking Module controlling the vehicle's security
SLCM
Control Module and closure-locking functions
Generic name for a device that senses

either the absolute value or a change in
a physical quantity such as
Sensor S
temperature, pressure or flow rate, and
converts that change into an electrical
quantity signal
Number generated by Jaguar Methods

& Techniques system which relates to
Service Repair the time allowed to complete a repair
Operation SRO operation. Further information on the
(number) system can be found in the separate
Jaguar Publications (for each model
range) entitled 'Repair Operation Times'
Controls shifting in an automatic

Shift Solenoid SS
transmission
Signal return SIG RTN
Sliding Roof
SRCM
Control Module
Society of
Automotive SAE
Engineers
Speed Control Module controlling Speed Control

SCCM
Control Module System
Square centimeter cm²
Standard std
A high-speed, serial communications

Standard system linking all body system control
SCP
Corporate Protocol modules. Control messages and data
are passed between modules at up to
786 messages per second
An intake system which utilizes a

supercharger (mechanically driven
device that pressurizes intake air,
Supercharger SC
thereby increasing density of charge air
and the consequent power output from
a given displacement)
Supercharger
SCB
Bypass
A circuit that provides input for an

Tachometer TACH
electronic tachometer display
Thermal Vacuum Controls vacuum levels or routing

TVV
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Valve based on temperature
Throttle Body TB Device containing the throttle
Throttle Position TP
Interprets throttle position and

Throttle Position
TP Sensor movement to identify idle, acceleration
Sensor
and full-power demands
Throttle Manifold Combines the inlet air temperature and

Absolute Pressure TMAP manifold pressure sensor in one
Sensor component
Top Dead Center TDC
Torque Converter
TCC
Clutch
Transmission Controls the shifting pattern of the

TCM
Control Module (automatic) transmission
Transmission Modifies the operation of electronically

TCS
Control Switch controlled transmissions
Transmission Oil Indicates temperature of transmission
TOT
Temperature fluid
Transmission The range in which the transmission is

TR
Range operating
Indicates rotational speed of

Turbine Shaft
TSS transmission output shaft or turbine
Speed
shaft
Vacuum Solenoid Vacuum operated valve used in the

VSV
Valve speed control system
Vacuum Solenoid Vacuum atmospheric valve used in the

VSV(VA)
Valve (atm) speed control system
Vacuum Solenoid Vacuum release valve used in the

VSV(VR)
Valve (rel) speed control system
Vacuum Solenoid Vacuum valve used in the speed control

VSV(VV)
Valve (vac) system
A system by which the relationship of

Variable Valve
VVT the crankshaft and camshaft may be
Timing
altered during engine running
Provides electrical power to the Jaguar

Vehicle Battery
VBA approved diagnostic system and
Adapter
supplies a battery reference level
Vehicle Control Instrument panel display which warns of

VCM
Monitor faults
Vehicle Emission
Control Information VECI Label
Label
Vehicle Number assigned to the vehicle by the

Identification VIN manufacturer, primarily for licensing and
Number identification purposes
Extends the Jaguar approved
Vehicle Interface diagnostic system capability and
VIA
Adapter provides a parallel interface to vehicle
harnesses and ECMs
Vehicle Speed Sensor which provides vehicle speed

VSS
Sensor information
Viscosity Index VI
Device which regulates the variable

Voltage Regulator VR
output voltage of a generator
Watt W SI unit of power (1 hp = 745.7 watts)
Wide Open Throttle WOT Full throttle position

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Health and Safety Precautions
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer. Washing facilities and
adequate means of skin protection should be provided.
Observe these recommendations:
• Wear protective clothing, including impervious gloves where practicable.

• Do not put oily rags in pockets. Avoid contaminating clothes, particularly underwear,
with oil.
• Overalls must be cleaned regularly. Discard oil impregnated clothing and footwear
which cannot be washed or cleaned.
• First Aid treatment should be obtained immediately for open cuts or wounds.
• Use barrier creams, applying before each work period, to enable easier removal of
dirty oil and grease from the skin.
• Wash with soap and water to make sure that all oil is removed (skin cleaner and a nail
brush will help). The use of preparations containing lanolin will help to replace the
natural skin oils which have been removed.
• Do not use petrol, kerosene, gas oil, thinners or solvents for washing skin.
• If skin disorders develop, obtain medical advice immediately.
• Where practical, degrease components prior to handling.
• Where there is a risk of fluids coming into contact with the eyes, eye protection should
be worn, for example, goggles or a face shield. An eye wash facility should be
provided.
The Health and Safety Precautions subsection refers to some commonly used chemicals and
materials, hazards associated with their use, and safety measures to be taken. Some of these
chemicals may be included in the following list either in their own right or as an ingredient in
a sealer or adhesive.
Acids and Alkalis

See also Battery Acids.
e.g. caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron,
gloves and goggles. Do not breath mists.
Ensure access to eye wash bottles, shower and soap are readily available for splashing
accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials - General
Highly flammable, explosive – observe No Smoking policy.
Used as a safety restraint system mounted in the steering wheel.
The inflator contains a high - energetic propellant which, when ignited, produces a VERY
HOT GAS (2500º C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the
module and is completely consumed during deployment. No attempt should be made to open
an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator
is ruptured, full protective clothing should be worn when dealing with the spillage.
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After normal deployment, gloves and safety goggles should be worn during the handling
process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations
at an approved chemical waste site.
Following any direct contact with gas generant.
• Wash affected areas thoroughly with water.

• Seek medical assistance if necessary.
Air Bags - Do's
• Do store in an airbag safe when not fitted to the vehicle.

• Do store modules in an upright position.
• Do keep modules dry.
• Do carry modules with the cover side pointing away from the body.
• Do place modules with their cover side upwards.
• Do carefully inspect modules for damage.
• Do stand to one side when connecting modules.
• Do make sure all test equipment is properly calibrated and maintained.
• Do wash you hands after handling deployed air bags.
Air Bags - Do Nots
• Do not store highly flammable material together with modules or gas generators.
• Do not store gas generators at temperatures exceeding 80º C.
• Do not store modules upside down.
• Do not attempt to open a gas generator housing.
• Do not expose gas generators to open flame or sources of heat.
• Do not place anything on top of a module cover.
• Do not use damaged modules.
• Do not touch a fired module or gas generator for at least 10 minutes.
• Do not use any electrical probes on the wiring circuit.
Air Conditioning Refrigerant

See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water
immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not
be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots

• Do not expose refrigerant bottles to sunlight or heat.
• Do not stand refrigerant bottles upright; when filling, hold them with the valve
downwards.
• Do not expose refrigerant bottles to frost.
• Do not drop refrigerant bottles.
• Do not vent refrigerant to atmosphere under any circumstance.
• Do not mix refrigerants i.e. R12 (Freon) and R134a.
Antifreeze
See also Fire, Solvents.
e.g. isopropanol, ethylene glycol, methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these
vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed can be fatal and medical attention should be sought immediately.
These products must not be used in any cooling or industrial water system which is connected
or linked to general, food preparation or drinking water supplies.
Asbestos
Used in brake and clutch linings, transmission brake bands and gaskets. Jaguar original
production and replacement items are asbestos free.
See also Warning Symbols on Vehicles at the end of this subsection.
Breathing asbestos dust may cause lung damage or, in some cases, cancer.
The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.
Asbestos dust waste should be dampened, placed in a sealed container and marked to make
sure safe disposal. If any cutting or drilling is attempted on materials containing asbestos the
item should be dampened and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
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Gases released during charging are explosive. Never use naked flames or allow sparks near
charging or recently charged batteries.
Ensure adequate ventilation.
Brake and Clutch Linings and Pads

See Asbestos.
Brakes Fluids (Polyalkylene Glycols)

See also Fire.
Splashes to the skin and eyes may cause irritation. Avoid skin and eye contact as far as
possible. Inhalation vapor hazards do not arise at ambient temperatures because of the very
low vapor pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored
and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable
and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly

experienced or permanent; cumulative; superficial; life threatening; or may reduce life -
expectancy.
Chemical Materials - Do's

• Do carefully read and observe hazard and precaution warnings given on material
containers (labels) and in any accompanying leaflets, posters or other instructions.
Material health and safety data sheets can be obtained from manufacturers.
• Do remove chemical materials from the skin and clothing as soon as practical after
soiling. Change heavily soiled clothing and have it cleaned.
• Do organise work practices and protective clothing to avoid soiling of the skin and
eyes, breathing vapors, aerosols, dusts or fumes, inadequate container labelling fire
and explosion hazards.
• Do wash before breaks, before eating, smoking, drinking or using toilet facilities when
handling chemical materials.
• Do keep work areas clean, uncluttered and free of spills.
• Do store chemical materials according to national and local regulations.
• Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots

• Do not mix chemical materials except under the manufacturer's instructions; some
chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes
or become explosive when mixed together.
• Do not spray chemical materials, particularly those based on solvents, in confined
spaces e.g. when people are inside a vehicle.
• Do not apply heat or flame to chemical materials except under the manufacturer's
instructions. Some are highly flammable and some may release toxic or harmful
fumes.
• Do not leave containers open. Fumes given off can build up to toxic, harmful or
explosive concentrations. Some fumes are heavier than air and will accumulate in
confined areas, pits etc.
• Do not transfer chemical materials to unlabeled containers.
• Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and
fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed
through the skin in toxic or harmful quantities.
• Do not use emptied containers for other materials except when they have been cleaned
under supervised conditions.
• Do not sniff or smell chemical materials. Brief exposure to high concentrations of
fumes can be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that CFCs and Halons are depleting the upper
ozone layer which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet
radiation may result in increases in skin cancer, cataracts and immune system suppression in
humans, as well as decreased productivity of crops and aquatic systems.
CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Jaguar supports worldwide elimination of CFC usage and it is recommended that Company
subsidiaries and affiliates should phase out CFC usage as soon as acceptable substitutes are
commercially available.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads

See Asbestos.
Corrosion Protection Materials

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See also Solvents, Fire.
Highly flammable, flammable – observe No Smoking policy.
These materials are varied and the manufacturer's instructions should be followed. They may
contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided.
They should only be sprayed in conditions of adequate ventilation and not in confined spaces.
Cutting
See Welding.
Dewaxing
See Solvents and Fuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory
protection if ventilation is inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits
and/or sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition.
Ensure that electrical equipment is maintained in good condition and frequently tested. Faulty
equipment should be labelled and preferably removed from the work station.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise
damaged.
Ensure that electrical equipment and flexes do not come into contact with water.
Ensure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The
results could be fatal.
Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Ensure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
• Switch off the power supply before approaching the victim.

• If this is not possible push or drag the victim from the source of electricity using dry
non - conductive material.
• Commence resuscitation if trained to do so.
• SUMMON MEDICAL ASSISTANCE.
Engine Oils
See Lubricants and Grease.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only
under conditions of adequate exhaust extraction or general ventilation and not in confined
spaces.
Gasolene (petrol) engine

There may not be adequate warning of odour or of irritation before toxic or harmful effects
arise. These may be immediate or delayed.
Fibre Insulation
See also Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a
physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of
work practices and the use of gloves.
Fire
See also Welding, Foams, Legal Aspects.
Many of the materials found on or associated with the repair of vehicles are highly
flammable. Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes.
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Ensure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air
immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the
container or label. Do not induce vomiting unless this action is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves
and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or

histories of allergic diseases should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and
may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate
ventilation and respiratory protection. Do not remove the respirator immediately after
spraying, wait until the vapor/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful
fumes. Smoking, naked flames or the use of electrical equipment during foaming operations
and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams or
partially cured foams should be conducted with extraction ventilation.
Freon
See Air Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin
with soap and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation and absorption from the stomach can
result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration
of liquid into the lungs e.g. through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated
contact. Liquid in the eye causes severe pain.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation,
and the concentration of gasoline vapors must be kept very low. High concentrations will
cause eye, nose and throat irritation, nausea, headache, depression and symptoms of
drunkenness. Very high concentrations will result in rapid loss of consciousness.
Ensure there is adequate ventilation when handling and using gasoline. Great care must be
taken to avoid the serious consequences of inhalation in the event of vapor build up arising
from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First
Aid.
Gas - oil (Diesel Fuel)

See warnings and cautions in relevant manual sections.
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin
disorders including skin cancer.
Kerosene (Paraffin)
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Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from
swallowing arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be
slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to
mists and vapors from kerosene at elevated temperature should be avoided (mists may arise in
dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at
pressures of up to 13.790 kPa, (2000 lb/in2) and great care should be taken in handling these
cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of
each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources
of ignition.
Only trained personnel should undertake work involving gas cylinders.

Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
See Viton.
General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct
safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed.
Never over – load equipment such as hoists, jacks, axle and chassis stands or lifting slings.
Damage caused by overloading is not always immediately apparent and may result in a fatal
failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such
as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause
serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment.
Ensure adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment

See also Lubricants and Greases.
Always keep high pressure equipment in good condition, and regularly maintained,
particularly at joints and unions.
Never direct a high pressure nozzle, e.g. diesel injector, at the skin as the fluid may penetrate
to the under - lying tissue etc., and cause serious injury.
Halon
See CFCs.
Legal Aspects
Many laws and regulations make requirements relating to health and safety in the use and
disposal of materials and equipment in workshops. Some of these laws which apply in the
U.K. are listed. Similar laws exist for other territories:
• The Factories Act (1961).

• The Asbestos Regulations (1969).
• Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972).
• Control of Pollution Act (1974).
• Health and Safety at Work Act (1974).
• The Classification, Packaging and Labelling of Dangerous Substances Regulations
(1978, 1981, 1983, 1984).
• Control of Lead at Work Regulations (1980).
• Control of Substances Hazardous to Health (COSHH) Regulations (1989).
• Abrasive Wheels Regulations (1970).
• Reporting of injuries, diseases and dangerous occurrences regulations 1985
(RIDDOR).
Workshops should be familiar, in detail, with these and associated laws and regulations.
Consult the local factory inspectorate if in any doubt.

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Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Used Engine Oil

Prolonged and repeated contact with mineral oil will result in the removal of natural oils from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer. Adequate means of skin
protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin
contact is likely to occur.
There are publications describing the problems and advising on precautionary measures. For
the UK a typical Health and Safety Executive publication is: SHW 397: Cautionary Notice:
Effects of mineral oil on the skin.
Health Protection Precautions

• Avoid prolonged and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including impervious gloves where practicable.
• Do not put oily rags into pockets.
• Avoid contaminating clothing.
• Heavily soiled clothing and oil - impregnated footwear should not be worn. Overalls
must be cleaned regularly.
• First Aid treatment should be obtained immediately for open cuts and wounds.
• Use barrier creams, applying them before each work period, to help the removal of oil
from the skin.
• Wash with soap and water to make sure all oil is removed (skin cleansers and nail
brushes will help). Preparations containing lanoline replace the natural skin oils which
have been removed.
• Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or
solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without delay.
• Where practical, degrease components prior to handling.
• Where there is a risk of eye contact, eye protection should be worn, for example,
chemical goggles or face shields; in addition an eye wash facility should be provided.
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units
of approved design. In the UK the heating system must meet the requirements of HM
Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the
appropriate local authority and/or manufacturer of approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or
licensed waste disposal sites, or to the waste oil reclamation trade, batterys should also be
disposed off under similar arrangments. If in doubt, contact the relevant local authority for
advice on disposal facilities.
It is illegal to pour used oil, antifreeze and automatic transmission fluid on to the ground,
down sewers, drains, or into water courses.
Noise
Some operations may produce high noise levels which could, in time, damage hearing. In
these cases, suitable ear protection must be worn.
Noise Insulation Materials

See Foams, Fibre Insulation.
0-Rings (Fluoroelastomer)
See Viton.
Paints
See also body and paint manual.
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No Smoking policy

Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test Equipment.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder application does not normally give rise to
toxic lead fumes, provided a gas/air flame is used. Oxy - acetylene flames should not be used,
as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease
etc. and inhalation of these should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is
not produced, which can give toxic effects if inhaled. Respiratory protection may be
necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air
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contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or
inhalation of solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene), Fire.
e.g. acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following
repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful
quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for
which there might not be adequate warning indications, can cause more serious toxic or
harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if
necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep
containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction
ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load e.g. suspended engine, etc.
Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are
adequate and suitable for the job, in good condition and regularly maintained.
Transmission Brake Bands

See Asbestos.
Underseal
See Corrosion Protection.
Viton
In common with many other manufacturers' vehicles, some components fitted to the Jaguar
range have 'O' rings, seals or gaskets which contain a material known as 'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is

commonly used for 'O' rings, gaskets and seals of all types. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are
exposed to temperatures in excess of 400º C, the material will not burn, but will decompose,
and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.
'O' rings, seals or gaskets which have been exposed to very high temperatures will appear
charred or as a black sticky substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been
used in the affected 'O' ring, seal or gasket. If they are of natural rubber or nitrile there is no
hazard. If in doubt, be cautious and assume that the material may be Viton or any
fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be
decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area
washed down using wire wool and a limewater (calcium hydroxide) solution to neutralize the
acid before disposing of the decomposed Viton residue and final cleaning of the area. After
use, the plastic gloves should be discarded carefully and safely.
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Welding
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas
Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes
and skin must be protected.
Arc Welding
This process emits a high level of ultra - violet radiation which may cause arc - eye and skin
burns to the operator and to other persons nearby. Gas - shielded welding processes are
particularly hazardous in this respect. Personal protection must be worn, and screens used to
shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY

SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves
which dry out the fluid between the lens and the eye. This may result in blindness when the
lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the
rods and from any applied coatings or contamination on the surfaces being worked on. These
gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction
ventilation to remove the fumes from the working area may be necessary particularly in cases
where the general ventilation is poor, or where considerable welding work is anticipated. In
extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed
respirators may be necessary.
Gas Welding (and Cutting)

Oxy - acetylene torches may be used for welding and cutting, and special care must be taken
to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra - violet emission is much
less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from
coatings on the work, particularly during cutting away of damaged body parts, and inhalation
of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe
hazard may arise if brazing rods containing cadmium are used. In this event particular care
must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING

TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE
MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and
persons carrying out service or repair operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the
warnings.
1 . Components or assemblies displaying the warning triangle and open book symbol advise
consultation of the relevant section of the owners handbook before touching or attempting
adjustments of any kind.
2 . Components or assemblies displaying the warning triangle with the electrified arrow and
open book symbol give warning of inherent high voltages. Never touch these with the engine
running or the ignition switched on. See Electric Shock in this subsection.
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3 . Jaguar vehicles and replacement parts which contain asbestos are identified by this
symbol. See Asbestos in this subsection.
4 . Components or assemblies displaying this symbol give warning that the component
contains a corrosive substance. See Acids and Alkalis in this subsection.
5 . Vehicles displaying the caution circle with a deleted lighted match symbol, caution against
the use of naked lights or flames within the immediate vicinity due to the presence of highly
flammable or explosive liquids or vapors. See Fire in this subsection.
6 . All vehicles fitted with the passenger air bag from the factory have a warning sticker
attached to the instrument panel, prohibiting the use of rear facing child seats in the front
seating position. Failure to follow this instructions may result in personal injury.
White Spirit
See Solvents.
Safety Precautions
WARNING: Working on the fuel system results in fuel and fuel vapor being
present in the atmosphere. Fuel vapor is extremely flammable, hence great care must be
taken whilst working on the fuel system. Adhere strictly to the following precautions:
• Do not smoke in the work area.

• Display 'no smoking' signs around the area.
• Disconnect the battery before working on the fuel system.
• Do not connect/disconnect electrical circuits, use electrical equipment or other
tools or engage in working practices which in any way may result in the
production of sparks.
• Ensure that a CO2 fire extinguisher is close at hand.
• Ensure that dry sand is available to soak up any fuel spillage.
• Empty fuel using suitable fire proof equipment into an authorized explosion
proof container.
• Do not empty fuel while working in a workshop or a pit.
• Ensure that working area is well ventilated.
• Ensure that any work on the fuel system is only carried out by experienced and
well qualified maintenance personnel.
• Ensure that fume extraction equipment is used where appropriate.
WARNING: Fume extraction equipment must be in operation when solvents are

used e.g. Trichloroethane, white spirit, sbp3, methylene chloride, perchlorethylene. Do
not smoke in the vicinity of volatile degreasing agents.
Whenever possible, use a ramp or pit whilst working beneath a vehicle, in preference to
jacking. Position chocks at the wheels as well as applying the parking brake. Never rely on a
jack alone to support a vehicle. Use axle stands, or blocks carefully placed at the jacking
points, to provide a rigid location. Check that any lifting equipment used has adequate
capacity and is fully serviceable. Ensure that a suitable form of fire extinguisher is
conveniently located. When using electrical tools and equipment, inspect the power lead for
damage and check that it is properly earthed. Disconnect the earth (grounded) terminal of the
vehicle battery. Do not disconnect any pipes of the air conditioning refrigeration system
unless you are trained and instructed to do so. A refrigerant is used which can cause blindness
if allowed to come into contact with the eyes. Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
Adhere strictly to handling and safety instructions given on containers and labels. Keep oils
and solvents away from naked flames and other sources of ignition. Do not apply heat in an
attempt to free seized nuts or fittings; as well as causing damage to protective coatings, there
is a risk of damage from stray heat to electronic equipment and brake lines. Do not leave
tools, equipment, spilt oil etc. around the work area. Wear protective overalls and use barrier
cream when necessary.
Environmental Protection
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In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into
water courses. The burning of used engine oil in small space heaters or boilers is not
recommended unless emission control equipment is fitted. Dispose of used oil through
authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil
reclamation trade. If in doubt, contact the Local Authority for advice on disposal facilities.
How To Use This Manual
Copyright Statement
Copyright.© Jaguar Cars Ltd. 1999
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 of Jaguar Cars Ltd., Customer Service Department, Browns
Lane, Coventry, CV5 9DR, England.
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 covers air conditioning, which is part of the climate
control system.
The first digit of the section number indicates the group. 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.
The last two digits of the section number indicate the part of the system covered by the
section.
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.
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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 overleaf.
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

NOTE:
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 handbrake is applied.

• The gear lever is in neutral.
• All instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check:
• Ignition controlled warning lights come on.

• Engine temperature gauge registers a reading compatible with the engine temperature.
• Fuel gauge registers a reading appropriate to the fuel level in the tank.
• The operation of the handbrake warning light and fluid level warning indicator light.
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.
• Clutch pedal operation is not stiff or heavy.

• Initial gear engagement is smooth and there is no evidence of clutch drag.
• Handbrake control operates smoothly and the handbrake releases quickly and
completely.
• Clutch takes up the drive smoothly, without slip or judder.
• The engine power output is satisfactory, full power is achieved, acceleration is smooth
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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 where fitted, 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
(where fitted) register the correct readings or operate correctly.
• Switches and controls operate smoothly and positively, warning or indicator lights
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 overtightness 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.
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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
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• 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 - VIN Range: G00442-

>G45703
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 Part Number Description

1 — VIN plate
2 — Bar code label (America)
3 — Vehicle identification label (Europe/rest of the world shown)
Vehicle Identification Number (Typical)
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1 — World manufacturer identifier
2 — Market, air bag specification
3 — Transmission and steering code
4 — Body code
5 — Emission control system
6 — Check digit
7 — Model year
8 — Assembly plant, model line
9 — Production sequence number
World Manufacturer Identifier

VIN Positions 1, 2 and 3
Codes Manufacturer Make Type
SAJ Jaguar Cars Limited, England Jaguar Passenger Car
Market, Air Bag Specification
VIN position 4
VIN Description
code
Rest of the world with twin air bags, side air bags and curtain air bags (from
A
2002.5my)
D USA with twin air bags, side air bags and curtain air bags (from 2002.5my)
F Canada with twin air bags, side air bags and curtain air bags (from 2002.5my)
Transmission, Steering Code

VIN Position 5
VIN Code Description
A Automatic LHS
B Manual LHS
C Automatic RHS
D Manual RHS
Body Code
VIN Position 6 and 7
83 X350 LWB 4 door saloon - XJ
84 X350 LWB 4 door saloon - SE
85 X350 LWB 4 door saloon - XJR/Sport
86 X350 LWB 4 door saloon - Daimler/VDP/SV8
Engine Emission System

VIN Position 8
N 3.0L Normally aspirated with evaporative emissions
P 3.5L Normally aspirated with stage 3 evaporative emissions
R 4.2L Normally aspirated with stage 3 evaporative emissions
S 4.2L Supercharged with stage 3 evaporative emissions
Check Digit
VIN Position 9
0 - 9 or X Calculated in accordance with American standard CFR part 565
Model Year
VIN Position 10
1 2001 model year
2 2002 model year
3 2003 model year
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Assembly Plant and Model Line

VIN Position 11
R Browns Lane 3.5L
S Browns Lane 4.2L
T Browns Lane 4.2L S/C
V Browns Lane 3.0L
Production Sequence Number

VIN Position 12 through 17
Sequence Number
L00001 - L99999
M00001 - M99999
N00001 - N99999
P00001 - P99999
R00001 - R99999
G00001 - G99999
Vehicle Identification Label
The vehicle certification label also contains a 17 character vehicle identification number. This
number is used for warranty identification of the vehicle. Refer to V.I.N coding chart/manual
for full list of code representations.
Vehicle Certification Number (Europe and Rest of the

world)
Part
Item Description
Number
Whole Vehicle Type Approval (WVTA) number printed here when
1 —
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 Identification Label (North America)
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6 — Type
8 — Paint code
Vehicle Identification Label (Saudi Arabia and Gulf
States)

1 — Date of manufacturer
4 — Paint code
Vehicle Identification Label (Canada)

6 — Paint code
8 — Type
Automatic Transmission Number

The serial number of the transmission unit is displayed on a metal label or bar code (where
equipped) attached to the transmission casing.
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Engine Number (V6)

The engine number is contained on a bar code label on the front cover and is also stamped in
the cylinder block casting on the left hand side of the engine below the engine mounting.
Engine Number (V8)

The serial number is stamped on an engine web on the left hand side of the cylinder block
behind the engine mounting. The emission code is also located here, on the transmission
flange.
Identification Codes - VIN Range: G45704-
>G99999
Vehicle Identification Number (VIN)
The official Vehicle Identification Number (VIN) for title and registration purposes is
stamped on a metal plate and fastened to the instrument panel. It is positioned close on the
left-hand side of the vehicle and is visible from the outside.
The VIN is also located on the vehicle certification label.

1 — VIN plate
2 — Bar code label (USA)
3 — VIN label (Europe/Rest of World shown)
Vehicle Identification Number (Typical)
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1 — World manufacturer identifier
2 — Market, air bag specification
3 — Transmission and steering code
4 — Body code
5 — Emission control system
6 — Check digit
7 — Model year
8 — Assembly plant, model line
9 — Production sequence number
World Manufacturer Identifier

VIN Positions 1, 2 and 3
Codes Manufacturer Make Type
SAJ Jaguar Cars Limited, England Jaguar Passenger Car
Market, Air Bag Specification
VIN position 4
VIN code Description

A/C Rest of World with twin air bags, side air bags and curtain air bags
K/L Japan with twin air bags, side air bags and curtain air bags
W USA with twin air bags, side air bags and curtain air bags
X Canada with twin air bags, side air bags and curtain air bags
Y Mexico with twin air bags, side air bags and curtain air bags
Transmission, Steering Code

VIN Position 5
A Automatic LHS
C Automatic RHS
Body Code
VIN Position 6 and 7
71 X350 SWB 5 seats - XJ
72 X350 SWB 5 seats - SE/Executive/Pack
73 X350 SWB 5 seats - XJR/Sport
74 X350 SWB 5 seats - Super V8/Daimler/VDP
75 X350 SWB 4 seats - XJ
76 X350 SWB 4 seats - SE/Executive/Pack
77 X350 SWB 4 seats - XJR/Sport
78 X350 SWB 4 seats - Super V8/Daimler/VDP
79 X350 LWB 5 seats - XJ
80 X350 LWB 5 seats - SE/Executive/Pack
82 X350 LWB 5 seats - Super V8/Daimler/VDP
83 X350 LWB 4 seats - XJ
84 X350 LWB 4 seats - SE/Executive/Pack
86 X350 LWB 4 seats - Super V8/Daimler/VDP
87 X350 SWB 5 seats - Sovereign
88 X350 SWB 4 seats - Sovereign
89 X350 LWB 5 seats - Sovereign
90 X350 LWB 4 seats - Sovereign
91 X350 LWB 4 seats - Armoured
Engine Emission System

VIN Position 8
NOTE:
*2 Includes the following markets; Austria, Belgium, Cyprus, Czech Rep, Denmark,
Estonia, Finland, France, Germany, Greece, Holland, Hungary, Italy, Latvia, Lithuania,
Luxembourg, Malta, Norway, Poland, Rep. of Ireland, Slovenia, Slovakia, Spain (incl.
Canary Islands) and UK.
VIN Engine Market

Code
Argentina, Chilie, Dominican Rep, Guatamala, Middle East,
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D 3.0L
Panama, Phillipines and Taiwan
E 3.5L
F 4.2L
4.2L
K
Supercharged
N/A 2.7L Diesel
D 3.0L China
N/A 3.5L
F 4.2L
4.2L
N/A
Supercharged
N/A 2.7L Diesel
East Europe*2, EU*2, Israel, Morrocco, Norway, Russia*2,
M 3.0L
Switzerland and Turkey
N 3.5L
P 4.2L
4.2L
R
Supercharged
1 2.7L Diesel
W and U 3.0L Brazil
N/A 3.5L
X 4.2L
4.2L
V
Supercharged
N/A 2.7L Diesel
S and T 3.0L Egypt and Syria
T 3.5L
U 4.2L
4.2L
V
Supercharged
N/A 2.7L Diesel
S and T 3.0L Korea
T 3.5L
B 4.2L
4.2L
V
Supercharged
N/A 2.7L Diesel
H and M 3.0L Japan
J 3.5L
K 4.2L
4.2L
L and R
Supercharged
N/A 2.7L Diesel
N/A 3.0L USA
N/A 3.5L
B and C 4.2L
4.2L
C
Supercharged
N/A 2.7L Diesel
N/A 3.0L Canada
N/A 3.5L
B 4.2L
4.2L
C
Supercharged
N/A 2.7L Diesel
N/A 3.0L Mexico
N/A 3.5L
H 4.2L
4.2L
L
Supercharged
N/A 2.7L Diesel
D 3.0L Indonisia, Malaysia, Singapore, Sri Lanka and Thailand
E 3.5L
F 4.2L
4.2L
G
Supercharged
N/A 2.7L Diesel
H and M 3.0L Austrailia, Hong Kong and New Zealand
J 3.5L
K 4.2L
4.2L
L
Supercharged
N/A 2.7L Diesel
S and T 3.0L South Africa
T 3.5L
U 4.2L
4.2L
V
Supercharged
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N/A 2.7L Diesel

M 3.0L Cyprus, Malta and UK (and Eire)
N 3.5L
P 4.2L
4.2L
R
Supercharged
1 2.7L Diesel
Check Digit
VIN Position 9
0 - 9 or X Calculated in accordance with American standard CFR part 565
Model Year
VIN Position 10
6 2006 model year
Assembly Plant and Model Line
VIN Position 11
R Browns Lane 3.5L
S Browns Lane 4.2L
T Browns Lane 4.2L S/C
V Browns Lane 3.0L
7 Castle Bromwich 2.7L Diesel
A Castle Bromwich 3.0L
C Castle Bromwich 3.5L
D Castle Bromwich 4.2L
E Castle Bromwich 4.2L S/C
Production Sequence Number

VIN Position 12 through 17
Sequence Number
G45704 - G99999
VIN Label
VIN Label (Europe and Rest of world)
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1 — Whole Vehicle Type Approval (WVTA)
2 — VIN
4 — Gross train weight
9 — Paint code
VIN Label (North America)

5 — VIN
6 — Type
8 — Paint code
VIN Label (Saudi Arabia and Gulf States)
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2 — VIN
4 — Paint code
VIN Label (Canada)

5 — VIN
6 — Paint code
8 — Type
VIN Label (China)

1 — VIN
3 — Occupant number
4 — Gross vehicle weight/Gross train weight
5 — Engine specification
6 — Vehicle type
7 — Trade mark
Automatic Transmission Number
The serial number of the transmission unit is displayed on a metal label or bar code (if
equipped) attached to the transmission casing.
Engine Number - 3.0L

The engine number is contained on a bar code label on the front cover and is also stamped in
the cylinder block casting on the left-hand side of the engine below the engine mounting.
Engine Number - 2.7L Diesel

The engine number is stamped next to the emission code on the lower right-hand side of the
cylinder block near the engine mounting. In addition it is also shown together with engine
information stamped onto the camshaft cover plate.
Engine Number - 3.5L, 4.2L and 4.2L Supercharged

The engine number is stamped on an engine web on the left-hand side of the cylinder block
behind the engine mounting. The engine emission code is located on a lug under the exhaust
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manifold towards the left-hand rear of the cylinder block.

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.
Published:
Jacking – Armoured Vehicles
Safety Precautions
WARNING: Make sure that any jacks or stands that are used on the vehicle have sufficient capacity to carry the
additional weight of the vehicle. Failure to follow these instructions may result in personal injury.
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
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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.
Vehicle Weight
The weight of the vehicle is greater than the standard vehicle. Always make sure that any jacks, lifts or
hoists are capable of carrying these loads. All the jacking and lifting points for the vehicle are exactly the
same as the standard vehicle.
Description Front Rear Total

Unladen 1402kg 1448kg 2850kg
Gross Vehicle Weight 1500kg 1720kg 3200kg
Lifting
Lifting Points—Twin-Post Hoist
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 hoists 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 twin post hoist, a cushioned pad must be utilized to
avoid body damage.
Lifting Points—Floor Jack and Axle Stands
CAUTION: If the vehicle is to be lifted using floor jacks, two jacks must be used
to raise either the front or rear of the vehicle. If one jack only is used, excessive body
twist may occur.
CAUTION: When using a floor jack to jack up the rear of the vehicle, the jack
head must be aimed at the NVH bar securing bolts to aviod fuel tank damage or body
damage.
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 or rear subframe assembly.
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Vehicle Recovery
NOTE:
Prior to vehicle recovery, make sure the vehicle keys are available and the security
system is disarmed.
Vehicle recovery methods are:
• By flat-bed transporter.
• By rear suspended tow.
Transporter or Trailer Recovery
When the vehicle is being recovered by transporter or trailer:
• the parking brake must be applied and the wheels chocked.

• the gear selector lever must be in Neutral. Do not select Park on automatic
transmission vehicles, as the parking lock mechanism may be damaged by the forward
and backward rocking motion of the vehicle.
• the vehicle must be securely tied down to the transporter or trailer.
Rear Suspended Tow
When the vehicle is being recovered by rear suspended tow:
• the ignition key must be removed from the ignition switch to lock the steering.
• the rear wheels must be correctly positioned in the lifting cradle and securely tied
down.
Emergency Towing
WARNING: If the engine is not running, the steering will become heavy and the
force necessary to effectively apply the brakes will be greatly increased.
CAUTION: A vehicle with a defective transmission must be towed by rear
suspended tow.
When the vehicle is being towed on its own wheels:
• Local regulations for the towing of vehicles must be followed. In some countries the
registration number of the towing vehicle and an 'On Tow' sign or warning triangle
must be displayed at the rear of the towed vehicle.
• The gear selector lever must be in Neutral.
• The ignition switch must be in position II to release the steering lock and make the
direction indicators, horn and stop lamps operate.
• A distance of 0,8 km (0.5 mile) must not be exceeded.
• A speed of 48 km/h (30 mph) must not be exceeded.
• The tow rope must be attached to the front towing eye.
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100-04 : Noise, Vibration and Harshness
General procedures
Exhaust System Neutralizing

1. Loosen the muffler inlet pipe and resonator pipe to exhaust manifold fasteners at the
flanges and the muffler inlet connection.
2. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe
bracket free of stress.
3. Tighten the muffler connection.
4. Position the exhaust pipes to the manifolds and tighten. Make sure that the catalytic
converter and heat shield do not contact the frame rails.
5. With the complete exhaust system tight (and cooled) the rear hanger insulator should be
angled forward, to allow the system to expand rearward when heated during normal running

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
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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

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 go to the
Symptom Chart.
How To Use This Diagnostic Procedure Section

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• 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 teardown and diagnosis.
• In 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 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 teardown 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:

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• 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 do not contribute to rotational vibration
disturbances.
Shudder or vibration during acceleration may be caused by the following:
• 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
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 disc 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 clutch or torque converter which turns at engine speed when the
vehicle is stopped. Refer to High Speed Shake in the Symptom Chart.
5 . Noise and Vibration While Turning: Clicking, popping, or grinding noises may be due to
the following:
• Worn, damaged, or incorrectly installed front wheel bearing.

• Worn or damaged incorrectly installed rear drive half shaft.
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• Air suspension fault due to low level of vehicle under certain road conditions wheels
may come into contact with the wheel arch liner.
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 driveshaft 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. <<100-02>>
1 . Raise and support the vehicle. <<100-02>>
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.
Symptom Chart
High-speed shake
Possible Source(s):
• Wheel end vibration.
• Engine/transmission.
• Driveline.
Action(s) to take:
• GO to Pinpoint Test A.
Tip-in moan
Possible Source(s):
• Air cleaner.
• Power steering (PS).
• Powertrain.
• Engine mounts.
• Exhaust system.
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Action(s) to take:
• GO to Pinpoint Test B.
Idle boom/shake/vibration, or
shudder
Possible Source(s):
• Cable(s)/hoses(s).
• Engine mounts.
• Exhaust system.
• Belt/pulleys.
Action(s) to take:
• GO to Pinpoint Test C.
Wheel end vibration analysis

Possible Source(s):
• Suspension/rear drive half shaft and CV joints.
• Tires/wheels.
• Wheel bearings.
• Rear wheel drive half shaft joint boots.

Action(s) to take:
• GO to Pinpoint Test D.
Non-axle noise
Possible Source(s):
• Trim/mouldings.
• A/C system.
• Accessories.
• Air suspension system.
Action(s) to take:
• GO to Pinpoint Test E.
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 G215673p1 : HIGH-

SPEED SHAKE
G215673t2 : 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 G215673t10.
PINPOINT TEST G215673p2 : TIP-IN
MOAN
G215673t3 : 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
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CORRECT the condition. REPEAT the Road Test as outlined.
G215673t4 : 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.
G215673t5 : 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 <<211-02>>
-> No
outlined.
PINPOINT TEST G215673p3 : IDLE
BOOM/SHAKE/VIBRATION/SHUDDER
G215673t6 : CHECK CABLE/HOSES
1. Check the engine compartment for any component that may be grounding between the
engine and body or chassis. Example: air conditioning (A/C) hoses.
• Are the components OK?
-> Yes
-> No
G215673t7 : 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
G215673t8 : 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
G215673t9 : CHECK THE EXHAUST SYSTEM
1. Carry out the exhaust system neutralizing procedure in this section.
• Is the exhaust system OK?
-> Yes
outlined.
-> No
REPAIR as necessary. REPEAT Road Test.
PINPOINT TEST G215673p4 : WHEEL

END VIBRATION ANALYSIS
G215673t10 : INSPECT THE TIRES
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1. Inspect the tires.
Raise and support the vehicle. <<100-02>>
Inspect the tires for:
Correct tire size
Tire/wheel compatibility
Wear or damage
Tire beads correctly seated
• Are the tires OK?
-> Yes
-> No
INSPECT the wheels. For additional information, refer to <<204-00>> .
G215673t11 : INSPECT WHEEL BEARINGS

1. Inspect the wheel bearings. <<204-00>>
• Are the wheel bearings OK?

-> Yes
-> No
REPAIR as necessary. REPEAT the Road Test as outlined.
G215673t12 : INSPECT THE CONSTANT VELOCITY

(CV) JOINT BOOTS
1. Inspect the CV joint boots.
Spin the rear tire by hand
Inspect for evidence of cracks, tears, splits or splattered grease
• Are the CV joint boots OK?
-> Yes
-> No
REPAIR as necessary. REPEAT the Road Test as outlined.
G215673t13 : INSPECT WHEEL AND TIRE RUNOUT

1. Inspect the wheel and tire runout.
Carry out the Wheel and Tire Check procedure. <<204-04>>
• 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. <<204-04>> REPEAT the Road Test as outlined.
PINPOINT TEST G215673p5 : NON-

AXLE NOISE
G215673t14 : 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. <<501-08>>
-> No
G215673t15 : 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. <<412-00>>
-> No
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G215673t16 : 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
G215673t1 : CHECK THE AIR SUSPENSION

1. Inspect the air suspension components for being the source of the noise.
• Is the air suspension the cause of the noise?
-> Yes
Install new components as required. <<204-05>>
-> 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

Item LH RH Split LH-RH
Castor Decimal degrees 7.57° ± 0.75° 7.04° ± 0.75° 0.54° ± 0.75°
Degrees/minutes 7° 34' ± 45' 7° 2' ± 45' 0° 32' ± 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 0.1° ± 0.2°
Degrees/minutes 0° 6' ± 12'
USA, Canada, Mexico and Dominican Republic

Castor Decimal degrees 7.48° ± 0.75° 7.48° ± 0.75° 0° ± 0.75°
Degrees/minutes 7° 29' ± 45' 7° 29' ± 45' 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'
Rest of the World

Castor Decimal degrees 7.48° ± 0.75° 7.48° ± 0.75° 0° ± 0.75°
Degrees/minutes 7° 29' ± 45' 7° 29' ± 45' 0° ± 45'
Camber Decimal degrees -0.4° ± 0.75° -0.6° ± 0.75° 0.2° ± 0.75°
Degrees/minutes -0° 24' ± 45' -0° 36' ± 45' 0° 12' ± 45'
Wheel Alignment Specification - Rear
All Vehicles
Item LH RH
Camber Decimal degrees -0.89° ± 0.75° -0.89° ± 0.75°
Degrees/minutes -0° 53' ± 45' -0° 53' ± 45'
Toe Decimal degrees 0.083° ± 0.14° 0.083° ± 0.14°
Degrees/minutes 0° 5' ± 8' 0° 5' ± 8'
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Rear thrust angle Decimal degrees 0° ± 0.14°
Degrees/minutes 0° ± 8'
General Specifications
Item Specification
Clear Vision
Clear vision (negative value is counterclockwise) 0° ± 3°
Ride Height
Front 386 ± 15 mm
Rear 373 ± 15 mm
Ball Joint Radial Play
Lower ball joint — maximum 0.8 mm
Upper ball joint — maximum 0.8 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.
Published: Mar 12, 2014
Specifications – Armoured vehicles
General Specifications, All Right-Hand Drive and Japan
CAUTION: The shock absorber and spring assemblies must be changed in axle sets. Failure to follow this
instruction may result in damage to the vehicle.
Item LH RH Total/Split
Alignment Specifications — Front
7.88° ± 0.7° or 7°53' ± 7.88° ± 0.7° or 7°53' ±
Caster 0° ± 0.7° or ± 42'
42' 42'
-0.6° ± 0.5° or -36' ± -0.4° ± 0.5° or -24' ± 0.2° ± 0.7° or 12' ±
Camber
30' 30' 42'
Toe @ curb ride height (positive value is toe-in, negative -0.04° ± 0.04° or -2.5' -0.04° ± 0.04° or -2.5' -0.08° ± 0.08° or -5'
value is toe-out) ± 2.5' ± 2.5' ± 5'
Alignment Specifications — Rear
Caster — — —
-0.75° ± 0.75° or -45' ± -0.75° ± 0.75° or -45' ±
Camber @ curb 0° ± 0.75° or ± 45'
45' 45'
Toe @ curb ride height (positive value is toe-in, negative 0.16° ± 0.08° or 10' ± 0.16° ± 0.08° or 10' ± 0.33° ± 0.08° or 20'
value is toe-out) 5' 5' ± 5'
General Specifications, USA, Canada and Mexico
7.88° ± 0.7° or 7°53' ± 7.88° ± 0.7° or 7°53' ±
Caster 0° ± 0.7° or ± 42'
42' 42'
-0.6° ± 0.5° or -36' ± -0.5° ± 0.7° or -30' ±
Camber -0.1° ± 0.5° or -6' ± 30'
30' 42'
value is toe-out) ± 2.5' ± 2.5' ± 5'
Caster — — —
-0.75° ± 0.75° or -45' ± -0.75° ± 0.75° or -45' ±
Camber @ curb 0° ± 0.75° or ± 45'
45' 45'
General Specifications, Rest of the World
7.88° ± 0.7° or 7°53' ± 7.88° ± 0.7° or 7°53' ±
Caster 0° ± 0.7° or ± 42'
42' 42'
-0.4° ± 0.5° or -24' ± -0.6° ± 0.5° or -36' ± -0.2° ± 0.7° or -12'±
Camber
30' 30' 42'
value is toe-out) ± 2.5' ± 2.5' ± 5'
Caster — — —
-0.75° ± 0.75° or -45' ± -0.75° ± 0.75° or -45' ±
Camber @ curb 0° ± 0.75° or ± 45'
45' 45'
General Specification
Item Specification
Crab angle — (right-hand rear toe - left-hand rear toe) ÷ 2 0° ± 0.1°
Clear Vision
Clear vision (negative value is counterclockwise) 0° ± 3°
Ride Height
Front 645 ± 2 mm (25.4 inches ± 0.07 inch)
Rear 645 ± 2 mm (25.4 inches ± 0.07 inch)
Ball Joint Radial Play
Lower ball joint — maximum 0.8 mm (0.03 inch)
Upper ball joint — maximum 0.8 mm (0.03 inch)
Shock Absorber And Spring Assembly Inital Setting

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NOTE:
The shock absorber and spring assembly ride height measurement is taken from the lower side of the lock nut to the lower
body of the shock absorber.
Item mm inch
Front shock absorber and spring assembly 200 7.87
Rear shock absorber and spring assembly 160 6.29
Spring Rate
Item N/mm lb/inch

Front Spring 66.5 375
Rear Spring 96.4 553
Torque Specification
Item Nm lb-ft
Rear lower arm to subframe retaining nut and bolt 175 129
Front lower arm to subframe retaining nut and bolt 175 129
Tie rod end lock nut 100 74
Rear toe link lock nut 55 41
General procedures
Camber and Caster Adjustment

NOTE:
The camber and caster adjustment for the left-hand side is shown, the procedure for
adjusting the right-hand side is similar.
NOTE:
This procedure must be carried out using a 4-post ramp.
1. Check the camber and caster settings. Follow the equipment manufacturers instructions.
2. NOTE:
Left-hand shown, right-hand similar.
Loosen the front lower arm lock nut.
3. NOTE:
Adjustments to the caster will affect the toe settings. Therefore, the caster and toe may
need to be adjusted at the same time to achieve the correct settings.
NOTE:
Rotate the caster adjustment cam bolt to adjust the caster.

4. Check the caster settings. Follow the equipment manufacturers instructions. Adjust as
necessary.
5. NOTE:
Make sure the caster adjustment cam bolt does not rotate.
NOTE:
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Tighten the caster adjustment cam bolt lock nut.

• Tighten to 175 Nm.
6. NOTE:
Adjustments to the camber will affect the toe settings. Therefore, the camber and toe may
need to be adjusted at the same time to achieve the correct settings.
NOTE:
Loosen the tie-rod end lock nut.

• Clean and lubricate the lock nut and tie-rod threads.
7.
CAUTION: Do not allow the tie-rod end or steering gear boot to twist when the
tie-rod is rotated. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Left-hand, shown right-hand similar.
Rotate the tie-rod to adjust the toe.
8. NOTE:
Loosen the rear lower arm lock nut.
9. NOTE:
Rotate the camber adjustment cam bolt to adjust the camber.

10. Check the camber and toe settings. Follow the equipment manufacturers instructions.
Adjust as necessary.
11. NOTE:
Make sure the camber adjustment cam bolt does not rotate.
NOTE:
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Tighten the rear lower arm lock nut.

12. NOTE:
Make sure the tie-rod or tie-rod end does not rotate.
NOTE:
Tighten the tie-rod end lock nut.

Front Toe Adjustment (57.65.01)
1. Start the engine and center the steering wheel.
2. Turn the engine off, and hold the steering wheel in the ' straight ahead' position by
attaching a rigid link from the steering wheel to the brake pedal.
3. Check the toe settings. Follow the equipment manufacturers instructions.
4. NOTE:
Loosen the tie-rod end lock nut.

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• Clean and lubricate the lock nut and tie-rod threads.
5.
CAUTION: Do not allow the tie-rod end or steering gear boot to twist when the
tie-rod is rotated. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Rotate the tie-rod to adjust the toe setting.

6. NOTE:
Make sure the tie-rod or tie-rod end does not rotate.
NOTE:
Tighten the tie-rod end lock nut.

7. Recheck the toe settings. Follow the equipment manufacturers instructions.

Published: Feb 7, 2002
Rear Toe Adjustment (57.65.08)

2. NOTE:
Left-hand, shown right-hand similar.
Loosen the toe link lock nut.

• Clean and lubricate the lock nut and toe link threads.
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3. Rotate the toe link to adjust the toe settings.
4. Tighten the toe link lock nut.


1. Raise and support the vehicle. For additional information, refer to<<100-02>>
2. NOTE:
Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Firmly grasp the tire at the top and bottom and move the wheel inward and outward while
lifting the weight of the tire off the wheel bearing.
3. If the tire and wheel is loose on the wheel hub assembly or does not rotate freely, install a
new front wheel hub or rear hub as necessary. For additional information, refer to<<204-
01>>or <<204-02>>
Wheel Alignment Angles

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
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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
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(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
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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 Design Height Setting – Armoured vehicles
Special Service Tools
C Spanner
204-603
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C Spanner
204-603
CAUTION: The shock absorber and spring assemblies must be replaced in axle sets. Failure to follow this
CAUTION: The suspension design height setting procedure must be carried out when the shock absorber and
spring assembly or suspension components have been removed or renewed. Failure to follow this instruction may result
in damage to the vehicle.
CAUTION: If equipped, make sure that the spare wheel and jack are removed from the vehicle before carrying out
the suspension design height setting. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that the fuel tank is full of fuel. Failure to follow this instruction may result in damage to the
vehicle.
CAUTION: Make sure that the vehicle contains no luggage or passengers. Failure to follow this instruction may
result in damage to the vehicle.
CAUTION: This procedure will need to be carried out on all four shock absorber and spring assemblies. Failure to
follow this instruction may result in damage to the vehicle.
NOTE:
The shock absorber and spring assemblies are supplied as complete assemblies and are not servicable.
1. Position the vehicle on a flat and level surface.
2. Check and adjust the tire pressures.
3. Measure the distance from the bottom of the wheel rim through the wheel centre to the lip of the wheel
arch.
4. NOTE:
If the suspension ride height is incorrect adjust as necessary.
Check that the suspension ride height is to the correct tolerance.

Specifications
5.
CAUTION: Make sure that the damper thread is dirt free and lubricated before loosening the lock nut and
adjustment nut. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Its is possible to gain access to adjust the front spring and damper assemblies whilst still installed to the vehicle. Access is
restricted to the rear spring and damper assembly adjustment nuts. The rear spring and damper assemblies may need to be
removed from the vehicle to make the necessary adjustments.
NOTE:
One full turn of the adjustment nut will adjust the height at the road wheel by approximatly 2.25 mm (0.09 inch) at the road
wheel.
NOTE:
Moving the adjustment nut towards the upper spring mount platform will raise the ride height.
Using the special tools, adjust the spring and damper assembly.
 Loosen the spring and damper locking nut.
 Adjust the spring seat position.
6. Using the special tools, tighten the lock nut.
7. Carry out a road test.

Suspension System
8. Repeat steps 1 to 4 and check that the suspension ride height is to the correct specification.
Specifications
9. If the suspension ride height is not to the correct specification repeat steps 5 to 8 until the correct
specification is reached.
Suspension System
WARNING: Before carrying out a road test, make sure the vehicle is safe to do so. Failure to
follow this instruction may result in personal injury.
1 . Gather as much information from the driver as possible and verify the customer concern by
carrying out a road test, as closely as possible reproducing the conditions under which the fault
occurs.
If the customer complaint is of vibration.

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2 . Visually inspect for obvious signs of mechanical damage.
Mechanical
• Tire pressures
• Damaged tires
• Wheel bearing(s)
• Loose or damaged front or rear suspension components
• Loose, damaged or missing suspension fastener(s)
• Damaged or leaking air suspension components
• Worn or damaged suspension bushing(s)
• Loose, worn or damaged steering system components
• Damaged axle components
3 . If an obvious cause for an observed or reported condition is found, correct the cause (if possible)
before proceeding to the symptom chart.
Symptom chart
Symptom Possible causes Action
• Incorrect rear thrust Check the rear alignment.

Crabbing Rear Toe Adjustment (57.65.08) Check the
angle
• Front or rear front and rear suspension for signs of damage
suspension or wear.
components
Check and adjust the tire pressures (see visual

• Tire pressures
• Uneven tire wear inspection). Check for uneven tire wear,
• Damaged steering investigate the cause and rectify as
components necesssary. Check the steering for
Drift/Pull/Wander
• Wheel alignment wear/damage. Check and adjust the wheel
• Brake drag alignment as necessary. Check for binding
• Unevenly loaded or
brakes, rectify as necessary. Advise the driver
overloaded vehicle
of the load issues.
• Damaged suspension Check the suspension components for

Front bottoming or
components damage. Check the dynamic suspension.
riding low • Air spring fault Vehicle Dynamic Suspension
• Incorrect tire pressure

(rapid center rib or
inner and outer edge
wear)
• Incorrect front or rear Check and adjust the tire pressures (see visual
toe (rapid inner or
inspection). Check and adjust the wheel
Uneven tire wear outer edge wear)
• Incorrect camber alignment as necessary. Balance the tires as
(rapid inner or outer necessary.
edge wear)
• Tires out of balance
(tires cupped or
dished)
• Damaged suspension Check the suspension components for

Harsh ride components damage. Check the dynamic suspension.
• Air spring fault Vehicle Dynamic Suspension
• Wheels/tires
• Loose wheel nut(s)
• Loose front suspension
fasteners Check the wheels and tires for condition and
• Front wheel bearing(s) balance. Check and tighten the wheel nuts
fault and suspension fasteners to specification.
Shimmy or wheel
• Worn or damaged Check the front wheel bearings, suspension
tramp suspension bushings, ball joints and steering components
component bushing for wear or damage. Check and adjust the
• Loose, worn or
wheel alignment as necessary.
damaged ball joint(s)
• Loose, worn or
damaged steering
components
• Front wheel alignment
Poor returnability of • Steering column Check the steering column universal joints,
the steering (self- • Ball joints etc. Check the ball joints and other steering
centering) • Steering components components.
• Loose front or rear

stabilizer bar
• Worn lower Check the stabilizer bar security and condition.
Sway or roll suspension arm Rectify as necessary. Check the air springs.
stabilizer bar Vehicle Dynamic Suspension
insulators
• Air spring fault
• Front or rear
Check the front and rear suspension. Check
Vehicle leans to one suspension
the air springs.
side components
• Air spring fault Vehicle Dynamic Suspension
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Component tests
Ball Joint Inspection

NOTE:
The front suspension is shown in the following procedures. The inspection of the rear
suspension upper ball joint is similar.
1 . Raise and support the vehicle.
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 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. Refer to
Upper Arm RH (60.35.42) or
Upper Arm (64.25.31) .
6 . Remove the safety stand.
7 . Lower the vehicle.

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204-01 : Front Suspension
Specification
Specifications
Description Nm lb-ft lb-in

Steering gear to subframe retaining bolts 100 74 -
Stabilizer bar link retaining nut 43 32 -
Stabilizer bar link retaining nut and bolt 70 52 -
Stabilizer bar clamp retaining bolts 55 41 -
Rear lower arm ball joint retaining nut 92 68 -
Front and rear lower arm to subframe retaining nut and bolt 175 129 -
Front lower arm to rear lower arm retaining nut and bolt A A A
Upper arm ball joint retaining nut 90 66 -
Upper arm to body retaining nuts and bolts 47 35 -
Air spring assembly to lower arm retaining bolt 175 129 -
Tie-rod end to wheel knuckle retaining nut 75 55 -
Wheel hub and bearing to wheel knuckle retaining bolts 90 66 -
Exhaust manifold to cylinder head retaining nuts (3.0l only) 20 15 -
Dipstick tube retaining bolt 10 7 -
Engine mount lower retaining nut 55 41 -
Front subframe front retaining bolt 200 148 -
Front subframe rear retaining bolt 115 85 -
Wheel and tire retaining nuts 125 92 -
Hydraulic control unit retaining bolts 9 - 80
A = refer to the procedure for the correct torque sequence - - -
Torque Specifications – Armoured XJ

Rear lower arm ball joint retaining nut 75 55 -
Shock absorber and spring assembly upper retaining nuts 25 18 -
Front Suspension
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1 — Upper arm
2 — Wheel knuckle
3 — Stabilizer bar link
4 — Wheel bearing and hub
5 — Rear lower arm
6 — Front lower arm
7 — Stabilizer bar
WARNING: No attempt must be made to weld or repair the front subframe. If it

is damaged a new one must be installed. Failure to follow this instruction may result in
personal injury.
The independent front suspension is of the double wishbone type and is mounted on the front
subframe, the front subframe consisting of a pressed steel fabrication.
The rear of the front subframe provides the mounting points for the power assisted steering
gear and the engine mounts.
A vertical knuckle arm is installed between the lower and upper suspension arms. This wheel
knuckle carries the lower arm swivel joint, front hub, ABS rotor, ABS sensor, wheel bearing
and brake assembly.
A stabilizer bar is mounted via clamps and bushes to the front subframe and is linked via
connecting links to each of the lower arms.
When cornering, weight is naturally transferred to the outer wheel and there is a natural
tendency for the inner wheel to lift. The stabilizer bar helps to reduce the vehicle roll.
Front Suspension – Armoured XJ

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1 — Retaining nut
2 — Washer
3 — Top mount
4 — Spring upper isolator
5 — Bump stop
6 — Spring
7 — Shock absorber
The additional weight of the armour on the vehicle means that certain parts have needed to be uprated. The
service life of many of the suspension components has been reduced due to the increased vehicle weight.
The armour vehicle is now fitted with shock absorber and spring assemblies to accomodate the extra weight
of the armour.
Front Suspension
For additional information, refer to <<204-00>>
Removal and installation
Published: Jun 25, 2002
Front Lower Arm (60.35.53)

Removal
1 . Remove the air deflector. <<501-02>>
2 . Remove the wheel and tire assembly. <<204-04>>

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3 . Remove the front lower arm retaining nut and bolt.
4 . NOTE:
Remove the front lower arm.
Remove and discard the nut and bolt.

Installation
1 . NOTE:
Install a new nut and bolt.
Install the front lower arm.
Stage 1: Tighten to 60 Nm.
Stage 2: Tighten 135º.
2 . Install the front lower arm inner retaining nut and bolt.
3 . Install the wheel and tire assembly. <<204-04>>
4 . Install the air deflector. <<501-02>>
5
. CAUTION: The final tightening of the front lower arm inner retaining nut and bolt
must be carried out with the vehicle on its wheels. Failure to follow this instruction may
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result in damage to the component.
Tighten to 175 Nm.
6 . Carry out the camber and caster adjustment. <<204-00>>

Rear Lower Arm (60.35.54)
Ball Joint Splitter

204-327
Removal
1 . Remove the wheel and tire assembly.
For additional information, refer to Wheel and Tire (74.20.05)
For additional information, refer to
2 . Remove the stabilizer bar link retaining nut.
3 . Remove the stabilizer bar link.

4 . Detach the headlamp leveling sensor retaining clip.
5 . Detach the tie rod end.

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6 . Detach the air spring assembly.
7 . Detach the rear lower arm.

8 . Detach the front lower arm.
Remove and discard the retaining nut and bolt.
9
. CAUTION: Prevent the rear lower arm ball joint ball pin hexagon from rotating.
Failure to follow this instruction may result in damage to the lower ball joint boot.
Loosen the rear lower arm ball joint retaining nut.
10
Adjust the rear lower arm ball joint retaining nut until the ball joint thread cannot be seen.
11
. WARNING: Make sure the special tool is supported while carrying out the
operation. Failure to follow this instruction may result in personal injury.
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CAUTION: Make sure the special tool is supported while carrying out the
operation. Failure to follow this instruction may result in damage to the special tool.
CAUTION: Make sure the special tool is correctly located and the lower ball joint
boot is not damaged while carrying out the operation. Failure to follow this instruction
may result in damage to the component.
Using the special tool, release the rear lower arm ball joint from the wheel knuckle lower
pivot.
Tighten the special tool adjusting bolt to a maximum of 60 Nm.
If the rear lower arm ball joint releases from the wheel knuckle lower pivot
using no more than 60 Nm on the special tool adjusting bolt, proceed to
step 13.
If the rear lower arm ball joint does not release from the wheel knuckle
lower pivot using no more than 60 Nm on the special tool adjusting bolt,
proceed to step 12.
12
. WARNING: Make sure the special tool is supported while carrying out the
CAUTION: Make sure the special tool is supported while carrying out the
operation. Failure to follow this instruction may result in damage to the special tool.
boot is not damaged while carrying out the operation. Failure to follow this instruction
may result in damage to the component.
NOTE:
Do not carry out this step if the rear lower arm ball joint released from the wheel
knuckle lower pivot in step 11.
pivot.
1) Tighten the special tool adjusting bolt to a maximum of 60 Nm.
Strike the top surface of the special tool directly above the rear lower arm
2)
ball joint at the point indicated using a copper and hide mallet.
13
Remove the rear lower arm.

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Remove and discard the retaining nut.
Installation
1
NOTE:
Install a new retaining nut.
Install the rear lower arm.

Tighten to 92 Nm.
2 . NOTE:
Install a new retaining nut and bolt.
Attach the front lower arm.
Stage 2: Tighten 135º.
3 . Attach the rear lower arm.

4 . Attach the air spring assembly.
Tighten to 175 Nm.
5 . Attach the tie rod end.

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Tighten to 75 Nm.
6 . Attach the head lamp leveling sensor retaining clip.

7 . Install the stabilizer bar link.
8 . Attach the stabilizer bar link.
Tighten to 43 Nm.
9 . Install the wheel and tire assembly.

10
. CAUTION: The final tightening of the rear lower arm inner retaining nut and bolt
must be carried out with the vehicle on its wheels.
Tighten to 175 Nm.

11 . Tighten to 70 Nm.
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12 . Carry out the camber and caster adjustment.

For additional information, refer to Camber and Caster Adjustment
Rear Lower Arm Bushing (60.35.56)
Guide Bush Installer

204-464
Remover Bush
204-333
Base Guide - Bush Installer

204-332
Installer Bush
204-465
Replacer bush
204-334
Removal
1 . Remove the rear lower arm.
2 . NOTE:
Note the orientation of the bushing before removal.
Using the special tools remove the rear lower arm bushing.
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Installation
1 . Install the special tools to the rear lower arm.
2 . Use the installer, align the special tools to the rear lower arm.
Tighten the retaining bolts
3 . NOTE:
Make sure the bushing is correctly orientated.
Install the rear lower arm bushing to the special tool.
4 . Using the special tools, partially install the rear lower arm bushing.
5 . Remove the special tool from the rear lower arm bushing.
6 . Using the special tool, completely install the rear lower arm bushing.
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7 . Install the rear lower arm.

Shock Absorber Bushing (60.30.16)
Remover Support Bush

204-335
Remover Bush
204-336
Replacer Support - Bush

204-337
Replacer - Bush
204-338
Removal
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2
. CAUTION: Make sure the supporting tools are orientated correctly to the rear lower
arm. Failure to follow this instruction may cause damage to the component.
Using the special tools remove the shock absorber bushing.

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Installation
1 . NOTE:
Make sure the shock absorber bushing boot is correctly located into the special tool.
Install the shock absorber bushing to the special tool.
2
. CAUTION: Make sure the supporting tools are orientated correctly to the rear lower
arm. Failure to follow this instruction may cause damage to the component.
Using the special tools install the shock absorber bushing.

Front Stabilizer Bar - 3.0L (60.10.01)
Powertrain Assembly Jack

HTJ1200-02
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Engine Lifting Bracket

303-661
Engine Support Bracket

303-021
Removal
1 . Remove the cowl vent screen. <<501-02>>
2 . Remove the cabin air filter.
1) Detach the cabin air filter.
2) Remove the cabin air filter.

3 . Remove the cabin air filter housing.
4 . Remove the right-hand engine compartment panel.
1) Remove the retaining bolt.
2) Remove the right-hand engine compartment panel.

5 . Remove the left-hand engine compartment access panel.
6 . Detach the dipstick tube.
Remove the dipstick tube retaining bolt.

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7 . NOTE:
Loosen the exhaust manifold retaining nut.
8 . NOTE:

Install the special tool to the exhaust manifold.
Install the retaining bolt.
9 . NOTE:
10 . Install the special tool support bars to the special tool.
11 . Install the special tool.

12 . NOTE:
Right-hand shown, left-hand similar.
Support the radiator.

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13 . Remove the radiator splash shield. <<501-02>>
14 . Remove the air deflector.
15 . NOTE:

Remove the front wheel and tire assembly.
16 . NOTE:
Remove the stabilizer bar link retaining nut.
17 . NOTE:
Remove the stabilizer bar link.

18 . Detach the steering gear.
19 . NOTE:
Detach the headlamp leveling sensor retaining clip.

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20 . NOTE:
Disconnect the headlamp leveling sensor electrical connector.

21 . NOTE:
Loosen the front lower arm retaining nut and bolt.
22 . NOTE:
Loosen the rear lower arm retaining nut and bolt.
23 . NOTE:
Detach the air spring assembly.

24 . NOTE:
Detach the engine mount.

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26 . NOTE:
Remove the front subframe front retaining bolt.

27 . NOTE:
Remove the front subframe rear retaining bolt.
28 . Lower the special tool by approximately 200 mm (7.9 in).
29 . NOTE:
Remove the stabilizer bar clamp.
30 . Remove the stabilizer bar.

Installation
1 . Install the stabilizer bar
2 . NOTE:

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Install the stabilizer bar clamp.
Tighten to 55 Nm.
3 . Using the special tool, install the front subframe.

4 . Check the front subframe alignment. <<502-00>>
5 . NOTE:
Install the front subframe front retaining bolt.
Tighten to 200 Nm.
6 . NOTE:
Install the front subframe rear retaining bolt.
Tighten to 115 Nm.
7 . Remove the special tool.

8 . NOTE:
Attach the engine mount.
Tighten to 55 Nm.
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9 . NOTE:
Attach the air spring assembly.
Tighten to 175 Nm.

10 . NOTE:
Tighten the rear lower arm retaining nut and bolt.
11 . NOTE:
Tighten the front lower arm retaining nut and bolt.
12 . Install the steering gear.

Tighten to 100 Nm.
13 . NOTE:

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Connect the headlamp leveling sensor electrical connector.
14 . NOTE:
Attach the headlamp leveling sensor retaining clip.

15 . NOTE:
Install the stabilizer bar link.
16 . NOTE:
Attach the stabilizer bar link.
Tighten to 43 Nm.
17 . NOTE:
Install the front wheel and tire assembly.
Tighten to 125 Nm.

18 . Install the air deflector.
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19 . Install the radiator splash shield. <<501-02>>
20
NOTE:
Tighten to 175 Nm.

21
NOTE:
Tighten to 175 Nm.
22 . NOTE:
Tighten to 70 Nm.
23 . NOTE:
Remove the radiator support.

Loosen the special tool adjustment bolts.

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25 . Remove the special tool support bars from the special tool.
26 . NOTE:
Remove the retaining bolt.

27 . NOTE:
Remove the special tool from the exhaust manifold.
28 . NOTE:
Install the exhaust manifold retaining nut.
Tighten to 20 Nm.
29 . Attach the dipstick tube.
Install the dipstick tube retaining bolt.
Tighten to 10 Nm.
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30 . Install the left-hand engine compartment access panel.
31 . Install the right-hand engine compartment panel.
1) Install the right-hand engine compartment panel.
2) Install the retaining bolt.

32 . Install the cabin air filter housing.
33 . Attach the cabin air filter.
1) Install the cabin air filter.
2) Attach the cabin air filter.
34 . Install the cowl vent screen. <<501-02>>
35 . Check the caster and camber adjustment. <<204-00>>

Front Stabilizer Bar - 3.5L/4.2L (60.10.01)

HTJ1200-02
Engine Lifting Brackets

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303-749

303-021
Subframe Alignment Bolt

502-007
Removal
Vehicles with 3.5L or 4.2L engine without supercharger
1 Remove the throttle body.
. For additional information, refer to Throttle Body - Vehicles Without: Supercharger, VIN
Range: G00442->G45703 (19.70.04)
For additional information, refer to Throttle Body - Vehicles Without: Supercharger, VIN
Range: G45704->G99999 (19.70.04)
All vehicles
2 . NOTE:
Support the radiator.
3 NOTE:
.
Vehicles with 3.5L or 4.2L engine without supercharger shown, vehicles with 4.2L engine
with supercharger similar.
Install the special tools.
4 NOTE:
.
Install the special tool.

5 . Remove the radiator splash shield.
For additional information, refer to Radiator Splash Shield (76.22.90)

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7 . Remove the front wheels and tires.

8 . NOTE:

9 . NOTE:
11 . NOTE:
Detach the headlamp leveling sensor retaining clip.

12 . NOTE:
Disconnect the headlamp leveling sensor electrical connector.
13 . NOTE:
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Loosen the front lower arm retaining nut and bolt.
14 . NOTE:
Loosen the rear lower arm retaining nut and bolt.

15 . NOTE:
16 . NOTE:
Detach the engine mount.

18 . NOTE:
Remove the front subframe front retaining bolts.

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19 . NOTE:
Remove the front subframe rear retaining bolts.
20 . Lower the special tool by approximately 200 mm (7.9 in).

21 . NOTE:
Remove the stabilizer bar clamp.
Installation
All vehicles
1 . Install the stabilizer bar
2 . NOTE:
Install the stabilizer bar clamp.
Tighten to 55 Nm.
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3 . Using the special tool, install the front subframe.

6 . NOTE:
Install the front subframe rear retaining bolts.
Tighten to 115 Nm.
8 . Install the front subframe front retaining bolt.

Stage 2: Tighten to 270°.

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10 . Install the front subframe front retaining bolt.
Stage 2: Tighten to 270°.

12 . NOTE:
Attach the engine mount.
Tighten to 55 Nm.
13 . NOTE:
Attach the air spring assembly.
Tighten to 175 Nm.

14 . NOTE:
Tighten the rear lower arm retaining nut and bolt.

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15 . NOTE:
Tighten the front lower arm retaining nut and bolt.

Tighten to 100 Nm.
17 . NOTE:
Connect the headlamp leveling sensor electrical connector.
18 . NOTE:
Attach the headlamp leveling sensor retaining clip.

19 . NOTE:
Install the stabilizer bar link.
20 . NOTE:
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Tighten to 43 Nm.
21 . Install the front wheels and tires.


23 . Install the radiator splash shield.
24 NOTE:
.
The final tightening of the rear lower arm inner retaining nut and bolt must be carried
out with the vehicle on its wheels.
NOTE:
Tighten to 175 Nm.
25 NOTE:
.
The final tightening of the front lower arm inner retaining nut and bolt must be carried
NOTE:
Tighten to 175 Nm.
26 . NOTE:

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Tighten to 70 Nm.
27 . NOTE:
Remove the radiator support.

28 NOTE:
.
Vehicles with 3.5L or 4.2L engine without supercharger shown, vehicles with 4.2L
engine with supercharger similar.
Remove the special tool.
Loosen the special tool adjustment bolts.
29 NOTE:
.
Remove the special tools.

30 Install the throttle body.
Range: G00442->G45703 (19.70.04)
Range: G45704->G99999 (19.70.04)
All vehicles
31 . Check the caster and camber adjustment.
For additional information, refer to Camber and Caster Adjustment
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Front Stabilizer Bar - 2.7L Diesel (60.10.01)
Removal
1 . Remove the front subframe.
For additional information, refer to Front Subframe - 2.7L Diesel (76.10.05)
2 . Remove the front subframe spacer.
Installation
1 . To install, reverse the removal procedure.
Tighten to 55 Nm.
Front Stabilizer Bar Link (60.10.02)
Removal

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Installation
2 . Install the stabilizer bar link retaining nut.

Tighten to 43 Nm.
4 NOTE:
.
The final tightening of the stabilizer bar retaining nut and bolt must be carried out with
the vehicle on its wheels.
Tighten to 70 Nm.
Stabilizer Bar Link Bushing (60.10.03)
Support
204-339
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Bush Installer
204-340
Support
204-341
Bush Remove
204-342
Removal
2 . Using the special tools remove the stabilizer bar link bushing.
Installation
1 . NOTE:
Apply water to lubricate the bushing.
Using the special tools install the stabilizer bar link bushing.

Removal
1 . Remove the air spring assembly. <<204-05>>
2 . Remove the cowl vent screen access panel.

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3 . Remove the upper arm rear retaining nut.
4 Remove the air cleaner assembly. For additional information, refer to <<303-12A>> or <<303-
. 12B>>
5 . Remove the upper arm front retaining nut.

6 . NOTE:
Note the position of the upper arm retaining bolt locating tangs to aid installation.
Remove the upper arm.
Installation
1
. CAUTION: Make sure the upper arm retaining bolt locating tangs are correctly
located. Failure to follow this instruction may result in damage to the vehicle.
Install the upper arm.

2 . Install the upper arm front retaining nut.
3 . Install the upper arm rear retaining nut.

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4 . Install the air spring assembly. <<204-05>>
5 NOTE:
.
The final tightening of the Upper arm retaining nut must be carried out with the vehicle
on its wheels.
Tighten to 47 Nm.
6 NOTE:
. The final tightening of the Upper arm retaining nut must be carried out with the vehicle
on its wheels.
Tighten to 47 Nm.
7 . Install the cowl vent screen access panel.
8 Install the air cleaner assembly. For additional information, refer to <<303-12A>> or <<303-
. 12B>>
Upper Arm RH (60.35.42)
Removal
1 . Remove the air spring assembly. <<204-05>>
2 . Remove the cowl vent screen access panel.

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3 . Remove the upper arm rear retaining nut.
4 . Detach the engine compartment battery junction box.
5 . Detach the hydraulic control unit.

6 . Remove the hydraulic control unit mounting bracket upper retaining bolt.
7 . Remove the hydraulic control unit mounting bracket retaining bolt.
8 . Detach the hydraulic control unit mounting bracket.

9 . Remove the upper arm front retaining nut.
10 . NOTE:
Note the position of the upper arm retaining bolt locating tangs to aid installation.
Remove the upper arm.

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Installation
1
. CAUTION: Make sure the upper arm retaining bolt locating tangs are correctly
located. Failure to follow this instruction may result in damage to the component.

2 . Install the upper arm front retaining nut.
3 . Install the upper arm rear retaining nut.
4 . Install the air spring assembly. <<204-05>>
5 NOTE:
.
on its wheels.
Tighten to 47 Nm.
6 NOTE:
.
on its wheels.
Tighten to 47 Nm.
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7 . Attach the hydraulic control unit mounting bracket.
8 . Install the hydraulic control unit mounting bracket retaining bolt.
9 . Install the hydraulic control unit mounting bracket upper retaining bolt.
10 . Attach the hydraulic control unit.
1) Tighten to 9 Nm.
11 . Attach the engine compartment battery junction box.
12 . Install the cowl vent screen access panel.

Front Wheel Bearing and Wheel Hub
(60.25.03)
Removal
1 Remove the brake disc.
. For additional information, refer to Brake Disc - Vehicles With: Standard Brakes, VIN Range:
G00442->G45703 (70.10.10)
For additional information, refer to Brake Disc - Vehicles With: Standard Brakes, VIN Range:
G45704->G99999 (70.10.10)
For additional information, refer to Brake Disc - Vehicles With: High Performance Brakes, VIN
Range: G00442->G45703 (70.10.10)
Range: G45704->G99999 (70.10.10)
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2 . Detach the front wheel speed sensor harness.
3 . Disconnect the front wheel speed sensor electrical connector.
4 . Remove the wheel bearing and wheel hub retaining bolts.

5 . Remove the wheel bearing and wheel hub.
Installation
Tighten to 90 Nm.
Ball Joint Splitter

204-327
Removal
1 Remove the brake disc shield.
. For additional information, refer to Brake Disc Shield - Vehicles With: Standard Brakes
(70.10.18)
For additional information, refer to Brake Disc Shield - Vehicles With: High Performance
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Brakes (70.10.18)

4
. CAUTION: Prevent the tie-rod end ball joint ball pin hexagon from rotating. Failure
to do so may result in damage to the tie-rod end ball joint boot.
Detach the tie-rod end.
5
. CAUTION: Prevent the upper ball joint ball pin hexagon from rotating. Failure to do
so may result in damage to the upper ball joint boot.
CAUTION: Make sure the wheel knuckle is supported. Failure to follow these
instructions may result in damage to the component.
Detach the upper arm.
6
Loosen the rear lower arm ball joint retaining nut.

7
Adjust the rear lower arm ball joint retaining nut until the ball joint thread cannot be seen.
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8
. WARNING: Make sure the special tool is supported while carrying out the operation.
Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the special tool is supported while carrying out the operation.
Failure to follow this instruction may result in damage to the special tool.
boot is not damaged while carrying out the operation. Failure to follow this instruction may
pivot.
Tighten the special tool adjusting bolt to a maximum of 60 Nm.
If the rear lower arm ball joint releases from the wheel knuckle lower pivot
using no more than 60 Nm on the special tool adjusting bolt, proceed to
step 10.
If the rear lower arm ball joint does not release from the wheel knuckle
lower pivot using no more than 60 Nm on the special tool adjusting bolt,
proceed to step 9.
9
. WARNING: Make sure the special tool is supported while carrying out the operation.
CAUTION: Make sure the special tool is supported while carrying out the operation.
boot is not damaged while carrying out the operation. Failure to follow this instruction may
NOTE:
Do not carry out this step if the rear lower arm ball joint released from the wheel
knuckle lower pivot in step 8.
pivot.
1) Tighten the special tool adjusting bolt to a maximum of 60 Nm.
Strike the top surface of the special tool directly above the rear lower arm
2)
ball joint at the point indicated using a copper and hide mallet.
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10
. WARNING: Make sure the wheel knuckle is supported while carrying out the
CAUTION: Make sure the wheel knuckle is supported while carrying out the
operation. Failure to follow this instruction may result in may result in damage to the
component.
CAUTION: Prevent the rear lower arm ball joint ball pin hexagon from rotating.
Remove the wheel knuckle.
Remove and discard the retaining nut.

Installation
1
NOTE:
Install a new retaining nut.
Install the wheel knuckle
Tighten to 92 Nm.
2 . Attach the upper arm.
Tighten to 90 Nm
3 . Attach the tie rod end.
Tighten to 75 Nm.
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5 . Attach the stabilizer bar link.
Tighten to 43 Nm.
6 Install the brake disc shield.
. For additional information, refer to Brake Disc Shield - Vehicles With: Standard Brakes
(70.10.18)
For additional information, refer to Brake Disc Shield - Vehicles With: High Performance
Brakes (70.10.18)
7 NOTE:
.
The final tightening of the stabilizer bar link retaining nut and bolt must be carried out
with the vehicle on its wheels.
Tighten to 70 Nm.
Shock Absorber and Spring Assembly (60.30.02) – Armoured vehicles
Removal

2 . NOTE:
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Remove the shock absorber and spring assembly retaining nuts.

4 . Detach the headlamp leveling sensor link rod.
5 . Detach the brake line from the inner fender securing clips.
6 . NOTE:
Detach the shock absorber and spring assembly.
7
.
CAUTION: Prevent the upper ball joint ball pin hexagon from rotating. Failure to do so may result in
damage to the upper ball joint boot.
CAUTION: Make sure the wheel knuckle is supported. Failure to follow these instructions may result in
damage to the vehicle.
NOTE:
8 . Remove the shock absorber and spring assembly.
Installation
1 NOTE:
. If a new shock absorber and spring assembly is to be installed, make sure the ride height adjustment retaining nuts
are set to the correct measurement.
NOTE:
The shock absorber and spring assembly ride height measurement is taken from the lower side of the lock nut to the
lower body of the shock absorber.
Adjust the shock absorber and spring assembly to the correct setting.

Tighten to 90 Nm.
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3 . NOTE:
Tighten to 175 Nm.
4 . NOTE:
Tighten to 25 Nm.
5 . Carry out the ride height adjustment procedure.

204-02 : Rear Suspension
Specifications
Specifications

Tie rod outer bolt 55 41 -
Lower arm inner bolts 163 120 -
Lower arm outer bolt 175* 129 -
Upper arm ball joint nut 90 66 -
Upper arm inner bolts 98 72 -
Shock absorber upper fixing nuts 28 21 -
Lower shock absorber bolt 133 98 -
Shock absorber top mounting nut without adaptive damping 50 37 -
Shock absorber top mounting nut with adaptive damping 27 20 -
Stabilizer bar 55 41 -
Stabilizer link mounting nuts 48 35 -
Wheel hub nut 300 221 -
*If you are re-using this fixing on a vehicle built prior to VIN H16808, then tighten to 150
Nm. If you are replacing a fixing, then you must replace both nut and bolt and tighten to 175
Nm.
Rear Suspension
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1 — Upper arm
2 — Tie rod
3 — Wheel knuckle
4 — Wheel hub
5 — Lower arm
6 — Stabilizer bar drop link
7 — Stabilizer bar
8 — NVH brace
The independent rear suspension features aluminium upper and lower control arms which carry the
hub assemblies and air springs.
Components
The wheel knuckle:
• carries the wheel hub.

• carries the brake caliper assembly.
• carries the Anti-lock brake (ABS) sensor.
• carries the wheel hub bearing and bearing seals.
• is of a unique design for vehicles with supercharger.
The stabilizer link:
• is of a steel construction with a ball joint at each end.

• transmits vertical movements of the rear suspension to the stabilizer bar.
The stabilizer bar:
• is mounted on the subframe.

• is connected to the left and right hand lower wishbones by the stabilizer bar drop links.
• is fitted to all models with or without sports suspension.
The upper arm:
• is a one piece aluminium casting and incorporates a built in ball joint.

• is the upper support for the wheel knuckle.
• is fitted with height sensors which are part of the high intensity discharge (HID) lights feature
and the air suspension.
The tie rod:
• is of a two piece steel construction with a ball joint at both ends.

• is utilized to adjust rear wheel alignment.
The lower arm:
• is a one piece aluminium casting, with integral mounting points for the shock absorber and
spring assembly and the stabilizer bar link.
• is the lower support for the wheel knuckle.
Rear Suspension – Armoured XJ

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1 — Retaining nut
2 — Washer
3 — Top mount
4 — Spring upper isolator
5 — Bump stop
6 — Spring
7 — Shock absorber
The additional weight of the armour on the vehicle means that certain parts have needed to be uprated. The
service life of many of the suspension components has been reduced due to the increased vehicle weight.
The armour vehicle is now fitted with shock absorber and spring assemblies to accommodate the extra
weight of the armour.
Rear Suspension
For additional information, refer to<<204-00>>.
Lower Arm (64.35.43)

Removal
All vehicles
1 . Make sure the park brake is in the off position.
2 . Remove the wheel and tire.

3 . Detach the shock absorber assembly from the lower arm.

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4 . Detach the stabilizer bar link.
Vehicles without Brembo brakes

5.
CAUTION: The brake caliper must be supported at all times.
Detach the brake caliper and secure to one side.
Remove and discard the brake caliper retaining bolts.
Vehicles with Brembo brakes

6.
All vehicles
7 . Remove and discard the retaining clips and reposition the brake disc.
8 . Detach the lower arm from the wheel hub assembly.
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9 . Remove the lower arm.
Installation
All vehicles
1
. CAUTION: The final tightening of the rear suspension components must be carried
Install the lower arm.

Install the retaining bolts.
2
Install the retaining nut and bolt.

3 . Attach the brake caliper.
Install new brake caliper retaining bolts.
Tighten to 103 Nm.

Tighten to 70 Nm.
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All vehicles
5
Tighten to 48 Nm.
6
Install the the shock absorber retaining bolt.
7 . Install the wheel and tire.

9
Tighten to 163 Nm.

10
Tighten to 175 Nm.

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NOTE:
If you are re-using this fixing on a vehicle built prior to VIN H16808, then tighten old fixing to 150
Nm. If you are replacing a fixing, then you must replace both nut and bolt and tighten to 175
Nm.
11
Tighten to 48 Nm.
12
Tighten to 133 Nm.
13 . Check the wheel alignment and adjust as necessary.

For additional information, refer to Wheel Alignment Angles
Rear Stabilizer Bar (64.35.08)
Powertrain assembly jack

HTJ1200-2
Removal
All vehicles
1 . Drain the right-hand fuel tank saddle. <<310-00>>
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2 . Remove both the upper arms.

3 . Remove the front muffler. <<309-00>>

4.
Detach the brake caliper and brake caliper anchor plate and secure to one side.

5.
All vehicles
6 . NOTE:
Left-hand shown right-hand similar.
Disconnect the anti-lock brake system (ABS) sensor electrical connector.
7 . NOTE:
Right-hand shown left-hand similar.
Detach the shock absorber and spring assembly from the lower arm.
8
. CAUTION: Under no circumstances must the flexible coupling (or its fixings) be
loosened or removed from the driveshaft
Detach the driveshaft from the rear drive axle flange.

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Mark the position of the driveshaft in relation to the rear drive axle flange.
Mark the position of the balance nut in relation to the rear drive axle flange
(if fitted).
Mark the position of each nut and bolt in relation to the rear drive axle
flexible joint.
9 . Detach the fuel filler pipe.
Remove and discard the hose clip.

10 . Detach the electric parking brake motor harness.
11 . Disconnect the electric parking brake motor electrical connector.
12 . Install the special tool to support the rear subframe.

13 . NOTE:
Remove the Noise,Vibration and Harshness brace retaining bolts.
14 . Using the special tool, support the subframe.

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15 . NOTE:
Remove the subframe rear mount retaining bolt.
16 . NOTE:
Remove the subframe front mount retaining bolt.

17 . Lower the subframe.
18 . NOTE:
Remove the stabilizer bar link retaining nut dust cover.
19 . NOTE:

20 . NOTE:
Remove the stabilizer bar.
Installation
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All vehicles
1 . NOTE:
Install the stabilizer bar.
Tighten to 55 Nm.
2 . NOTE:
Install the stabilizer bar link retaining nut.

Tighten to 48 Nm.
3 . NOTE:
Install the stabilizer bar link retaining nut dust cover.
4 . Reposition the subframe.
5 . NOTE:
Install the subframe front mount retaining bolt.
Tighten to 125 Nm.

6 . NOTE:
Install the subframe rear mount retaining bolt.
Tighten to 125 Nm.

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7 . NOTE:
Install the Noise, Vibration and Harshness brace retaining bolts.
Tighten to 48 Nm.
8 . Remove the special tool from the rear subframe.
9 . Connect the electric parking brake motor electrical connector.
10 . Attach the electric parking brake motor harness.

11 . Attach the fuel filler pipe.
Fit and tighten new hose clip.
12 . Attach the driveshaft to the rear drive axle flange.
Tighten to 88 Nm.
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13 . NOTE:
Connect the ABS sensor electrical connector.

Tighten to 103 Nm.
15 . Install the brake pads. <<206-04>>

Tighten to 70 Nm.
All vehicles
17 . Install the front muffler. <<309-00>>
18 . Install both the upper arms.
19 . Fill the right-hand fuel tank saddle. <<310-00>>
20
Tighten to 133 Nm.

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21 . Check the wheel alignment and adjust as necessary. <<204-00>>
22 . Carry out the rear subframe alignment procedure. <<502-00>>

Rear Stabilizer Bar Link (64.35.24)
Removal
2 . NOTE:
Remove the stabilizer bar link retaining nut dust cover.
3 . NOTE:
Detach the stabilizer bar link.
4 . NOTE:

Installation
Tighten to 48 Nm.
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Upper Arm (64.25.31)
Removal
1 . Remove the wheel and tire. <<204-04>>
2 . Detach the high intensity discharge (HID) sensor link rod.
3 . Detach the anti-lock brake system (ABS) sensor wiring harness.
4 . Detach the upper arm from the wheel knuckle.
5 . Remove the upper arm.

Installation
1
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CAUTION:
2
Attach the upper arm to the wheel knuckle.

3 . Attach the anti-lock brake system (ABS) sensor wiring harness.
4 . Attach the high intensity discharge (HID) sensor link rod.
5 . Install the wheel and tire. <<204-04>>
7
Tighten to 98 Nm.
8
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Tighten to 90 Nm.
9 . Check and adjust the wheel alignment as necessary. <<204-00>>

Hub puller
205-491
Adaptor nuts
205-491-01
Flange remover forcing screw

204-269
Rear hub support tool

204-249
Rear hub bearing removal tool

204-250
Front hub remover
204-193
Bearing support
204-252
Removal
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1 . Loosen the wheel hub nut.

G00442->G45703 (70.10.11)
Range: G00442->G45703 (70.10.11)
For additional information, refer to Brake Disc - VIN Range: G45704->G99999 (70.10.11)
3 . Detach the anti-lock brake system (ABS) sensor.

4 . Detach the outer tie rod.
5 . Detach the lower arm from the wheel knuckle.
6 . Remove the wheel hub nut.
7 . Using the special tools, detach the halfshaft.

8 . Remove the wheel knuckle assembly.
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9 . Using the special tools, remove the wheel hub from the bearing.
10 . Using the special tools, remove the inner bearing race from the hub.
11 . Remove the circlip.
12 . Using the special tools, remove the bearing from the wheel knuckle.
Installation
1
Using the special tools, install the bearing to the wheel knuckle.
2 . Install the circlip.

3 . Using the special tools, install the wheel hub to the bearing.
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4 . Install the wheel knuckle assembly.
Tighten to 90 Nm.
5 NOTE:
.
Using the old wheel hub nut tighten to 150 Nm.
NOTE:
Remove and discard the old wheel hub nut, install a new wheel hub nut tighten to 150
Nm.
Attach the wheel knuckle to the halfshaft.
6 . Install the lower arm to the wheel knuckle.
7 . Install the outer tie rod retaining bolt.
8 . Install the ABS sensor.
Tighten to 10 Nm.
9 Install the brake disc.
. For additional information, refer to
Range: G00442->G45703 (70.10.10)
Range: G45704->G99999 (70.10.10)
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10 . Tighten the wheel hub nut.
Tighten to 300 Nm.
11
Tighten to 150 Nm.

12
Tighten to 55 Nm.
Shock Absorber and Spring Assembly – Armoured Vehicles
Removal
1 . Remove the luggage compartment floor covering.

1) Remove the luggage compartment floor covering securing screws.
2) Remove the luggage compartment floor covering.
2 . NOTE:
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Remove the luggage compartment side trim panel.
3 . NOTE:
Remove the shock absorber and spring assembly trim panel.

4 . NOTE:
Remove the shock absorber and spring assembly retaining nuts.
5 . Remove the rear wheel and tire assembly.

6 . NOTE:
Left hand shown, right-hand similar.
7 . NOTE:
Remove the shock absorber and spring assembly.

Installation
NOTE:
If a new shock absorber and spring assembly is to be installed, make sure the ride height adjustment retaining nuts are set to
the correct measurement.
1 NOTE:
. If a new shock absorber and spring assembly is to be installed, make sure the ride height adjustment retaining nuts
are set to the correct measurement.
NOTE:
The shock absorber and spring assembly ride height measurement is taken from the lower side of the lock nut to the
lower body of the shockabsorber.
Adjust the shock absorber and spring assembly to the correct setting.
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2 . NOTE:
Install the shock absorber and spring assembly.

Tighten to 133 Nm.
3 . NOTE:
Tighten to 48 Nm.
4 . Install the rear wheel and tire assembly.
5 . NOTE:
Tighten to 25 Nm.
6 . NOTE:
Install the shock absorber and spring assembly trim panel.
7 . NOTE:
Install the luggage compartment side trim panel.

8 . Install the luggage compartment floor covering.
1) Install the luggage compartment floor covering.
2) Install the luggage compartment floor covering securing screws.
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204-04 : Wheels and Tires
Specifications
Specifications
US/Canada Tire Pressures
For Speeds up to 160 For Speeds over 160

Km/h (100 miles/h) Km/h (100 miles/h)
Wheel Size Tire Size & Type All Load Conditions All Load Conditions
Front Rear Front Rear
235/55R17 99H 1.90 bar 2.10 bar 2.10 bar 2.20 bar
17 inch
Continental (28 lbf/in²) (30 lbf/in²) (30 lbf/in²) (32 lbf/in²)
235/50R18 97H
Continental Conti
1.90 bar 2.10 bar 2.10 bar 2.20 bar
18 inch Touring Contact CH95
(28 lbf/in²) (30 lbf/in²) (30 lbf/in²) (32 lbf/in²)
or Michelin Pilot HX
MXM4
255/40R19 96 or 100Y 1.90 bar 2.10 bar 2.20 bar 2.30 bar
19 inch
Pirelli P-Zero (28 lbf/in²) (30 lbf/in²) (32 lbf/in²) (34 lbf/in²)
255/35R20 97Y 2.20 bar 2.30 bar 2.30 bar 2.50 bar
20 inch
Michelin Pilot Sport (32 lbf/in²) (34 lbf/in²) (34 lbf/in²) (36 lbf/in²)
18 inch (temporary
use spare wheel)
135/80R 18 4.2 bar (60lbf/in²) –
Up to 80 km/h (50
mph)
Out-Side North America (OSNA) Tire Pressures
NOTE:
Not including other markets.

Tire Size & Km/h (100 miles/h) All Km/h (100 miles/h) All
Wheel Size Load Conditions Load Conditions
Type
235/55R17 99W 1.90 bar (28 2.10 bar (30 2.20 bar (32 2.30 bar (34
17 inch
Continental lbf/in²) lbf/in²) lbf/in²) lbf/in²)
235/50R18 97W 1.90 bar (28 2.10 bar (30 2.50 bar (36 2.60 bar (38
18 inch
Pirelli P6000 lbf/in²) lbf/in²) lbf/in²) lbf/in²)
255/40R19 96 or
1.90 bar (28 2.10 bar (30 2.20 bar (32 2.30 bar (34
19 inch 100Y Pirelli P-
lbf/in²) lbf/in²) lbf/in²) lbf/in²)
Zero
255/35R20 97Y
2.20 bar (32 2.30 bar (34 2.30 bar (34 2.50 bar (36
20 inch Michelin Pilot
Sport
18 inch (temporary
use spare wheel) Up 135/80R 18 4.2 bar (60lbf/in²) –
to 80 km/h (50 mph)
Other Markets Tire Pressures
NOTE:
Other markets includes: Russia, Estonia, Argentina, Brazil, Chile, Dominican Republic,
Panama, Morroco, Phillippines and Sri Lanka.
Front at all Rear at all

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Wheel Size Tire Size & Type

Speeds Speeds
235/50R18 97W Pirelli 2.50 bar (36 2.60 bar (38
18 inch
P6000 lbf/in²) lbf/in²)
255/40R19 96 or 100Y 2.20 bar (32 2.30 bar (34
19 inch
Pirelli P-Zero lbf/in²) lbf/in²)
255/35R20 97Y 2.30 bar (34 2.50 bar (36
20 inch
Michelin Pilot Sport lbf/in²) lbf/in²)
18 inch (temporary use spare wheel)
135/80R 18 4.2 bar (60lbf/in²)
Up to 80 km/h (50 mph)
Description Nm lb/ft lb/in

Wheel nuts 125 92 -
Wheel Specification
Wheel Type Wheel Size

Ten spoke alloy 7.5 x 17
Eleven spoke alloy 7.5 x 17
Nineteen spoke alloy 8 x 18
Eight spoke alloy 8 x 18
Double seven spoke alloy 8 x 18
Twenty spoke alloy 8 x 18
Double five spoke alloy 8.5 x 19
Sport five spoke alloy 8.5 x 19
Tire Specification (winter)
Tire Manufacturer Tire Size

Continental 235/55R17 103 V
Pirelli 235/50R18 101 V
Tire Specification (all seasons)

Continental 235/55R17 99 H
Continental or Michelin 235/50R18 97 H
Tire Specification (summer)

Continental 235/55R17 99 W
Pirelli 235/50R18 97 W
Pirelli 255/40R19 96 or 100 Y
Specifications

Km/h (100 miles/h) Km/h (100 miles/h)
Wheel Size Tire Size & Type All Load Conditions All Load Conditions
235/50R18 97 H
Continental Conti
1.90 bar 2.10 bar 2.10 bar 2.20 bar
18 inch Touring Contact CH95
(28 lbf/in²) (30 lbf/in²) (30 lbf/in²) (32 lbf/in²)
or Michelin Pilot HX
MXM4
255/40R19 96 Y Pirelli 1.90 bar 2.10 bar 2.20 bar 2.30 bar
19 inch
P-Zero (28 lbf/in²) (30 lbf/in²) (32 lbf/in²) (34 lbf/in²)
255/35R20 97 Y 2.20 bar 2.30 bar 2.30 bar 2.50 bar
20 inch
Michelin Pilot Sport (32 lbf/in²) (34 lbf/in²) (34 lbf/in²) (36 lbf/in²)
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255/35ZR20 97 Y 2.20 bar 2.30 bar 2.30 bar 2.50 bar

20 inch
Dunlop SP Sport 01 (32 lbf/in²) (34 lbf/in²) (34 lbf/in²) (36 lbf/in²)
18 inch (temporary
use spare wheel)
135/80R18 4.2 bar (60 lbf/in²) –
Up to 80 km/h (50
mph)
NOTE:
OSNA markets includes: Russia, Estonia, Argentina, Brazil, Chile, Dominican Republic,

Speeds Speeds
235/50R18 97 W Pirelli 2.50 bar (36 2.60 bar (38
18 inch
255/40R19 96 Y Pirelli P- 2.20 bar (32 2.30 bar (34
19 inch
Zero lbf/in²) lbf/in²)
255/35R20 97 Y Michelin 2.30 bar (34 2.50 bar (36
20 inch
Pilot Sport lbf/in²) lbf/in²)
255/35ZR20 97 Y Dunlop 2.30 bar (34 2.50 bar (36
20 inch
SP Sport 01 lbf/in²) lbf/in²)
135/80R18 4.2 bar (60 lbf/in²)
All Other Markets Tire Pressures

Km/h (100 miles/h) All Km/h (100 miles/h) All
Wheel Size Tire Size & Type Load Conditions Load Conditions
235/50R18 97 W 1.90 bar (28 2.10 bar (30 2.50 bar (36 2.60 bar (38
18 inch
255/40R19 96 Y 1.90 bar (28 2.10 bar (30 2.20 bar (32 2.30 bar (34
19 inch
Pirelli P-Zero lbf/in²) lbf/in²) lbf/in²) lbf/in²)
255/35R20 97 Y
2.20 bar (32 2.30 bar (34 2.30 bar (34 2.50 bar (36
Sport
255/35ZR20 97 Y
2.20 bar (32 2.30 bar (34 2.30 bar (34 2.50 bar (36
20 inch Dunlop SP Sport
01
18 inch (temporary
use spare wheel) Up 135/80R18 4.2 bar (60 lbf/in²) –
to 80 km/h (50 mph)

Wheel nuts 125 92 -
Wheel Specification

Luxury alloy 8 x 18
Dynamic alloy 8 x 18
Rapier alloy 8 x 18
Tucana alloy 8 x 18
Custom alloy 8.5 x 19
Sabre alloy 8.5 x 19
Sepang alloy 9 x 20
Callisto alloy 9 x 20
Tire Specification (winter)

Pirelli 235/50R18 101 V

Continental or Michelin 235/50R18 97 H

Pirelli 235/50R18 97 W
Pirelli 255/40R19 96 Y
Michelin or Dunlop 255/35ZR20 97 Y
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Specifications
Front at Rear at all

all Speeds Speeds
235/50R18 97 H Continental Conti
2.10 bar 2.20 bar
18 inch Touring Contact CH95 or Michelin
(30 lbf/in²) (32 lbf/in²)
Pilot HX MXM4
2.20 bar 2.30 bar
19 inch 255/40R19 96 Y Pirelli P-Zero
2.20 bar 2.30 bar
19 inch 255/40 R19 100V Pirelli P6 4 Seasons
2.30 bar 2.50 bar
20 inch 255/35R20 97 Y Michelin Pilot Sport
2.30 bar 2.50 bar
20 inch 255/35ZR20 97 Y Dunlop SP Sport 01
18 inch (temporary use
spare wheel) Up to 80 km/h 135/80R18 4.2 bar (60 lbf/in²)
(50 mph)
NOTE:
OSNA markets includes: Russia, Estonia, Argentina, Brazil, Chile, Dominican Republic,

Speeds Speeds
235/50R18 97 W Pirelli 2.50 bar (36 2.60 bar (38
18 inch
255/40R19 96 Y Pirelli P- 2.20 bar (32 2.30 bar (34
19 inch
Zero lbf/in²) lbf/in²)
255/35R20 97 Y Michelin 2.30 bar (34 2.50 bar (36
20 inch
Pilot Sport lbf/in²) lbf/in²)
255/35ZR20 97 Y Dunlop 2.30 bar (34 2.50 bar (36
20 inch
SP Sport 01 lbf/in²) lbf/in²)
135/80R18 4.2 bar (60 lbf/in²)
All Other Markets Tire Pressures

Km/h (100 miles/h) All Km/h (100 miles/h) All
Wheel Size Tire Size & Type Load Conditions Load Conditions
235/50R18 97 W 1.90 bar (28 2.10 bar (30 2.50 bar (36 2.60 bar (38
18 inch (Petrol)
235/50R18 97 W 2.10 bar (30 2.10 bar (30 2.50 bar (36 2.60 bar (38
18 inch (Diesel)
255/40R19 96 Y 1.90 bar (28 2.10 bar (30 2.20 bar (32 2.30 bar (34
19 inch
Pirelli P-Zero lbf/in²) lbf/in²) lbf/in²) lbf/in²)
255/35R20 97 Y
2.20 bar (32 2.30 bar (34 2.30 bar (34 2.50 bar (36
Sport
255/35ZR20 97 Y
2.20 bar (32 2.30 bar (34 2.30 bar (34 2.50 bar (36
20 inch Dunlop SP Sport
01
18 inch (temporary
www.JagDocs.com
use spare wheel) Up 135/80R18 4.2 bar (60 lbf/in²) –

to 80 km/h (50 mph)

Wheel nuts 125 92 -
Wheel Specification

Tucana 8 x 18
Carelia 8.5 x 19
Polaris 8.5 x 19
Sabre 8.5 x 19
Sabre chrome 8.5 x 19
Vela 8.5 x 19
Sepang 9 x 20
Concept 8 (Callisto) 9 x 20
Cremona 9 x 20
Callisto 9 x 20

Continental Pro Contact 235/50 R18 97H
Michelin Pilot HX MXM4 235/50 R18 97H
Pirelli P6 4 Seasons 255/40 R19 100V
Dunlop SP Sport 01 255/35 ZR20 97Y

Pirelli P6000 Powergy 235/50 R18 97W
Continental Premium Contact 2 235/50 R18 97W
Pirelli P-Zero 255/40 R19 100V
Tire Specification (spare)

Pirelli Temp Spare 135/80 R18 104M
Wheels and Tires - VIN Range: G00442-

>G45703
WARNING: Do not mix different types of tires on the same vehicle such as radial, bias or
bias belted tires except in emergencies (temporary spare usage). Failure to follow these
instructions may result in personal injury.
WARNING: Never run the engine with one wheel off the ground, for example when
changing a wheel. The wheel resting on the ground may cause the vehicle to move. Failure to
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follow these instructions may result in personal injury.
WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the
customer to make sure these products have not been used. Failure to follow these instructions
may result in personal injury.
WARNING: Always wear safety goggles or a face shield when performing any work with
wheel and tire assemblies. Failure to follow these instructions may result in personal injury.
WARNING: Retighten the wheel nuts at 800 km (500 miles) after any wheel change or
anytime the wheel nuts are loosened. Failure to follow these instructions may result in personal
injury.
WARNING: Failure to retighten the wheel nuts at the specified mileage could cause the
wheels to become detached while the vehicle is in motion. Failure to follow these instructions may
result in personal injury.
WARNING: Each individual axle, wheel and tire has its own maximum weight or tire
inflation rating. Do not overload or over-inflate beyond the capacity of the lowest rated
components of the system. Failure to follow these instructions may result in personal injury.
WARNING: When changing a wheel, make sure that the vehicle cannot move. Always apply
the parking brake and select the transmission park position. Failure to follow these instructions
WARNING: Reduce air pressure as much as possible by pushing the valve core plunger in
before removing the valve core. Failure to follow these instructions may result in personal injury.
CAUTION: Do not clean aluminium wheels with steel wool, abrasive type cleaners or
detergents. Failure to follow these instructions may result in damage to the vehicle.
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1 - Nineteen spoke alloy
2 - Ten spoke alloy
3 - Double five spoke alloy
4 - Double seven spoke alloy
5 - Sport five spoke alloy
6 - Eight spoke alloy
7 - Eleven spoke alloy
8 Twenty spoke alloy

1 - Locking wheel nut
2 - Locking wheel nut socket
Locking Wheel Nuts

Locking wheel nuts are fitted to certain markets and are available as an accessory in other markets.
One locking wheel nut is fitted to each road wheel and may only be removed by using the correctly
coded socket.
Locking wheel nuts are available in one length. The correct socket is supplied with the vehicle tool kit.
Sets of sockets are available to Jaguar dealers.
Recommended Tires
The radial ply tires recommended by Jaguar meet the high speed performance of the vehicle. Only
tires of identical specification may be fitted as replacements. Under no circumstances must cross-ply
tires be fitted.
Tire Inflation Pressures

All recommended tires, including winter tires, must be inflated to the pressures shown in the
Specifications sub-section. Inflation pressures must only be checked when the tires are cold.
Tire Replacement and Wheel-Interchanging

When the replacement of a tire is necessary, it is preferable to fit a complete set. If two replacement
tires are fitted (to one axle), they must be of the same manufacturer and type as those on the other
axle.
New tires must be balanced before fitting to the vehicle.
Winter (Snow) Tires

Winter tires must only be fitted in complete four-wheel sets of the same type and size. The maximum
speed with winter tires fitted (without snow chains) is 210 km/h (131 mile/h) for H rated tires or 240
km/h (149 mile/h) for V rated tires.
When using snow chains, note that:
• Snow chains must only be fitted to the rear wheels.

• Only Jaguar snow chains should be used.
• Snow chains must not be used on roads which are clear of snow.
• The maximum speed with winter tires and snow chains fitted is 48 km/h (30 mile/h).
• Traction control (where fitted) must be switched OFF when using snow chains.
Rotational Indicators
Some recommended winter tires may have an arrow moulded in the sidewall to indicate the correct
direction of rotation. It is essential tires are fitted so that the arrow is pointing in the direction of
rotation.
Some of the recommended tires for normal and winter use have an asymmetric tread pattern. These
tires have inside and outside markers which should be fitted appropriately to the wheel.
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Temporary-Use Spare Wheel

In certain markets, the spare wheel supplied with the vehicle is of the temporary-use type. It is
narrower than the normal road wheel and takes up less room in the wheel luggage compartment.
When using this type of spare wheel note that:
• Maximum speed must not exceed 80 km/h (50 mile/h).

• The normal road wheel must be replaced as soon as possible.
• Only one temporary-use wheel may be fitted to the vehicle at any time.
• Traction control (where fitted) must be switched OFF.
Tread Wear Indicator

Tread wear indicators are molded into the bottom of the tread grooves across the width of the tire.
The tire must be renewed when tread wear indicators become visible at the surface of the tread, in
two or more adjacent tread grooves.
Note that tire tread depth and condition must comply with prevailing local legislation.
>H18679
WARNING: Do not mix different types of tires on the same vehicle such as radial, bias or
bias belted tires except in emergencies (temporary spare usage). Failure to follow these
WARNING: Never run the engine with one wheel off the ground, for example when
changing a wheel. The wheel resting on the ground may cause the vehicle to move. Failure to
WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the
customer to make sure these products have not been used. Failure to follow these instructions
WARNING: Always wear safety goggles or a face shield when performing any work with
wheel and tire assemblies. Failure to follow these instructions may result in personal injury.
WARNING: Tighten the wheel nuts at 800 km (500 miles) after any wheel change or anytime
the wheel nuts are loosened. Failure to follow these instructions may result in personal injury.
WARNING: Failure to tighten the wheel nuts at the specified mileage could cause the
wheels to become detached while the vehicle is in motion. Failure to follow these instructions may
WARNING: Each individual axle, wheel and tire has its own maximum weight or tire
inflation rating. Do not overload or over-inflate beyond the capacity of the lowest rated
components of the system. Failure to follow these instructions may result in personal injury.
WARNING: Reduce air pressure as much as possible by pushing the valve core plunger in
before removing the valve core. Failure to follow these instructions may result in personal injury.
CAUTION: Do not clean aluminium wheels with steel wool, abrasive type cleaners or
www.JagDocs.com
detergents. Failure to follow these instructions may result in damage to the vehicle.
1 - Luxury
2 - Dynamic
3 - Sepang
4 - Rapier
5 - Tucana
6 - Custom (Crome option available in the US)
7 - Sabre (Crome option available in the US)
8 Callisto
1 - Locking wheel nut
2 - Locking wheel nut socket
Locking Wheel Nuts

Locking wheel nuts are fitted to certain markets and are available as an accessory in other markets.
One locking wheel nut is fitted to each road wheel and may only be removed by using the correctly
coded socket.
Locking wheel nuts are available in one length. The correct socket is supplied with the vehicle tool kit.
Sets of sockets are available to Jaguar dealers.
Recommended Tires
The radial ply tires recommended by Jaguar meet the high speed performance of the vehicle. Only
tires of identical specification may be fitted as replacements. Under no circumstances must cross-ply
tires be fitted.
Tire Inflation Pressures
All recommended tires, including winter tires, must be inflated to the pressures shown in the
specifications. For additional information, refer to Specifications - VIN Range: G45704->G99999 (204-
04 Wheels and Tires)
Tire Replacement and Wheel-Interchanging

When the replacement of a tire is necessary, it is preferable to fit an axle set. If two replacement tires
are fitted (to one axle), they must be of the same manufacturer and type as those on the other axle.
New tires must be balanced before fitting to the vehicle.
Winter (Snow) Tires

Winter tires must only be fitted in complete four-wheel sets of the same type and size. The maximum
speed with winter tires fitted (without snow chains) is 210 km/h (131 miles/h) for H rated tires or 240
km/h (149 miles/h) for V rated tires.
When using snow chains, note that:

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• Snow chains must only be fitted to the rear wheels

• Only Jaguar snow chains should be used
• Snow chains must not be used on roads which are clear of snow
• The maximum speed with winter tires and snow chains fitted is 48 km/h (30 miles/h)
• Traction control (where fitted) must be switched OFF when using snow chains.
Rotational Indicators
Some recommended winter tires may have an arrow moulded in the sidewall to indicate the correct
direction of rotation. It is essential tires are fitted so that the arrow is pointing in the direction of
rotation.
Some of the recommended tires for normal and winter use have an asymmetric tread pattern. These
tires have inside and outside markers which should be fitted correctly to the wheel.
Temporary-Use Spare Wheel

In certain markets, the spare wheel supplied with the vehicle is of the temporary-use type. It is
narrower than the normal road wheel and takes up less room in the luggage compartment.
When using this type of spare wheel note that:
• Maximum speed must not exceed 80 km/h (50 miles/h)

• The normal road wheel must be replaced as soon as possible
• Only one temporary-use wheel may be fitted to the vehicle at any time
• Traction control (where fitted) must be switched OFF.
Tread Wear Indicator
Tread wear indicators are molded into the bottom of the tread grooves across the width of the tire.
The tire must be renewed when tread wear indicators become visible at the surface of the tread, in
two or more adjacent tread grooves.
Note that tire tread depth and condition must comply with specific market legislations.
Tire Changing
Caution: When removing or installing a new tire care must be taken to make sure that the tire low
pressure sensor is not damaged. Make sure the tire bead is broken from the wheel rim 180 degrees
from the tire low pressure sensor. Failure to follow this instruction may cause damage to the tire low
pressure sensor.
Tire Pressure Monitoring
Visual Identification
Wheels fitted with the tire low pressure sensor can be visually identified by the external metal lock
nut and valve (1). All Jaguar non-tire pressure monitoring system wheels have a rubber valve fitted
(2).
The tire pressure monitoring system monitors pressure in each tire including the full size spare tire
(temporary-use spare wheels are not fitted with tire low pressure sensors and are consequently not
monitored).
Tire Pressure Monitoring System - Component Location
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1 Tire pressure monitoring system antenna
2 Tire low pressure sensor
3 Instrument cluster
4 External antenna
5 Tire pressure monitoring system module
The purpose of the tire pressure monitoring system is to assist the driver in maintaining the vehicle’s
tire pressures at the optimum level in order to:
• 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 in specific markets.
The tire pressure monitoring system measures the pressure in each of the tires on the vehicle and
issues warnings to the driver if any of the pressures deviate from a defined tolerance, which is
dependant on the vehicle market and the size and type of tire fitted.
Note: During a blow out a very rapid reduction in tire 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 tire pressure monitoring
system is to assist the driver in keeping the tires at the correct pressure, which may to reduce the
likelihood of a tire blow out occurring.
Tire Pressure Monitoring System Module
The tire pressure monitoring system module is located with the parking aid module in the luggage
compartment of the vehicle.
The tire pressure monitoring system module’s main function is to detect the following:
• the tire pressure is below the recommended low tolerance value – under inflated tire
• the position of the tire on the vehicle.
The tire pressure monitoring system module communicates with the vehicle instrument cluster to
provide the driver with appropriate warnings and also indicates the status/failure of tire pressure
monitoring system components.
Tire Location
Because of the requirement for different pressure targets and thresholds for the front and rear tires,
the tire pressure monitoring system module can identify the position of the tires on the vehicle, and
assign a received tire pressure sensor identification to a specific position on the vehicle (i.e. FL (front
left), FR (front right), RL (rear left) or RR (rear right)).
Tire location is performed automatically by the module using an auto-location function. This function
requires no manual intervention by the driver. The tire pressure monitoring system module can
automatically learn the position of tires on the vehicle if the tire pressure sensors or their positions
are changed on the vehicle.
The tire pressure monitoring system module can automatically detect, under normal conditions, the
following:
• one or more tire pressure sensors have been replaced

• one or more tire pressure sensor identifications are missing
• one or more ‘alien’ identifications are being received, i.e. the module can reject
identifications from tire pressure sensors that do not belong to the vehicle
• the spare tire and one of the tires in use on the vehicle have exchanged position on the
vehicle.
Spare Tire Identification
Depending on the vehicle specification, the spare tire may or may not be fitted with a tire pressure
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sensor. Temporary-use spare wheels are not fitted with sensors and are consequently not
monitored.
If the spare tire is fitted with a tire pressure sensor, the tire pressure monitoring system module can
detect it, determine that it is the spare tire and monitor its pressure and issue warnings to the driver
accordingly. If the tire pressure monitoring system module does not detect a spare tire pressure
sensor, the tire pressure monitoring system module will not show a fault to the driver, however a
fault code will be stored in the tire pressure monitoring system module.
If the spare tire is being monitored and the driver replaces a flat road tire with the spare tire, the tire
pressure monitoring system module will not continually warn the driver that the original flat tire
(now in the spare position) is flat. This prevents distraction of the driver by constant pressure
warnings being issued. Warnings will only be displayed for 20 seconds after the ignition is switched
on.
The tire pressure monitoring system uses ‘active’ tire low pressure sensors which are mounted on
each wheel, inside the tire cavity. The sensor is retained in position by the valve attachment to the
wheel. The tire low pressure sensors transmit their Radio Frequency (RF) signals at either 315 MHz or
433 MHz dependent on market requirements.
The tire low pressure sensor periodically measure the pressure and temperature of the air inside the
tire. Pressure and temperature measurements are transmitted periodically to the external RF
antenna on the vehicle.
The tire low pressure sensors are self-contained units which have no electrical connections into or
out of the tire low pressure sensor.
The care points detailed in 'Tire Changing' must be followed to avoid damage to the tire low pressure
sensor. If the tire low pressure sensor is removed, the nut, valve core, cap, seal and washer must also
be replaced and the tire low pressure sensor tightened to the correct torque value. It is also
recommended that the nut, valve core, cap, seal and washer are replaced at every tire change.
The RF transmission from the tire low pressure sensor contains a unique identification code in its
transmission data, so that the tire pressure monitoring system module can identify the tire on the
vehicle. If the tire low pressure sensor is replaced on a road wheel, the new sensor identification will
be learnt when the vehicle is first driven at a speed of more than 20 km/h (12.5 miles/h) for 15
minutes. If a new tire low pressure sensor is fitted to the spare wheel, the identification for that tire
low pressure sensor must be programmed into the tire pressure monitoring system module using a
Jaguar approved diagnostic tool or that wheel will not be monitored. The code is provided on a label
with the complete wheel and tire assembly when new and is also printed on the casing of each tire
low pressure sensor.
In order to conserve battery power, the tire pressure monitoring system module uses different
transmission rates when the wheel is stationary or moving. The wheel speed required to change
between the stationary and moving transmission rates is approximately 20 kph (12.5 mile/h).
Antenna
The antennas are located near the front of the front wheel arches, and the rear of the rear wheel
arches. The tire pressure monitoring system has four antennas. Each antenna has a connector which
connects with the body wiring harness.
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The antenna is a passive, Low Frequency (LF) transmitter. Each antenna is controlled by the tire
pressure monitoring system module and provides an auto-location feature to identify tire positions
on the vehicle.
The tire pressure monitoring system module energizes each antenna in turn using LF drivers. The
corresponding tire low pressure sensor detects the resulting LF transmission and modifies the mode
status within the RF transmission. This data is received by the tire pressure monitoring system
module through the external RF antenna. The tire pressure monitoring system module can then
determine which sensor is transmitting and its location on the vehicle.
External Antenna
The tire pressure monitoring system external antenna is located at the rear of the vehicle and is
mounted between the spare wheel well and rear subframe.
The unit receives tire pressure, temperature and acceleration readings from each tire and interfaces
with the tire pressure monitoring system module. The tire pressure monitoring system module then
transmits the appropriate messages to the instrument cluster.
The unit also receives further information from each tire pressure sensor concerning wheel
identification, mode status and the condition of the tire pressure sensor battery.
Instrument Cluster Indications
1 Low tire pressure warning indicator
2 Secondary amber warning indicator
3 Message center
Warnings are displayed by the low tire pressure warning indicator, the secondary amber warning
indicator and a text message displayed in the message center.
The warning indicators are driven by controller area network (CAN) messages from the tire pressure
monitoring system module. The warning indicators are illuminated by the instrument cluster
software for three seconds when the ignition is switched to position II for a bulb check.
Note: If the vehicle is not fitted with the tire pressure monitoring system, the warning indicators will
not illuminate at any time.
System Operation
The tire low pressure sensor transmits by RF (315 MHz or 433 MHz depending on market) signal.
These signals contains data which corresponds to tire low pressure sensor identification, tire
pressure, tire temperature, acceleration and tire low pressure sensor mode.
Each time the vehicle is driven, the tire pressure monitoring system module activates each LF
antenna in turn. The corresponding tire low pressure sensor detects the LF signal and responds by
modifying the mode status within the RF transmission.
The system enters 'parking mode' after the vehicle speed has been less than 20 km/h (12.5 miles/h)
for 12 minutes. In parking mode the tire low pressure sensors transmit a coded signal to the tire
pressure monitoring system module once every 13 hours. If the tire pressure decreases by more than
0.06 bar (1 lbf/in²) the tire low pressure sensor will transmit more often as pressure is lost.
The spare tire sensor transmits a signal every 13 hours in the same manner as the road wheels when
in parking mode. If the tire pressure decreases by more than 0.06 bar (1 lbf/in²) the tire low pressure
sensor will transmit more often as pressure is lost.
As each wheel responds to the LF signal from the tire pressure monitoring system module, it is
assigned a position on the vehicle and is monitored for the remainder of that drive cycle in that
position.
When the vehicle has been parked for more than 15 minutes and then driven at a speed of more
than 20 km/h (12.5 miles/h), the antennas fire in turn for 6 seconds on all except North American
specification vehicles or for 18 seconds on North American specification only vehicles in the following
order:
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• Front left
• Six second pause (for the tire pressure monitoring system module to detect a response from
the tire low pressure sensor)
• Front right
• Six second pause
• Rear right
• Rear left
Each tire low pressure sensor responds in turn so the tire pressure monitoring system module can
establish the tire low pressure sensor positions at the start of the drive cycle. This process is repeated
up to three times but less if the tire low pressure sensor positions are already known in the tire
pressure monitoring system module. This process is known as 'Auto Location' and takes three to four
minutes on all except North American specification vehicles and seven to eight minutes on North
American specification vehicles to complete. During this period the tire low pressure sensors
transmit at regular intervals, once every 5 seconds on all except North American specification
vehicles and once every 15 seconds on North American specification vehicles. For the remainder of
the drive cycle the tire low pressure sensors transmit once every 60 seconds or if a change in tire
pressure is sensed until the vehicle stops and the tire pressure monitoring system returns to parking
mode.
Once the wheel position is established, the antennas stop firing and do not fire again until the vehicle
has been parked for more than 15 minutes. The signal transmissions from each tire low pressure
sensor continue at one minute intervals whilst the vehicle is being driven. This transmission is to
monitor the tire pressure. The warning occurs at 25% deflation and comprises of message center
amber secondary warning light, the low tire pressure warning indicator and an appropriate message
displayed in the instrument cluster message center. The message center will also display additional
information about the position of the affected wheel(s).
Wheels and Tires - VIN Range: H18680-
>H99999
OVERVIEW
A number of wheel and tire size combinations are available. A Tire Pressure Monitoring System
(TPMS) is also available. The system monitors the pressure in each tire and informs the driver if the
pressure falls below predetermined thresholds.
TIRES
Tires are available in a number of different sizes and tread patterns dependent on vehicle
specification. Tire sizes are as follows:
• T135/80R18 (space saver wheel)

• 235/50R18 Front / Rear
• 255/40R19 Front / Rear
• 255/35R20 Front / Rear.
WARNING: Tires should be inflated to the recommended pressures (as given in the Owners
Handbook) 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 with 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.
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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 90º 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 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.
TREAD Act - North America 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, positioned on the driver's side 'B' pillar, 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.
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 (vehicle identification number) of the vehicle.
TIRE PRESSURE MONITORING SYSTEM COMPONENT LOCATION
1 Initiator (4 off)
2 Tire pressure sensor (5 off)
3 Instrument cluster
4 Radio Frequency (RF) antenna
5 TPMS module
NOTE:
A tire pressure sensor is not fitted to a temporary spare wheel.
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 NAS vehicles and an optional fitment in other
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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 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 tend 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 RF antenna, 4 initiators and 4 or 5 tire pressure sensors,
depending on the type of spare wheel fitted.
The TPMS module is located on the LH (left-hand) side of the trunk. The RF antenna is located
beneath the rear of the vehicle. 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 hardwired 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 antenna 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 high speed CAN (controller area
network) 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
• 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
traveling at less than 12 mph (20 km/h) for 15 minutes. This is known as 'parking mode'. The
learn/locate process requires the vehicle to be driven at speeds of more than 20 km/h (12.5 mph) for
15 minutes. If the vehicle speed reduces to below 20 km/h (12.5 mph), the learn process timer is
suspended until the vehicle speed increases to more than 20 km/h (12.5 mph), after which time the
timer is resumed. If the vehicle speed remains below 20 km/h (12.5 mph) 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.
INITIATOR
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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. It transmits signals which are received by the tire pressure
sensors prompting them to modify their mode status.
The TPMS module energizes each initiator in turn using LF drivers. The corresponding tire pressure
sensor detects the LF signal and responds by modifying the mode status within the RF transmission.
TIRE PRESSURE SENSOR

The TPMS uses active tire pressure sensors which are located on each wheel, inside the tire cavity.
The sensor incorporates the tire valve and is secured by a nut on the outside of the wheel. The
sensor contains a Printed Circuit Board (PCB) which houses a PTC (positive temperature coefficient)
sensor, a Piezo pressure sensor, a radio receiver and transmitter and a lithium battery.
The tire pressure sensors use the PTC (positive temperature coefficient) 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. 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.
If a sensor is replaced on a 'running wheel', the vehicle must remain stationary for 15 minutes before
being driven. This allows the system to detect the new sensor. To initiate full TPMS operation, the
vehicle must then be driven at a speed of more than 20 km/h (12.5 mph) for 15 minutes, then remain
stationary for a further 15 minutes.
Care Points
The care points detailed in 'Tire Changing' earlier in this section must be followed to avoid damage to
the sensor.
If a new sensor or tire 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 Removal and Installation section of this manual.
If the valve nut is loosened, the seal, washer and nut must be replaced.
RF ANTENNA
The TPMS RF antenna is located at the rear of the vehicle and is mounted between the spare wheel
well and rear subframe. The unit receives tire pressure, temperature and acceleration readings from
each tire and interfaces with the TPMS module. The TPMS module then transmits the appropriate
messages to the instrument cluster. The unit also receives further information from each tire
pressure sensor concerning wheel identification, mode status and the condition of the tire pressure
sensor battery.
INSTRUMENT CLUSTER AND MESSAGE CENTER

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1 Low tire pressure warning indicator
2 Message Center
The warning indications to the driver are common on all vehicles fitted with TPMS. The driver is
alerted to system warnings by a low tire pressure warning indicator in the instrument cluster and an
applicable text message in the message center.
The TPMS module passes system status information to the instrument cluster on the high speed CAN
(controller area network) 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 (controller area
network) bus message from the TPMS. During this time the TPMS performs internal tests and CAN
(controller area network) bus initialization. The warning indicator will be extinguished if the TPMS
module does not issue a fault message or tire pressure warning message.
If a TPMS fault warning message is detected by the instrument cluster at ignition on, the warning
indicator will flash for 72 seconds after the 3 second bulb check period and then remain permanently
illuminated.
If a tire pressure warning message is detected by the instrument cluster at ignition on, the warning
indicator will extinguish briefly after the 3 second bulb check period, before re-illuminating to
indicate a tire pressure warning.
The following table shows the warning indicator functionality for given events:
Message Reason Action
CHECK Stop the vehicle as soon as safely

RH (right-hand) front tire pressure has
PRESSURE RH possible. Check all tire pressures and
fallen to 25% of recommended pressure.
FRONT TYRE inflate to recommended pressure.

LH (left-hand) front tire pressure has fallen
PRESSURE LH possible. Check all tire pressures and
to 25% of recommended pressure.
FRONT TYRE inflate to recommended pressure.

RH (right-hand) rear tire pressure has fallen
PRESSURE RH possible. Check all tire pressures and
REAR TYRE inflate to recommended pressure.

LH (left-hand) rear tire pressure has fallen
PRESSURE LH possible. Check all tire pressures and
REAR TYRE inflate to recommended pressure.
Pressure sensor failure, a wheel has been A fault has occurred in the TPMS.
TYRE PRESSURE fitted to the vehicle that does not contain a Interrogate the TPMS module for faults
SENSOR FAULT pressure sensor, or interference from an and diagnose using the Jaguar
unapproved accessory. approved diagnostic system.
No transmission from more than one A fault has occurred in the TPMS.
TYRE PRESSURE pressure sensor, more than one pressure Interrogate the TPMS module for faults
SYSTEM FAULT sensor fault, or CAN (controller area and diagnose using the Jaguar
network) bus signal missing. approved diagnostic system.
TYRE
Stop the vehicle as soon as safely
PRESSURES Tire pressures are not suitable for high
possible. Check all tire pressures and
LOW FOR speed driving.
inflate to recommended pressure.
SPEED
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High Speed CAN (controller area network) bus; F = RF Transmission; W = LF
Transmission
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1 Battery
2 Battery fuse box

3 Rear power distribution box
4 RF antenna
5 Spare wheel pressure sensor (if fitted)
6 LH (left-hand) rear pressure sensor
7 RH (right-hand) rear pressure sensor
8 LH (left-hand) front pressure sensor
9 RH (right-hand) front pressure sensor
10 RH (right-hand) front initiator
11 LH (left-hand) front initiator
12 RH (right-hand) rear initiator
13 LH (left-hand) rear initiator
14 High speed CAN (controller area network) bus to other vehicle systems
15 TPMS module
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 signal which is received by the RF antenna. 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 3 times but less if the sensor
positions are already known. The process is known as 'Auto Location' and takes 2 to 4 minutes 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 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.
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Wheels and Tires – Armoured Vehicles
WARNING: Do not mix different types of tires on the same vehicle such as radial, bias or bias belted tires except in
emergencies (temporary spare usage). Failure to follow these instructions may result in personal injury.
WARNING: Never run the engine with one wheel off the ground, for example when changing a wheel. The wheel
resting on the ground may cause the vehicle to move. Failure to follow these instructions may result in personal injury.
WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure
these products have not been used. Failure to follow these instructions may result in personal injury.
WARNING: Always wear safety goggles or a face shield when performing any work with wheel and tire assemblies.
Failure to follow these instructions may result in personal injury.
WARNING: Retighten the wheel nuts at 800 km (500 miles) after any wheel change or anytime the wheel nuts are
loosened. Failure to follow these instructions may result in personal injury.
WARNING: Failure to retighten the wheel nuts at the specified mileage could cause the wheels to come become
detached while the vehicle is in motion. Failure to follow these instructions may result in personal injury.
WARNING: Each individual axle, wheel and tire has its own maximum weight or tire inflation rating. Do not
overload or over-inflate beyond the capacity of the lowest rated components of the system. Failure to follow these
WARNING: When changing a wheel, make sure that the vehicle cannot move. Always apply the parking brake and
select the transmission park position. Failure to follow these instructions may result in personal injury.
WARNING: Reduce air pressure as much as possible by pushing the valve core plunger in before removing the
valve core. Failure to follow these instructions may result in personal injury.
CAUTION: Do not clean aluminium wheels with steel wool, abrasive type cleaners or detergents. Failure to follow
these instructions may result in damage to the vehicle.
CAUTION: The vehicle is fitted with directional tires, which should always be fitted in accordance with the
direction of rotation symbol on the tire.
NOTE:
The maximum distance that can be driven on a punctured tire varies greatly depending on the type of terrain.
The vehicle is only available with 19 inch wheels, due to the specification of the brakes and tires fitted. The
vehicle is fitted with 255/45 ZR19 104Y Pirelli P Zero, which feature a run-flat capability. For additional
information, refer to Wheel and Tire (204-04)
In the event of a puncture, the vehicle can still be driven at a maximum speed of 50 kph (31 mile/h); for a
distance of approximately 100 kph (62 mile/h). Note: Care must be taken not to damage the tire low pressure
sensor when removing and installing the tire. For additional information, refer to Wheel and Tire (204-04)
Rodgard Runflat Components
The Rodgard runflat system consist of two main components.

1 Roller
2 Runner
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1 Retaining clip
2 Installation label
Rodgard Runflat
The Rodgard toolbox contains the equipment used in the installation.

1 Torch
2 Bead stretcher/release bar
3 Gauge
4 13mm Insulated spanner
5 13mm spanner
6 Nylon blocks
Tire Low Pressure Sensor Components
The tire low pressure sensors have 3 major components.

1 Coloured washers
2 Tire low pressure sensors
3 Tire valves
NOTE:
The colour of the washer must match the colour of the mark on the tire low pressure sensor.

1 Coloured washer
2 Coloured mark
For further information on the tire run flat system contact; Rodgard, 1355 Clinton Street, Buffalo, New York
14206, U.S.A Tel: (716)823-1411. Fax: (716)823 1607. www.rodgard.com.

>G45703
General notes
Factory installed tires and wheels are designed to operate satisfactory when inflated to the
recommended inflation pressures; refer to the Specifications sub-section. The recommended
pressures apply to vehicle loads up to and including full-rated load capacity.
Correct tire pressures and driving technique have an important influence on tire life. Heavy
cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear.
Replacement tires should follow the recommended:

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• size.
• speed rating.
• load range.
• radial construction type.
The use of any other size or type may seriously affect:
• safety.
• ride.
• handling.
• speedometer and odometer calibration.
• vehicle ground clearance.
• tire clearance between body and chassis.
• wheel bearing life.
• brake cooling.
Wheels need to be renewed when:
• impact damaged.
• heavily corroded.
• porous.
• wheel stud holes or seats become damaged.
• they have excessive radial or lateral runout.
Safety notes
WARNING: Do not mix different types of tires on the same vehicle. Handling may be
seriously affected resulting in loss of control. Failure to follow these instructions may result in
WARNING: When using winter tires, observe the direction of the sidewall moulded
indicators; correct tire rotational direction is critical. Failure to follow these instructions may result
in personal injury.
WARNING: A tire and wheel must always be correctly matched. Wider or narrower tires
than recommended could cause danger through sudden deflation. Failure to follow these
WARNING: When using the temporary spare wheel, maximum speed must not exceed 80
km/h (50 mile/h). Drive with caution and replace with the specified wheel and tire assembly as
soon as possible. Failure to follow these instructions may result in personal injury.
WARNING: Traction control (if available) must not be engaged with a temporary spare
wheel fitted. Failure to follow these instructions may result in personal injury.
WARNING: Never run the engine with one wheel off the ground, for example, when
changing the wheel. The wheel resting on the ground may cause the vehicle to move. Failure to
WARNING: Tighten the wheel nuts to specification. Too tight may cause damage, too loose
may allow the wheel to become detached. Failure to follow these instructions may result in
personal injury.
WARNING: Use only wheels and wheel nuts supplied by Jaguar. Aftermarket wheels or
wheel nuts may not fit or function correctly and could cause injury or damage. Failure to follow
these instructions may result in personal injury.
1 . Verify the customer's concern by driving the vehicle.
2 . Visually inspect for obvious signs of damage:
Visual Inspection Chart

Mechanical
Incorrect tire pressure

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Wheel imbalance
Tires worn beyond tread wear indicators
Cuts
Abrasions
Bulges (blister)
Ply separation
Embedded objects
Impact damage
Incorrect speed rating
Incorrect load rating
Incorrect rotational direction
1 . If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
2 . If the concern is not visually evident, verify the symptom and refer to Symptom Chart.
Tire Wear Inspection

To maximize tire performance, inspect the tires for signs of incorrect inflation and uneven wear
which may indicate a need for balancing, rotation or front suspension alignment. Tires should also be
checked frequently for cuts, stone bruises, abrasions, blisters, and for objects that may have become
embedded in the tread. More frequent inspections are recommended when rapid or extreme
temperature changes occur or when road surfaces are rough or occasionally littered with debris.
Tire Wear Diagnosis

New tires should be installed if the wear indictors are exposed or if there is severe shoulder wear.
Shoulder wear is usually caused by either excessive camber or excessive toe on radial tires.
Sometimes incorrect rear toe settings or damaged struts will cause severe cupping' or scalloped' tire
wear on non-drive wheels.
Incorrect rear toe alignment will also cause other unusual wear patterns.
Road Test
A tire vibration diagnostic procedure always begins with a road test. The road test and customer
interview (if available) will provide much of the information needed to find the source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is
apparent, note and record the following:
• The speed at which the vibration occurs.

• What type of vibration occurs in each speed range. Mechanical or audible.
• How the vibration is affected by changes in the following: Engine torque. Vehicle speed.
Engine speed.
• Type of vibration-sensitivity: torque sensitive, vehicle speed sensitive or engine speed
sensitive.
The following explanations help isolate the source of the vibration.
Torque Sensitive
This means that the condition may be improved or made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive

This means that the vibration always occurs at the same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear selected.
Engine Speed Sensitive

This means that the vibration occurs at varying vehicle speeds when a different transmission gear is
selected. It may sometimes be isolated by increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related to the tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise originates with
the contact between the tire and the road surface.
A thumping noise usually means that the tire has a flat or soft spot making a noise as they slap the
roadway. Tire whine may be distinguished from axle noise. Tire whine remains the same over a range
of speeds.
Tires show excess wear on edge of treads
Possible Source(s):
• Tires under-inflated.
Action(s) to take:
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• Correct pressure to specification.
Possible Source(s):
• Vehicle overloaded.
Action(s) to take:
• Correct as required.
Tires show excess wear on edge of treads (having the correct tire
pressures)
Possible Source(s):
• Incorrect toe setting.
Action(s) to take:
• Set to specification. For additional information, <<204-00>>
Tires show excess wear in center of tread
Possible Source(s):
• Tires over-inflated.
Action(s) to take:
Other excessive tire wear problems
Possible Source(s):
• Incorrect tire pressure.
Action(s) to take:
Possible Source(s):
• Incorrect tire and wheel usage.
Action(s) to take:
• Install correct tire and wheel combination.
Possible Source(s):
• Loose or leaking air springs.
Action(s) to take:
• Tighten or install new air springs as necessary. For additional information, <<204-05>>
Possible Source(s):
• Geometry out of alignment.
Action(s) to take:
• Check and adjust. For additional information, <<204-00>>
Possible Source(s):
• Loose, worn or damaged suspension components.
Action(s) to take:
• Inspect, repair or install new suspension components as necessary.
Possible Source(s):
• Wheel and tire assembly out of balance.
Action(s) to take:
• Balance wheel and tire assembly.
Possible Source(s):
• Excessive lateral or radial runout of wheel or tire.
Action(s) to take:
• Check, repair or install a new wheel or tire as necessary. Refer to the procedure in this
section.
Wheel mounting is difficult
Possible Source(s):
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• Incorrect application or mismatched parts, including wheel studs and wheel nuts. Corroded,
worn or damaged parts.
Action(s) to take:
• Clean or install a new part.
Wobble or shimmy affecting wheel runout
Possible Source(s):
• Damaged wheel (eventually damaging wheel bearings and causing uneven tire wear).
Action(s) to take:
• Inspect wheel rims for damage and runout. Install a new wheel rim as necessary.
Excessive vibration, rough steering or severe tire

wear
Possible Source(s):
• Loose or incorrect attaching parts.
Action(s) to take:
• Tighten or install new parts.

Vehicle vibrations
Possible Source(s):
• Tires and wheels mismatched.
Action(s) to take:
• Install correct tire and wheel combination.
Possible Source(s):
• Inflation pressure too high or too low.
Action(s) to take:
Possible Source(s):
• Uneven tire wear.
Action(s) to take:
• Refer to Diagnosis and Testing in this section.
Possible Source(s):
• Out-of-balance wheel, tire, wheel hub or disc assembly.
Action(s) to take:
• Determine the out-of-balance component and balance or install a new part.
Possible Source(s):
• Damaged or distorted wheel from road impact hazard or incorrect handling.
Action(s) to take:
• Install a new wheel.
Possible Source(s):
• Excessive radial runout.

Action(s) to take:
• Install a new wheel or tire. Check for incorrect wheel and tire specifications.
Possible Source(s):
• Excessive lateral runout.
Action(s) to take:
• Install a new wheel or tire.
Possible Source(s):
• Incorrectly seated tire.
Action(s) to take:
•
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Remount the tire.
Possible Source(s):
• Loose wheel mountings - damaged wheel studs, wheel nuts, worn or broken wheel hub face
or foreign material on mounting faces.
Action(s) to take:
• Tighten or install new parts. Clean mounting surfaces.
Possible Source(s):
• Defective wheel bearings.
Action(s) to take:
• Install a new bearing set. For additional information refer to <<204-01>> or <<204-02>>
Possible Source(s):
• Brake disc imbalance.
Action(s) to take:
• For additional information refer to <<206-00>>
Possible Source(s):
• Water in tires.
Action(s) to take:
• Remove water.
Possible Source(s):
• Loose engine or transmission mounts.
Action(s) to take:
• Tighten or install a new mount.
Possible Source(s):
• Incorrect front end alignment.
Action(s) to take:
• Align front end. For additional information, <<204-01>>
Possible Source(s):
• Loose or worn driveline or suspension parts.
Action(s) to take:
• Repair or install new parts.
Possible Source(s):
• Excessive driveshaft runout or imbalance.
Action(s) to take:
• Install a new driveshaft. For additional information, <<205-01>>
Possible Source(s):
• Worn or damaged flexible drive joint.
Action(s) to take:
• Install a new driveshaft. For additional information, <<205-01>>

Damaged wheel hub stud threads
Possible Source(s):
• Sliding wheel across the wheel studs during installation. Loose wheel nuts.
Action(s) to take:
• Install new wheel studs.
Broken wheel studs
Possible Source(s):
• Loose or overtightened wheel nuts.
Action(s) to take:
•
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Install new wheel studs.
Corrosion and contamination streaks from the wheel hub wheel stud holes
Possible Source(s):
• Loose wheel nuts.
Action(s) to take:
• Check complete assembly. Install new parts. Follow correct torque procedure.
Damaged wheel nuts
Possible Source(s):
• Loose wheel assembly.
Action(s) to take:
• Install new wheel nuts. Follow correct torque procedure.
Possible Source(s):
• Over-tightened wheel nuts.
Action(s) to take:
• Install new wheel nuts. Follow correct torque procedure.
Frozen wheel nuts
Possible Source(s):
• Corrosion or galling.
Action(s) to take:
• If corrosion is light, wire brush away corrosion. If corrosion is excessive install new wheel
studs and wheel nuts.
>G99999
Overview
This section will provide basic information to assist in the diagnosis of tire-related faults.
Tire pressure monitoring systems (TPMS) have been introduced on 2006 my vehicles and this section
will also provide information to assist in the diagnosis of the system fitted to Jaguar vehicles.
Tire pressure monitoring system
Principle of operation
Each road wheel has a sensor which feeds information to the control module which will then
interpret the information and display a message on the driver message center, along with a warning
light and an amber lozenge if appropriate.
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The messages are self-explanatory, but full descriptions can be found in the owner guide.
For additional information on the description and operation of the TPMS.

TPMS inspection and verification

1 . Verify the customer complaint.
NOTE:
Record any messages displayed by the system.
2 . Visually inspect for obvious signs of mechanical or electrical damage.
Mechanical Electrical
• Tire pressures • Fuses (FPDB, RPDB, PJB)

• Tire/Wheel damage • Front antenna fitment/damage
• Tire low pressure sensor fitment/damage • Rear antenna fitment/damage
• Front antenna fitment/damage • External antenna fitment/damage
• Rear antenna fitment/damage • TPMS module
• External antenna fitment/damage • Connectors/Harnesses
4 . If the cause is not visually evident use the Jaguar approved diagnostic system or a scan tool to
retrieve the fault codes before proceeding to the diagnostic trouble code (DTC) index.
DTC Index
NOTE:
Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5
digits from the scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last
2 digits give extra information read by the manufacturer-approved diagnostic system).
DTC Description Possible causes Action
External • Antenna: short circuit to

B1A5611 GO to Pinpoint Test G528618p1.
antenna ground
• Antenna: high resistance

External
B1A5612 • Antenna: short circuit to GO to Pinpoint Test G528618p1.
antenna battery
External • Antenna: signal

B1A5638 Replace the external antenna.
antenna frequency incorrect
Module • TPMS module not

Configure the module using the Jaguar
B247700 configuration configured at end of line
or at PDI approved diagnostic system
failure
Left hand front

Replace the tire low pressure sensor.
C1A5616 tire low • Low battery detected
pressure sensor
Check for stored DTCs B1A5611,

B1A5612 or B1A5638 and follow the
Left hand front
actions indicated. If none of these
C1A5631 tire low • No signal detected
DTCs are stored replace the tire low
pressure sensor
pressure sensor.
Left hand front

C1A5691 tire low • Data out of range
pressure sensor
• No sensor can be found

C1A5693 Left hand front at this location
Check for stored DTCs C1A5711,
tire low C1A5712, C1A5713 or C1A5631 and
pressure sensor follow the actions indicated.
Left hand front • Output circuit: short

C1A5711 GO to Pinpoint Test G528618p2.
antenna circuit to ground
Left hand front • Output circuit: short

antenna circuit to battery
Left hand front • Output circuit: high

antenna resistance
Right hand
C1A5816 front tire low • Low battery detected
pressure sensor

Right hand
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C1A5831 front tire low • No signal detected

pressure sensor
pressure sensor.
Right hand
C1A5891 front tire low • Data out of range
pressure sensor
Right hand Check for stored DTCs C1A5911,

C1A5893 front tire low C1A5912, C1A5913 or C1A5831 and
at this location
Right hand • Output circuit: short

front antenna circuit to ground
Right hand • Output circuit: short

front antenna circuit to battery
Right hand • Output circuit: high

front antenna resistance
Left hand rear

pressure sensor
C1A6031 Left hand rear • No signal detected Check for stored DTCs B1A5611,
tire low B1A5612 or B1A5638 and follow the
pressure sensor actions indicated. If none of these
pressure sensor.
Left hand rear

pressure sensor
Left hand rear Check for stored DTCs C1A6111,

C1A6093 tire low C1A6112, C1A6113 or C1A60 31 and
at this location
Left hand rear • Output circuit: short

Left hand rear • Output circuit: short

Left hand rear • Output circuit: high

antenna resistance
Right hand rear

pressure sensor

Right hand rear
C1A6231 tire low • No signal detected
pressure sensor
pressure sensor.
Right hand rear

pressure sensor
Right hand rear Check for stored DTCs C1A6311,

C1A6293 tire low at this location
C1A6312, C1A6313 or C1A6231 and
Right hand rear • Output circuit: short

Right hand rear • Output circuit: short
Right hand rear • Output circuit: high

antenna resistance
Spare tire low Replace the tire low pressure sensor.

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

C1A6491 • Data out of range
pressure sensor Tire Low Pressure Sensor
If the vehicle is fitted with a temporary

spare wheel and tyre take no action.
Spare tire low • No sensor can be found B1A5612 or B1A5638 and follow the
C1A6493
pressure sensor at this location actions indicated. If none of these
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pressure sensor.
• The control module Check for DTCs indicating a

C1D1800 Location failure
cannot locate the sensor component fault.
• CAN communication For network tests,

U007300 CAN BUS off
error Communications Network
For network tests,

U1A1449 CAN error • CAN failed to initialise
• CAN signal fault: DATC,

ambient For network tests,
U251800 CAN error
temperature/barometric Communications Network
pressure
• CAN signal fault: ABS, For network tests,

U252100 CAN error
vehicle reference speed Communications Network
• CAN signal fault: ECM, For network tests,

U252300 CAN error
engine speed Communications Network
Wheels and tires inspection and verification

Basic information on the wheels and tires available for this model year can be found at.
Specifications for the wheels and tires (pressures, torques, etc) can be found at the same link.
When replacing wheels or tires you must comply with local legislation regarding health and safety
and correct fitment.
If the vehicle is fitted with TPMS, only Jaguar approved wheels and tyres should be used. If the wheel
and tyre 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 tyre 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 fitment (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.
Pinpoint tests
NOTE:
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When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to
3 decimal places, and with an up-to-date calibration certificate. When testing resistance, always
take the resistance of the DMM leads into account.
NOTE:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
NOTE:
If DTCs are recorded and a fault is not present when performing the pinpoint tests, an
intermittent concern may be the cause. Always check for loose connections and corroded
terminals.
PINPOINT TEST G528618p1 :

EXTERNAL ANTENNA NO
CONNECTION
G528618t1 : Check the external antenna signal circuit for short circuit to
ground
1. Key off. 2. Disconnect the TPMS external antenna electrical connector, CR99. 3.
Measure the resistance between:
CR99, harness side Battery
Pin 01, signal Negative terminal
• Is the resistance less than 10,000 ohms?
-> Yes
-> No
G528618t2 : Check the external antenna signal circuit for short circuit to
power
1. Measure the resistance between:
Pin 01, signal Positive terminal
-> Yes
-> No
G528618t44 : Check whether the short circuit is in the harness or the

module
1. Disconnect the TPMS module connector, CR96. 2.

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Pin 01, signal Negative terminal
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagram. Clear the DTC and
test the system for normal operation.
-> No
INSTALL a new TPMS control module.

module

Pin 01, signal Positive terminal
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagram. Clear the DTC and
-> No
G528618t3 : Check the external antenna signal circuit for high resistance
CR96, harness side CR99, harness side
Pin 01, signal Pin 01, signal
• Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance. For additional information, refer to the wiring diagram. Clear the DTC and
-> No
INSTALL a new external antenna.
PINPOINT TEST G528618p2 : LEFT

HAND FRONT LOW-FREQUENCY
ANTENNA CIRCUIT
G528618t7 : Check the antenna negative circuit for short circuit to ground
1. Key off. 2. Disconnect the left hand front low-frequency antenna electrical connector, EC83. 3.
EC83, harness side Battery
Pin 02, negative Negative terminal

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-> Yes
-> No
G528618t4 : Check the antenna negative circuit for short circuit to power
Pin 02, negative Positive terminal
-> Yes
-> No
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G528618t29 : Check the antenna positive circuit for short circuit to ground
Pin 01, positive Negative terminal
-> Yes
-> No
G528618t31 : Check the antenna positive circuit for short circuit to power
Pin 01, positive Positive terminal
-> Yes
-> No
module

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-> Yes
REPAIR the short circuit. This circuit contains intermediate connector, EC17. For additional
information, refer to the wiring diagram. Clear the DTC and test the system for normal operation.
-> No

module

-> Yes
-> No

module
-> Yes
-> No
module

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-> Yes
-> No
G528618t9 : Check the antenna negative circuit for high resistance

CR94, harness side EC83, harness side
Pin 14, negative Pin 02, negative
-> Yes
REPAIR the high resistance circuit. This circuit contains intermediate connector, EC17. For additional
-> No
G528618t8 : Check the antenna positive circuit for high resistance

Pin 13, positive Pin 01, positive
-> Yes
-> No
INSTALL a new left hand front low-frequency antenna.
PINPOINT TEST G528618p3 : RIGHT

HAND FRONT LOW-FREQUENCY
ANTENNA CIRCUIT
1. Key off. 2. Disconnect the right hand front low-frequency antenna electrical connector, EC84. 3.

-> Yes
-> No

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

module
-> Yes
-> No

module

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-> Yes
-> No

module

-> Yes
-> No

module
-> Yes
-> No
G528618t16 : Check the antenna negative circuit for high resistance

-> Yes
-> No

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-> Yes
-> No
INSTALL a new right hand front low-frequency antenna.

HAND REAR LOW-FREQUENCY
ANTENNA CIRCUIT
1. Key off. 2. Disconnect the left hand rear low-frequency antenna electrical connector, BR08. 3.
BR08, harness side Battery
-> Yes
-> No
-> Yes
-> No
-> Yes
-> No
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-> Yes
-> No
module
-> Yes
REPAIR the short circuit. This circuit contains intermediate connector, BR01. For additional
-> No

module

-> Yes
-> No

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

module
CR94, harness side BR08, harness side
Pin 06, negative Pin 02, ground
-> Yes
REPAIR the high resistance circuit. This circuit contains intermediate connector, BR01. For additional
-> No

-> Yes
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-> No
INSTALL a new rear left hand low-frequency antenna.

HAND REAR LOW-FREQUENCY
ANTENNA CIRCUIT
1. Key off. 2. Disconnect the right hand rear low-frequency antenna electrical connector, BR09. 3.

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

module
-> Yes
-> No

module

-> Yes
-> No

module
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-> Yes
-> No

module
-> Yes
-> No

module
-> Yes
-> No
INSTALL a new rear right hand low-frequency antenna.

Removal
NOTE:
It is strongly recommended that a new tire low pressure sensor O-ring seal, washer, nut, valve
core and cap are installed each time a tire is removed and installed. The O-ring seal, washer, nut,
valve core and cap must be replaced if the tire low pressure sensor is removed. Removal of the
tire low pressure sensor retaining nut must be regarded as tire low pressure sensor removal. The
tire low pressure sensor valve cap must always be in place except when inflating, releasing
pressure or checking pressure.
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2
. CAUTION: Make sure the tire bead is broken from the wheel rim 180 degrees from
the tire low pressure sensor. Failure to follow this instruction may result in damage to the
tire low pressure sensor.
Remove the tire.

For additional information, refer to Wheels and Tires - VIN Range: G45704->H18679
3
. CAUTION: Make sure you do not push on the tire low pressure sensor valve. Failure
to follow this instruction may result in damage to the valve.
Remove the tire low pressure sensor.
Remove and discard the tire low pressure sensor retaining nut, valve core,
valve cap, O-ring seal and washer.
Installation
1
. CAUTION: The base of the valve stem must be held whilst pushing on the new seal
and washer. Failure to follow this instruction may result in damage to the tire low pressure
sensor.
NOTE:
Make sure that the washer and O-ring seal are installed correctly. The flat face of washer
must be seated against the sensor housing. The taper of O-ring seal points towards the
wheel.
Install a new washer and O-ring seal.
Install a new valve core and valve cap.
2
. CAUTION: Make sure solvents or cleaning agents of any type are not used to clean
the tire low pressure sensor. Failure to follow this instruction may result in damage to the
tire low pressure sensor.
NOTE:
If the tire low pressure sensor is replaced on a road wheel, the new tire low pressure
sensor identification code will be learnt when the vehicle is first driven. If a new tire low
pressure sensor is fitted to the spare wheel the identification code for that tire low
pressure sensor must be programmed into the tire pressure monitoring system module.
The identification code is printed on the casing of each tire low pressure sensor and is
prefixed with ID.
Install the tire low pressure sensor.
Support the base of the valve stem when installing the tire low pressure
1)
sensor.
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Hold the tire low pressure sensor against the wheel rim when tightening the
2)
retaining nut.
Install a new tire low pressure sensor retaining nut.
Tighten the nut to 8 Nm.

3.
CAUTION: Make sure no damage occurs to the tire low pressure sensor.
Install the tire and balance the wheel.

For additional information, refer to Wheels and Tires - VIN Range: G45704->H18679
4 . Install the wheel and tire.

Tire Pressure Monitoring System (TPMS)
Front Antenna
Removal
1 . NOTE:
Detach the fender splash shield.

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2 . NOTE:
Remove the tire pressure monitoring system front antenna.
1) Disconnect the electrical connector.
2) Remove the tire pressure monitoring system front antenna.
Installation
Module
Removal
1 . Reposition the luggage compartment floor covering.
2 . Disconnect the tire pressure monitoring system module electrical connectors.
3 . Reposition the tire pressure monitoring system module.
1) Remove the retaining nut.
2) Reposition the tire pressure monitoring system module.

4 . Remove the tire pressure monitoring system module.
Disconnect the external antenna.

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Installation
Tighten to 5 Nm.
Rear Antenna
Removal
1 . NOTE:
Detach the fender splash shield.
2 . NOTE:
Remove the tire pressure monitoring system rear antenna.
2) Remove the tire pressure monitoring system rear antenna.

Installation
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Removal
1
. CAUTION: Do not use heat to loosen a seized wheel nut. Excessive heat may cause
damage to the wheel and wheel bearings.
Loosen the wheel nuts.
Installation
1
. WARNING: Make sure there is no contamination of the wheel, hub or brake disc
contact surfaces. Installation without metal to metal contact at the mounting surfaces may
cause the wheel nuts to loosen and allow the wheel to detach with the vehicle in motion.
WARNING: Apply a small amount of grease to the hub and wheel mating surfaces
before installation. Make sure the grease does not come into contact with the vehicles
braking components and the wheel stud threads. Failure to follow these instructions may
To install, reverse the removal procedure.
Tighten to 125 Nm.

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Wheel and Tire (74.20.05) – Armoured Vehicles
Removal
NOTE:
For further information on the tire run flat system contact; Rodgard, 1355 Clinton Street, Buffalo, New York 14206, U.S.A Tel:
(716)823-1411. Fax: (716)823 1607. www.rodgard.com.
NOTE:
It is advised that the tire is removed and installed on a Hofmann Racing machine.
1
.
CAUTION: Do not use heat to loosen a seized wheel nut. Excessive heat may cause damage to the wheel
and wheel bearings.
Loosen the wheel nuts.

4 . Install the wheel to the Hofmann Racing machine and clamp the installation bed.
5.
CAUTION: Make sure that the tire does not come into contact with the tire low pressure sensor.
Detach the tire upper bead.

6 . Install the nylon spacers.
7 . Remove the retaining clip.

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8 NOTE:
. If there is a problem using the third arm on the Hofmann Racing machine to pull the tire bead back, then use the
bead stretcher supplied in the Rodgard toolbox.
Detach the roller.

Remove the retaining nut.
9
.
CAUTION: Make sure that the Rodgard runflat system does not come into contact with the tire low
pressure sensor.
Remove the the Rodgard runflat system.

10 .
Remove the tire.
Installation
1.
CAUTION: Use suitable lubrication to aid tire installation.
CAUTION: Make sure the directional arrow on the side of the tire wall is facing in the correct direction.
Install the tire to the wheel.
2 . Separate one end of the roller.

Loosen the retaining nut on the roller assembly.
3 . Install two nylon blocks between the tire and the face of the wheel.
4
.
CAUTION: Make sure the side marked OUTBOARD is facing upwards.
Check that the opening of the runner is located correctly around the tire low pressure sensor. Once this has been verified,
reposition the runner to the upper ridge of the wheel.
5.
CAUTION: Make sure the side marked OUTBOARD is facing upwards.
Install the roller to the wheel and tire assembly.

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6 Reposition the rollers into the tire and around the runner. Once this has been done, make sure that the connections on the
. roller assembly are at 90° to the tire low pressure sensor.
7
.
CAUTION: Make sure the roller is slotted into the runner.
Pull the roller halfs together so that the retaining bolt threads are within the other roller half. Additional nylon blocks need
to be inserted between the tire and roller, to keep the roller against the runner.
Install the retaining nut.
8 NOTE:
. If there is a problem using the third arm on the hofmann racing machine to pull the tire bead back, then the bead
stretcher supplied in the Rodgard toolbox should be used as an alternative.
Check that the opening of the runner is still correctly located around the tire low pressure sensor. If this is satisfactory then
install the third arm on the hofmann racing machine to pull the tire bead back around the first connection on the roller.
9 . Tighten both retaining nuts equally.
10 . NOTE:
To measure the gap use the Gauge provided, which is equal to 11mm (0.43 inch).
Set the gap evenly with the gauge.
11 . Rotate the nut until the small dot is facing directly upwards.
12 . Install the retaining clip into the slot until it engages the hole in the bolt thread.
13 To check that the retaining clip is fully engaged, try to rotate the nut with the pin in place. This will also lock the pin.
. Repeat for the other connection at the opposite end.
14 . Remove all of the installed nylon blocks from between the tire and the face of the wheel.
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15 .
Attach the tire upper bead.
16 . Check the wheel and tire to ensure no damage has been caused during any of the procedure.
17 . Remove the wheel from the Hofmann racing machine.
18 . Install an installation label behind the valve on the skirt of the wheel.
19 . Inflate the tire

For additional information, refer to , test and balance the wheel and tire assembly as per customer requirements.
20
.
WARNING: Make sure there is no contamination of the wheel, hub or brake disc contact surfaces.
Installation without metal to metal contact at the mounting surfaces may cause the wheel nuts to loosen and
allow the wheel to detach with the vehicle in motion. Failure to follow these instructions may result in personal
injury.
WARNING: Apply a small amount of grease to the hub and wheel mating surfaces before installation.
Make sure the grease does not come into contact with the vehicles braking components and the wheel stud
threads. Failure to follow these instructions may result in personal injury.
Install the wheel and tire assembly.

Tighten to 125 Nm.
204-05 : Vehicle Dynamic Suspension
Specifications
Specifications

Compressor to body retaining nuts 20 15 -
Reservoir to body retaining nuts 7 - 62
Solenoid valve block to reservoir retaining nuts 5 - 44
Air pipes 5 - 44
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Air suspension module to body retaining nuts 4 - 35

Front height sensors retaining bolts 20 15 -
Front height sensor to bracket retaining bolts 5 - 44
Rear height sensors retaining bolts 20 15 -
Front vertical accelerometer to body retaining nuts 4 - 35
Rear vertical accelerometer to body retaining nuts 4 - 35
Front air spring to body upper retaining nuts 25 18 -
Front suspension upper arm retaining nut 90 66 -
Front air spring assembly to lower arm retaining bolt 175 129 -
Rear air spring to body upper retaining nuts 25 18 -
Rear air spring assembly to lower arm retaining bolt 133 98 -
Compressor air pipe retaining nut 2 - 18
General procedures
Air Leaks
1.
CAUTION: Any spray used must have a corrosion inhibitor, and must not cause
damage to paintwork, plastics, metals or plastic pipes.
NOTE:
The recommended leak detection spray is GOTEC LDS, Jaguar part number C2C 22398.
The recommended leak detection spray should be used to identify any suspected leaks. This
procedure should also be used where any of the air suspension components have been
disturbed.
2. Clean around the area of the suspected air leak.
3. Using the recommended leak detection spray, spray around all of the air suspension
components, working systematically until the source of the air leak has been found.
4. NOTE:
If a new air suspension component is to be fitted, and no air leak has been detected at the
pipe connectors, remove and discard the new air pipe connections supplied with the
component.
If any of the air suspension components are found to be leaking e.g. air spring, compressor,
reservoir or the solenoid valve block repair is effected by replacement only. If an air leak from
the pipe connector has also been identified, a new air pipe connector, supplied with the air
suspension component, must be installed.
5. NOTE:
Only Jaguar approved connectors have been tested to the correct pressure and temperature
specifications.
NOTE:
Air pipes must only be cut using either Hose cutter 204-494, available from SPX LTD or
Hose cutter YA1000A, available from Snap-On Tools.
NOTE:
If the color coded markings adjacent to the pipe connections are removed when cutting air
pipes, the cut end of the air pipe must be clearly marked with a suitable colored tape or
paint mark.
If the source of the air leak is found to be a pipe connection cut 5 mm (0.2 in) off the end of
the air pipe and fit a new connector.
6. NOTE:
Air pipes must only be cut using either Hose cutter 204-494, available from SPX LTD or
Hose cutter YA1000A, available from Snap-On Tools.
NOTE:
Only Jaguar approved air pipes have been tested to the correct pressure and temperature
specifications.
If the source of the air leak is found to be in a section of pipe cut out the damaged section of
air pipe and replace with new air pipe and air pipe connectors as required.
7. NOTE:
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If the repair has been unsuccessful repeat the above steps until the air leak is rectified.
Using the Jaguar approved diagnostic system ensure that the system is fully pressurized.
8. Using the recommended leak detection spray, spray around all of the air suspension
components, working systematically to make sure that the source of the air leak has been
found.
Ride height gauge.

204-484
1. NOTE:
Fit special tool 204-484 as illustrated.
NOTE:
Make sure that the ride height gauge is vertical as shown.
Using the Jaguar approved diagnostic system carry out the ride height adjustments.

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Part
Item Description
Number
1 — Front vertical accelerometer

2 — Front air spring
3 — Left-hand rear suspension height sensor
4 — Left-hand front suspension height sensor
Right-hand front suspension height sensor (not used on vehicles built after
5 —
December 2003)
6 — Right-hand rear suspension height sensor
7 — Rear air spring
8 — Solenoid valve block and air reservoir
9 — Rear vertical accelerometer
10 — Air suspension control module
11 — Compressor
The vehicle dynamic suspension is a passive air suspension system providing vehicle levelling
independent of load. The system also improves the drag coefficiency by automatically lowering the
vehicle for high speed driving.
When driving at high speeds, the air suspension system will lower the vehicle to improve
aerodynamics and vehicle stability. The suspension will automatically return the vehicle to the
normal ride height when the vehicle slows.
NOTE:
Speed lowering is disabled when towing. Only Jaguar approved towing equipment will inhibit
this feature.
The air suspension system ensures that the vehicle is always at the correct ride height for varying
load conditions.
The air suspension system automatically adjusts the amount of air in the air springs to level the
vehicle. Air is supplied either from an air reservoir or a compressor. The compressor will run
periodically to fill the air reservoir.
The air suspension module (ASM) controls the operation of the solenoids in the valve block. The front
air springs are operated as a pair, the rear air springs are operated independently of each other. The
ASM adjusts one axle at a time, for example, when lifting the vehicle the rear axle is controlled first;
when lowering the vehicle the front axle is controlled first. This reduces headlamp glare during
leveling operations.
The ASM uses two different filter rates. When stationery, a 'fast' filter allows the system to react
quickly to payload changes. Whilst driving a 'slow' filter allows for compensation of the fuel level
change but does not react to road inputs for example pot holes and speed bumps.
Suspension Height Sensors

Vehicles built before December 2003 have four suspension height sensors which are mounted on the
front and rear subframe assemblies, two front and two rear. Vehicles built after December 2003 have
only three (the right front sensor being deleted), although the functionality of the system remains
the same. The suspension height sensors are linked to the suspension arms by drop link connections
and secured by means of a spring clip.
NOTE:
There may be some early vehicles which will have four sensors fitted, but which have the three-
sensor module, making the right front sensor redundant. To confirm the level of equipment,
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read the module part number from the special applications menu in configuration on the Jaguar
approved diagnostic system. Part numbers before 'BJ' are four sensor, while 'BJ' and after are
three sensor. If the Jaguar approved diagnostic system is not available, remove the rear seat and
sound deadening and read the part number from the module.
NOTE:
Suspension height sensors require calibration if removed/refitted or replaced.
Air Springs
Two derivatives of the air spring are available, comfort and sport, the sport having slightly smaller
working volumes for higher spring rates.
The air springs are complemented by two versions of damper assembly, passive and active.
CAUTION: When removing and refitting the air spring and damper assemblies, care must be
taken to avoid damage to the internal seal assembly.
CAUTION: When working on the air spring and damper assembly, ensure that no twisting
occurs between the air spring top mounting and damper body. Twisting may result in damage to
the air spring inner components.
A pressure retaining valve (PRV) is located in each air spring which retains sufficient pressure to
protect the air spring membrane during service and handling.
NOTE:
De-pressurization and re-pressurization of the air suspension system should be performed using
the Jaguar approved diagnostic system prior to, and after, any work being carried out.
Solenoid Valve Block

The solenoid valve block contains five individual solenoid valves (one per air spring and one for the
vehicle reservoir). A pressure sensor is incorporated into the solenoid valve block and monitors air
spring and reservoir pressure. The solenoid valve block is mounted on isolators to reduce valve
operation noise. Pipe connections are provided for the front and rear air spring assemblies and also
the reservoir and compressor. The compressor to valve block port and the rear air spring ports are 4
mm in diameter with the front air spring ports being 6 mm in diameter. Each of the solenoid valve
block ports and air pipes are color coded (pink, blue, white, yellow, red and brown) for correct
connection.
Reservoir
The reservoir has a volume of 4.5 liters with a maximum design pressure of 15 bar (218 psi).
Dependent on load conditions, this store of reserve air is sufficient for two full lifts. The system
automatically replenishes the reservoir by way of the compressor.
Air Suspension Module

The air suspension module (ASM) is accessed from the right-hand side of the vehicle, behind the back
of the rear seat. The ASM can be recognized by the 4 individually colored connectors (gold, grey,
yellow and pink) and the 'WABCO' logo on the front of the module. ASM calibration is required when
either a replacement module is fitted, or if any height sensors have been removed/refitted or
replaced.
NOTE:
When installing a new air suspension module it will be necessary to configure the module into
the customer mode using the Jaguar approved diagnostic system.
Compressor
The air compressor is located in the left-hand front wheel arch behind the bumper beam assembly. It
contains an air filter, an integral regenerative air drier element plus an air exhaust solenoid valve.
The compressor is isolated from the main body structure by 3 mounts, each incorporating a rubber
bush and metal spring. The maximum pressure developed by the system is 15 bar (218 psi) with a
compressor pressure relief valve fitted, set to relieve pressures above 17 Bar (247 psi). The
compressor only operates whilst the engine is running. To guard against the compressor overheating
the ASM may shut down the compressor to allow cooling to take place. Re-activation of the
compressor depends on vehicle activity and is generally no longer than 120 seconds.
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Operating modes
Before it will be possible to verify the customer concern, it will be necessary to understand the
modes of the system to establish what the system should and should not do in each mode. The table
below should help in understanding the operating modes.
Vehicle operating Air suspension

Levelling status
condition operating mode
Static, parked. No
• Compressor unpowered
occupant or loading Sleep mode
• Only lowering allowed
activity for 30 minutes
Static, parked. Occupant

• Lifting with reservoir
entry and/or loading Preliminary
• Lowering permitted
activity within past 30 mode • Compressor unpowered
minutes

• Lowering permitted
Static, parked with engine • Compressor unpowered unless reservoir
Stance mode pressure is below a preset minimum and the
running
vehicle is below the compressor activation
height
• Lowering permitted at all speeds
When vehicle speed is below 40 km/h (25 mph):

• Compressor unpowered unless reservoir
pressure is below a preset minimum and the
Driving Drive mode
vehicle is below the compressor activation
height
When vehicle speed is above 40 km/h (25 mph):
• Compressor powered to lift vehicle and refill

reservoir
TRANSPORTATION MODE
The vehicle will arrive at the dealership in transportation mode, and will need to be reset to
customer mode at PDI (this will be carried out by a Jaguar dealer).
Transportation mode keeps the vehicle in a raised condition to allow adequate clearance for
transporter loading and unloading. If the vehicle has lowered, the compressor is used to lift the
vehicle. Until a suitable height is reached, the message center will display Vehicle too low. The
message, Air Suspension Fault will be displayed on the message center at all times whilst the vehicle
is in transportation mode.
CUSTOMER MODE
The modes below are all enabled in this mode.
SLEEP MODE
The system shuts down into sleep mode 30 minutes after the vehicle is left, and "wakes up" to check
the ride height every 24 hours. If the vehicle is not level, the system lowers until the vehicle attitude
is correct. The system will not lift the vehicle while in sleep mode to conserve reservoir pressure and
battery power.
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PRELIMINARY MODE
When a door or luggage compartment is opened, or the engine is switched off from a standstill
condition, (see below) this mode is enabled.
In Preliminary mode, the reservoir is used to lift the vehicle to level it to within a greater tolerance
than in stance or drive modes (see below).
STANCE MODE
When the vehicle is stationary with the engine running, (standstill condition) the vehicle will be
levelled to within a closer tolerance than in preliminary mode to ensure that the trim heights are
correct before moving off.
Any lifting necessary will be done from the reservoir, unless the vehicle is below a preset minimum
height and the reservoir pressure is below a preset minimum, in which case, the compressor be will
used to lift the vehicle.
DRIVE MODE
When the vehicle speed is above the preset threshold, the compressor is always used to lift the
vehicle. This threshold is also used to initiate recharging of the reservoir. The following functions are
enabled in drive mode;
Speed Lowering Function

To reduce aerodynamic drag and enhance vehicle stability, the system lowers the vehicle at high road
speeds.
Levelling Inhibit Function
When the system detects significant cornering, braking and acceleration, it inhibits levelling such that
it will not attempt to compensate for vehicle attitude changes.
Inclination Function
The system enables this function when parking on an uneven surface, (or with a wheel on a kerb, for
example) to ensure the vehicle attitude remains correct when driving off.
Rough Road Detection

When the system detects a rough road surface, the speed lowering function is inhibited, or cancelled,
bringing the vehicle back up to standard ride height to aid passenger comfort.
Trailer Towing Function

When the system detects that the vehicle is towing, (via the connection of the trailer socket) the
speed lowering function is inhibited.
NOTE:
This function will only be enabled by the Jaguar approved towing equipment.
Jacking Function
When the system detects that the vehicle is being jacked, or raised on a wheel-free lift, the vehicle
enters jacking mode, which inhibits lowering to prevent air loss.
Jacking mode is exited when the vehicle is driven, or the ride height passes below a threshold value.

1 . Verify the customer concern.
2 . Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
The following messages can be displayed:
• vehicle too low

• air suspension fault
• Tire pressures • Fuse(s)

• Suspension components • Wiring harness/electrical connectors
(wear/damage/security) • Controller area network circuits. For
• Air springs (leakage/damage/tampering) additional information,
• Reservoir
• Compressor • Sensors
• Pipework and unions • Valve block
• Sensor fitment • Air suspension control module (ASU)
• Valve block
5 . Check the vehicle ride height.

retrieve the fault codes before proceeding to the diagnostic trouble code (DTC) index chart, or the
symptom chart if no DTCs are set.
Symptom Chart
Symptom Message Possible Source Action
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• Check for DTC C2780

• Air suspension
• The Jaguar approved
fault • Vehicle is in
diagnostic system is
(permanent) Transportation
required to reconfigure
• Vehicle too low mode
the vehicle into customer
(occasional)
mode
Vehicle sits
too high
and does To verify, drive the vehicle to
not lower above 3 km/h (1.8 mph) to exit
• Vehicle is in Jacking
jacking mode and check for
mode (this does
None lowering. If the vehicle does not
NOT indicate a
fault) lower, the system must be tested
using the Jaguar approved
diagnostic system
Run the engine and listen for the

compressor operating:
• Low spring pressure • If the vehicle attempts to

Vehicle too low following chassis lift for 45 seconds, then
Vehicle sits (flagged when any rework flags C2302, check that air
• Spring airline is being delivered to the
too low corner is more than 60
failure air springs by
mm too low) disconnecting the Voss
• Spring leakage
fittings at the springs
• If air is being delivered to
the springs, check the
springs for leakage
• If air is not being
delivered to the springs,
verify where air flow is
restricted or lost in the air
harness
• If the vehicle does not
attempt to lift, the system
must be tested using the
Jaguar approved
diagnostic system
• If safe, drive the vehicle

steadily to above 40 km/h
(25 mph) for a minimum
The reservoir is depleted, 5 minutes. Bring the
vehicle to a halt and
and the vehicle is not below
check if the vehicle has
None the compressor activation
lifted
height (this does NOT • If the vehicle does not lift,
indicate a fault) the system must be
tested using the Jaguar
approved diagnostic
system
Vehicle
gradually • Air spring leak Check the air harness, springs and
lowers None • Air harness leak fittings for leakage. Rectify as
while • Voss fitting leak necessary
stationary
Vehicle • Height sensor • Visually inspect the

linkage/clip height sensor
attitude is
displaced linkage/clip. Rectify as
not flat None
• Water ingress into necessary
after the height sensor • Check the connectors.
levelling connector Rectify as necessary
Check/adjust the tire pressures.

• Tire pressures Make sure that the wheels and
incorrect tires are to specification. Check
• Non-standard
the ride height.
wheels/tires
Hard ride None Ride Height Adjustments Check
• Ride height
incorrect for DTCs indicating a harness or
• Harness fault system fault, refer to the DTC
• Air spring fault index. Check the air springs (see
visual inspection).
Soft ride None • Tire pressures

Check/adjust the tire pressures.
incorrect
• Ride height Check the ride height.
incorrect Ride Height Adjustments
• Air spring fault Disconnect the electrical
connector from the suspect air
spring and recheck. If the ride is
still soft, install a new air spring.
Rear Air Spring - VIN Range:
G00442->G45703 (60.32.10)
Rear Air Spring - VIN Range:
G45704->G99999 (60.32.10)
Diagnostic Trouble Code (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.
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NOTE:
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM)
accurate to 3 decimal places, and with an up-to-date calibration certificate. When testing
resistance, always take the resistance of the DMM leads into account.
NOTE:
DTC Description Possible Source Action
For headlamp circuit tests,

Head lamp circuit • Head lamp circuit; short
B1312 GO to Pinpoint Test
malfunction circuit to B+
G256924p2.
Contact dealer technical

support for confirmation
B1342 Control module failure • Control module failure
of control module failure,
and/or raise an EPQR.
B1471 Head lamp circuit For headlamp circuit tests,

• Head lamp circuit; open
GO to Pinpoint Test
malfunction circuit, short to ground G256924p2.
• Control module power

supply circuit; short to high
voltage
Control module circuit For control module supply
• Control module power
B1671 malfunction (high/low circuit tests, GO to
supply circuit; open circuit,
voltage) high resistance, short to Pinpoint Test G256924p3.
ground
• Charging system fault
Reconfigure the control

• Control module incorrectly
Module configuration module using the Jaguar
B2477 configured to vehicle
failure specification approved diagnostic
system.
• Reservoir solenoid signal For solenoid circuit tests,

Reservoir solenoid signal
B2804 circuit; short to B+ GO to Pinpoint Test
circuit malfunction • Reservoir solenoid failure G256924p4.
• Pressure sensor signal For pressure sensor signal

Pressure sensor signal
B2807 circuit; short to B+ circuit tests, GO to
circuit malfunction • Pressure sensor failure Pinpoint Test G256924p5.
For pressure sensor supply

Pressure sensor supply • Pressure sensor supply short circuit to B+ tests,
B2808
circuit malfunction circuit; short to B+ GO to Pinpoint Test
G256924p6.
For pressure sensor supply

Pressure sensor supply • Pressure sensor supply short circuit to ground
B2809 circuit; short to ground
circuit malfunction tests, GO to Pinpoint Test
G256924p7.
• Vent solenoid circuit; open

For vent solenoid circuit
Air suspension vent circuit, short to ground,
B2810 tests, GO to Pinpoint Test
solenoid circuit malfunction short to B+
• Vent solenoid failure G256924p8.
For right-hand front air

Right-hand front air spring • Air spring solenoid circuit; spring solenoid circuit
C1416
solenoid circuit malfunction short to B+ tests, GO to Pinpoint Test
G256924p9.
C1417 Right-hand front air spring For right-hand front air

• Air spring solenoid circuit;
spring solenoid circuit
solenoid circuit malfunction short to ground tests, GO to Pinpoint Test
G256924p9.
For right-hand front air

Right-hand front air spring • Air spring solenoid circuit; spring solenoid circuit
C1419
solenoid circuit malfunction open circuit tests, GO to Pinpoint Test
G256924p9.
For left-hand front air

Left-hand front air spring • Air spring solenoid circuit; spring solenoid circuit
C1421
G256924p10.

C1422
G256924p10.
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C1424
G256924p10.
For right-hand rear air

Right-hand rear air spring • Air spring solenoid circuit; spring solenoid circuit
C1425
G256924p11.

C1426
G256924p11.

C1427
G256924p11.
For left-hand rear air

Left-hand rear air spring • Air spring solenoid circuit; spring solenoid circuit
C1430 open circuit
solenoid circuit malfunction tests, GO to Pinpoint Test
G256924p12.
C1431 Left-hand rear air spring For left-hand rear air

• Air spring solenoid circuit;
spring solenoid circuit
G256924p12.
For left-hand rear air

Left-hand rear air spring • Air spring solenoid circuit; spring solenoid circuit
C1432
G256924p12.
For rear vertical

• Rear vertical accelerometer accelerometer signal
Rear vertical accelerometer
C1437 signal circuit; short to circuit tests, GO to
signal circuit malfunction ground Pinpoint Test
G256924p13.
For rear vertical

accelerometer signal
Rear vertical accelerometer • Rear vertical accelerometer
C1438 circuit tests, GO to
signal circuit malfunction signal circuit; short to B+
Pinpoint Test
G256924p13.
For front vertical

• Front vertical accelerometer signal
Front vertical accelerometer
C1457 accelerometer signal circuit; circuit tests, GO to
signal circuit malfunction short to ground Pinpoint Test
G256924p14.
For front vertical

• Front vertical accelerometer signal
Front vertical accelerometer
C1458 accelerometer signal circuit; circuit tests, GO to
signal circuit malfunction short to B+ Pinpoint Test
G256924p14.
• Acceleration sensor supply For acceleration sensor

Acceleration sensor supply circuit; open circuit, high supply circuit tests, GO to
C1460
circuit malfunction resistance, short to ground, Pinpoint Test
short to B+ G256924p15.
• Left-hand front height

sensor supply circuit; open
circuit, short to ground, For height sensor supply
Height sensor supply circuit short to B+ circuit tests, GO to
C1723
malfunction • Right-hand front height Pinpoint Test
sensor supply circuit; open G256924p16.
circuit, short to ground,
short to B+
• Left-hand rear height
sensor supply circuit; short
to ground, open circuit,
short to B+
• Right-hand rear height
sensor supply circuit; open
short to B+
• Reservoir solenoid drive

For reservoir solenoid
Air suspension reservoir circuit; open circuit, short
C1800 drive circuit tests, GO to
solenoid drive circuit failure to ground
• Reservoir solenoid failure Pinpoint Test G256924p4.
For suspension relay drive

• Compressor relay drive
Air suspension compressor circuit tests, GO to
C1830 circuit; open circuit, short
relay circuit malfunction to ground, short to B+ Pinpoint Test
G256924p17.
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Right-hand front height

For right-hand front height
sensor signal circuit • Sensor signal circuit; open
sensor signal circuit tests,
C1881 malfunction (only on circuit, short to ground
• Sensor failure GO to Pinpoint Test
vehicles built before
G256924p18.
December 2003)
Right-hand front height

For right-hand front height
sensor signal circuit • Sensor signal circuit; short
C1883 malfunction (only on to B+
vehicles built before
G256924p18.
December 2003)
For right-hand rear height

Right-hand rear height • Sensor signal circuit; open
C1885 sensor signal circuit circuit, short to ground
malfunction
G256924p19.
For right-hand rear height

Right-hand rear height • Sensor signal circuit; short
C1887 sensor signal circuit to B+
malfunction
G256924p19.
For left-hand front height

Left-hand front height • Sensor signal circuit; open
C1889 sensor signal circuit circuit, short to ground
malfunction
G256924p20.
For left-hand front height
Left-hand front height • Sensor signal circuit; short
C1891 sensor signal circuit to B+
malfunction
G256924p20.
For left-hand rear height

• Sensor signal circuit; open
Left-hand rear height sensor sensor signal circuit tests,
C1893 circuit, short to ground
signal circuit malfunction • Sensor failure GO to Pinpoint Test
G256924p21.
For left-hand rear height

• Sensor signal circuit; short
Left-hand rear height sensor sensor signal circuit tests,
C1895 to B+
signal circuit malfunction • Sensor failure GO to Pinpoint Test
G256924p21.
Calibrate the control

module using the Jaguar
C1991 Module calibration failure • Module calibration failure
approved diagnostic
system.
• Pressure sensor signal For pressure sensor signal

Pressure sensor signal circuit; open circuit, short circuit tests, GO to
C1993 to ground
circuit malfunction Pinpoint Test
• Pressure sensor failure G256924p22.
Carry out mechanical

checks (air leaks, etc).
C2302 Levelling plausibility error • Levelling plausibility error
Refer to the service
bulletins.
Carry out mechanical

checks (air leaks, etc).
C2303 Reservoir plausibility error • Reservoir plausibility error
Refer to the service
bulletins.
For air spring supply

Air spring supply circuit • Air spring supply circuit; circuit tests, GO to
C2304
malfunction short to ground Pinpoint Test
G256924p23.
For air spring supply

Air spring supply circuit • Air spring supply circuit; circuit tests, GO to
C2305
malfunction short to B+ Pinpoint Test
G256924p23.
• Air spring solenoid supply
circuit; short to ground,
short to B+
• Left-hand front air spring
solenoid drive circuit; open
short to B+
• Right-hand front air spring For air spring solenoid
Air spring solenoid solenoid drive circuit; open
supply/drive circuit tests,
C2779 supply/drive circuit circuit, short to ground,
short to B+ GO to Pinpoint Test
malfunction
• Left-hand rear air spring G256924p24.
short to B+
• Right-hand rear air spring
short to B+
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Programme the control

Control module in • Control module module using the Jaguar
C2780 programming
manufacturer sub-state approved diagnostic
system.
CAN communication bus For CAN circuit tests,

U1900 • CAN communication error
fault
Air suspension module bus For CAN circuit tests,

U2516 • CAN communication error
off
For CAN circuit tests,

U2518 RCCM CAN message missing • CAN communication error

U2521 ABS CAN message missing • CAN communication error

U2523 ECM CAN message missing • CAN communication error
Pinpoint tests
NOTE:
NOTE:
Vehicles built before December 2003 have four suspension height sensors which are mounted
on the front and rear subframe assemblies, two front and two rear. Vehicles built after
December 2003 have only three (the right front sensor being deleted), although the functionality
of the system remains the same. There may be some early vehicles which will have four sensors
fitted, but which have the three-sensor module, making the right front sensor redundant. To
confirm the level of equipment, read the module part number from the special applications
menu in configuration on the Jaguar approved diagnostic system. Part numbers before 'BJ' are
four sensor, while 'BJ' and after are three sensor. If the Jaguar approved diagnostic system is not
available, remove the rear seat and sound deadening and read the part number from the
module.
NOTE:
PINPOINT TEST G256924p1 : CHECK

FOR LEAKS FROM AIR HARNESS
G256924t1 : VISUALLY INSPECT THE AIR HARNESS CONNECTIONS
1. Make sure the system is pressurized, either from the reservoir, or by activating the compressor. 2.
Clean around the area of the suspected leak. 3. Using GOTEC LDS, spray around the air suspension
components until the source of the leak is found.
• Was a leak found?
-> Yes
REPAIR the leak as necessary. For additional information,
Air Leaks Test the system for normal operation.
-> No
Recheck system operation. Check for DTCs.
PINPOINT TEST G256924p2 : B1312,
B1471; HEADLAMP CIRCUIT
MALFUNCTION
G256924t2 : CHECK THE HEADLAMP TO ASU PWM SIGNAL CIRCUIT FOR
HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ASU electrical connector, CR89. 3.
Disconnect the right-hand headlamp electrical connector, EC06. 4. Disconnect the left-hand
headlamp electrical connector, EC57. 5. Measure the resistance between CR89, pin 03 (Y) and EC06,
pin 02 (Y). 6. Measure the resistance between CR89, pin 03 (Y) and EC57, pin 02 (YB).
• Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
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DTC. TEST the system for normal operation.
-> No

SHORT TO GROUND
1. Reconnect the battery negative terminal. 2. Measure the resistance between CR89, pin 03 (Y) and
GROUND.
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC.
TEST the system for normal operation.
-> No

SHORT TO B+
1. Measure the voltage between CR89, pin 03 (Y) and GROUND.
• Is the voltage greater than 3 volts?

-> Yes
-> No
CONTACT dealer technical support for confirmation of possible control module failure, and/or raise
an EPQR.
PINPOINT TEST G256924p3 : B1671;

BATTERY VOLTAGE OUT OF RANGE
G256924t5 : CHECK THE POWER SUPPLY TO THE ASU
1. Disconnect the ASU electrical connector, CR88. 2. Measure the voltage between CR88, pin 01 (NW)
and GROUND.
• Is the voltage approximately 10 volts?
-> Yes
RECHECK DTCs.
-> No
G256924t6 : CHECK THE ASU POWER SUPPLY CIRCUIT FOR HIGH

RESISTANCE
1. Disconnect the battery negative terminal. 2. Remove fuse 52 of the rear power distribution box. 3.
Measure the resistance between CR88, pin 01 (NW) and the output terminal of fuse 52.
-> Yes
-> No
RECHECK the voltage to the ASU. If the voltage is high, check the charging system,
Charging System - 2.7L Diesel

C1800; RESERVOIR SOLENOID DRIVE
CIRCUIT FAULT
G256924t7 : CHECK THE SOLENOID DRIVE CIRCUIT FOR SHORT TO B+
1. Disconnect the ASU electrical connector, CR91. 2. Disconnect the valve block electrical connector,
CR22. 3. Measure the voltage between CR22, pin 05 (BO) and GROUND.
-> Yes
-> No
G256924t49 : CHECK THE SOLENOID DRIVE CIRCUIT FOR SHORT TO

GROUND
1. Measure the resistance between CR22, pin 05 (BO) and GROUND.
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-> Yes
-> No
G256924t50 : CHECK THE SOLENOID DRIVE CIRCUIT FOR HIGH RESISTANCE

1. Measure the resistance between CR22, pin 05 (BO) and CR91, pin 08 (BO).
-> Yes
-> No
INSTALL a new valve block.
PRESSURE SENSOR SIGNAL CIRCUIT
FAULT
G256924t8 : CHECK THE PRESSURE SENSOR SIGNAL CIRCUIT FOR SHORT TO
B+
CR92. 3. Measure the voltage between CR92, pin 02 (G) and GROUND.
-> Yes
-> No

PRESSURE SENSOR SUPPLY CIRCUIT
FAULT
G256924t9 : CHECK THE PRESSURE SENSOR SUPPLY CIRCUIT FOR SHORT
TO B+
CR92. 3. Measure the voltage between CR92, pin 03 (GY) and GROUND.
-> Yes
-> No
PRESSURE SENSOR SUPPLY CIRCUIT
FAULT
G256924t10 : CHECK THE PRESSURE SENSOR SUPPLY CIRCUIT FOR SHORT
TO GROUND
CR92. 3. Measure the resistance between CR92, pin 03 (GY) and GROUND.
-> Yes
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-> No

VENT SOLENOID CIRCUIT FAULT
G256924t11 : CHECK THE VENT SOLENOID SUPPLY CIRCUIT FOR HIGH
RESISTANCE
Disconnect the vent solenoid electrical connector, EC62. 4. Measure the resistance between CR91,
pin 10 (YU) and EC62, pin 02 (YU).
-> Yes
-> No
G256924t12 : CHECK THE VENT SOLENOID SUPPLY CIRCUIT FOR SHORT TO
GROUND
1. Reconnect the battery negative terminal. 2. Measure the resistance between CR91, pin 10 (YU)
and GROUND.
-> Yes
-> No
G256924t13 : CHECK THE VENT SOLENOID SUPPLY CIRCUIT FOR SHORT TO

B+
1. Measure the voltage between CR91, pin 10 (YU) and GROUND.
-> Yes
-> No
G256924t14 : CHECK THE VENT SOLENOID SIGNAL CIRCUIT FOR HIGH

RESISTANCE
1. Measure the resistance between CR91, pin 11 (U) and EC62, pin 01 (U).
-> Yes
-> No
G256924t15 : CHECK THE VENT SOLENOID SIGNAL CIRCUIT FOR SHORT TO

GROUND
1. Measure the resistance between CR91, pin 11 (U) and GROUND.
-> Yes
-> No
G256924t16 : CHECK THE VENT SOLENOID SIGNAL CIRCUIT FOR SHORT TO

B+
1. Measure the voltage between CR91, pin 11 (U) and GROUND.
-> Yes
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-> No
INSTALL a new compressor,
PINPOINT TEST G256924p9 : C1416,

C1417, C1419; RIGHT-HAND FRONT AIR
SPRING DRIVE CIRCUIT
MALFUNCTION
G256924t17 : CHECK THE RIGHT-HAND FRONT AIR SPRING DRIVE CIRCUIT
FOR SHORT TO B+
1. Disconnect the right-hand front air spring electrical connector, EC12. 2. Measure the voltage
between EC12, pin 02 (BG) and GROUND.
-> Yes
-> No
FOR SHORT TO GROUND
1. Measure the resistance between EC12, pin 02 (BG) and GROUND.
-> Yes
-> No

FOR HIGH RESISTANCE
Measure the resistance between EC12, pin 02 (BG) and CR89, pin 10 (BG).
-> Yes
-> No
INSTALL a new air spring solenoid, CLEAR the DTC. TEST the system for normal operation.

C1422, C1424; LEFT-HAND FRONT AIR
MALFUNCTION
G256924t20 : CHECK THE LEFT-HAND FRONT AIR SPRING DRIVE CIRCUIT
FOR SHORT TO B+
1. Disconnect the left-hand front air spring electrical connector, EC47. 2. Measure the voltage
between EC47, pin 02 (BO) and GROUND.
-> Yes
-> No

FOR SHORT TO GROUND
1. Measure the resistance between EC47, pin 02 (BO) and GROUND.
-> Yes
-> No
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FOR HIGH RESISTANCE
Measure the resistance between EC47, pin 02 (BO) and CR89, pin 01 (BO).
-> Yes
-> No

C1426, C1427; RIGHT-HAND REAR AIR
MALFUNCTION
G256924t23 : CHECK THE RIGHT-HAND REAR AIR SPRING DRIVE CIRCUIT
FOR SHORT TO B+
1. Disconnect the right-hand rear air spring electrical connector, CR23. 2. Measure the voltage
between CR23, pin 02 (BG) and GROUND.
-> Yes
-> No

FOR SHORT TO GROUND
1. Measure the resistance between CR23, pin 02 (BG) and GROUND.
-> Yes
-> No

FOR HIGH RESISTANCE
Measure the resistance between CR23, pin 02 (BG) and CR89, pin 11 (BG).
-> Yes
-> No
C1431, C1432; LEFT-HAND REAR AIR
MALFUNCTION
G256924t26 : CHECK THE LEFT-HAND REAR AIR SPRING DRIVE CIRCUIT
FOR SHORT TO B+
1. Disconnect the left-hand rear air spring electrical connector, TL33. 2. Measure the voltage
between TL33, pin 02 (BK) and GROUND.
-> Yes
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-> No

FOR SHORT TO GROUND
1. Measure the resistance between TL33, pin 02 (BK) and GROUND.
-> Yes
-> No

FOR HIGH RESISTANCE
Measure the resistance between TL33, pin 02 (BK) and CR89, pin 02 (BK).
-> Yes
-> No

C1438; REAR VERTICAL
ACCELEROMETER SIGNAL CIRCUIT
G256924t29 : CHECK THE REAR ACCELEROMETER SIGNAL CIRCUIT FOR
SHORT TO GROUND
1. Disconnect the ASU electrical connector, CR89. 2. Disconnect the rear accelerometer electrical
connector, TL34. 3. Measure the resistance between TL34, pin 02 (GO) and GROUND.
-> Yes
-> No
G256924t30 : CHECK THE REAR ACCELEROMETER SIGNAL CIRCUIT FOR

SHORT TO B+
1. Measure the voltage between TL34, pin 02 (GO) and GROUND.
-> Yes
-> No
INSTALL a new rear vertical accelerometer,
Rear Vertical Accelerometer (86.56.55) CLEAR the DTC. TEST the system for normal operation.

C1458; FRONT VERTICAL
ACCELEROMETER SIGNAL CIRCUIT
G256924t31 : CHECK THE FRONT ACCELEROMETER SIGNAL CIRCUIT FOR
SHORT TO GROUND
1. Disconnect the ASU electrical connector, CR89. 2. Disconnect the accelerometer electrical
connector, EC13. 3. Measure the resistance between EC13, pin 02 (G) and GROUND.
-> Yes
-> No
G256924t32 : CHECK THE FRONT ACCELEROMETER SIGNAL CIRCUIT FOR

SHORT TO B+
1. Measure the voltage between EC13, pin 02 (G) and GROUND.
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-> Yes
-> No
INSTALL a new front vertical accelerometer,
Rear Vertical Accelerometer (86.56.55) CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST G256924p15 : C1460;

ACCELEROMETER SENSOR SUPPLY
CIRCUIT FAULT
G256924t33 : CHECK THE ACCELEROMETER SENSOR SUPPLY CIRCUIT FOR
SHORT TO GROUND
1. Disconnect the ASU electrical connector, CR91. 2. Measure the resistance between CR91, pin 16
(Y) and GROUND.
-> Yes
-> No

SHORT TO B+
1. Measure the voltage between CR91, pin 16 (Y) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
1. Disconnect the front accelerometer electrical connector, EC13. 2. Disconnect the rear
accelerometer electrical connector, TL34. 3. Measure the resistance between CR91, pin 16 (Y) and
EC13, pin 03 (Y). 4. Measure the resistance between CR91, pin 16 (Y) and TL34, pin 03 (Y).
-> Yes
-> No
CHECK for DTCs indicating a sensor fault. Contact dealer technical support for confirmation of
possible module failure, and/or raise an EPQR.

HEIGHT SENSOR(S) SUPPLY
CIRCUIT(S) FAULT
G256924t36 : CHECK THE LEFT-HAND FRONT HEIGHT SENSOR SUPPLY
CIRCUIT FOR SHORT TO GROUND
(G) and GROUND.
-> Yes
-> No

CIRCUIT FOR SHORT TO B+
1. Measure the voltage between CR90, pin 01 (G) and GROUND.
-> Yes
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-> No

CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the left-hand front height sensor electrical connector, EC45. 2. Measure the resistance
between CR90, pin 01 (G) and EC45, pin 05 (G).
-> Yes
-> No
G256924t39 : CHECK THE RIGHT-HAND FRONT HEIGHT SENSOR SUPPLY

1. Measure the resistance between CR90, pin 04 (GO) and GROUND.

-> Yes
-> No

1. Measure the voltage between CR90, pin 04 (GO) and GROUND.
-> Yes
-> No

1. Disconnect the right-hand front height sensor electrical connector, EC18. 2. Measure the
resistance between CR90, pin 01 (G) and EC18, pin 05 (GO).
-> Yes
-> No
G256924t42 : CHECK THE LEFT-HAND REAR HEIGHT SENSOR SUPPLY

1. Measure the resistance between CR90, pin 07 (BW) and GROUND.
-> Yes
-> No

1. Measure the voltage between CR90, pin 07 (BW) and GROUND.
-> Yes
-> No
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1. Disconnect the left-hand rear height sensor electrical connector, CV03. 2. Measure the resistance
between CR90, pin 07 (BW) and CV03, pin 05 (BW).
-> Yes
-> No
G256924t45 : CHECK THE RIGHT-HAND REAR HEIGHT SENSOR SUPPLY

1. Measure the resistance between CR90, pin 10 (YR) and GROUND.
-> Yes
-> No

1. Measure the voltage between CR90, pin 10 (YR) and GROUND.
-> Yes
-> No

1. Disconnect the right-hand rear height sensor electrical connector, CV04. 2. Measure the resistance
between CR90, pin 10 (YR) and CV04, pin 05 (YR).
-> Yes
-> No

RELAY DRIVE CIRCUIT FAULT
G256924t51 : CHECK THE RELAY DRIVE CIRCUIT FOR SHORT TO B+
1. Remove the air suspension relay. 2. Measure the voltage between the relay base, pin 02, and
GROUND.
-> Yes
-> No
G256924t48 : CHECK THE RELAY DRIVE CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between the relay base, pin 02, and GROUND.
-> Yes
-> No
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G256924t52 : CHECK THE RELAY DRIVE CIRCUIT FOR HIGH RESISTANCE

Measure the resistance between CR91, pin 12 (NR).
-> Yes
-> No
INSTALL a new air suspension relay. CLEAR the DTC. TEST the system for normal operation. If the DTC
is repeated, contact dealer technical support for confirmation of possible module failure, and/or
raise an EPQR.

C1883; RIGHT-HAND FRONT HEIGHT
SENSOR SIGNAL CIRCUIT FAULT
G256924t53 : CHECK THE RIGHT-HAND FRONT SIGNAL CIRCUIT FOR SHORT
TO B+
1. Disconnect the right-hand front height sensor electrical connector, EC18. 2. Measure the voltage
between EC18, pin 04 (GW) and GROUND.

-> Yes
-> No
G256924t54 : CHECK THE RIGHT-HAND FRONT SIGNAL CIRCUIT FOR SHORT

TO GROUND
1. Measure the resistance between EC18, pin 04 (GW) and GROUND.
-> Yes
-> No
G256924t55 : CHECK THE RIGHT-HAND FRONT SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between CR90, pin 05 (GW) and EC18, pin 04 (GW).
-> Yes
-> No

C1887; RIGHT-HAND REAR HEIGHT
G256924t56 : CHECK THE RIGHT-HAND REAR SIGNAL CIRCUIT FOR SHORT
TO B+
1. Disconnect the right-hand rear height sensor electrical connector, CV04. 2. Measure the voltage
between CV04, pin 04 (YG) and GROUND.
-> Yes
-> No
G256924t57 : CHECK THE RIGHT-HAND REAR SIGNAL CIRCUIT FOR SHORT

TO GROUND
1. Measure the resistance between CV04, pin 04 (YG) and GROUND.
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-> Yes
-> No
G256924t58 : CHECK THE RIGHT-HAND REAR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between CR90, pin 11 (YG) and CV04, pin 04 (YG).
-> Yes
-> No
C1891; LEFT-HAND FRONT HEIGHT
G256924t59 : CHECK THE LEFT-HAND FRONT SIGNAL CIRCUIT FOR SHORT
TO B+
1. Disconnect the left-hand front height sensor electrical connector, EC45. 2. Measure the voltage
between EC45, pin 04 (GU) and GROUND.
-> Yes
-> No
G256924t60 : CHECK THE LEFT-HAND FRONT SIGNAL CIRCUIT FOR SHORT

TO GROUND
1. Measure the resistance between EC45, pin 04 (GU) and GROUND.
-> Yes
-> No
G256924t61 : CHECK THE LEFT-HAND FRONT SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between CR90, pin 02 (GU) and EC45, pin 04 (GU).
-> Yes
-> No

C1895; LEFT-HAND REAR HEIGHT
G256924t62 : CHECK THE LEFT-HAND REAR SIGNAL CIRCUIT FOR SHORT
TO B+
1. Disconnect the left-hand rear height sensor electrical connector, CV03. 2. Measure the voltage
between CV03, pin 04 (BR) and GROUND.

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-> Yes
-> No
G256924t63 : CHECK THE LEFT-HAND REAR SIGNAL CIRCUIT FOR SHORT

TO GROUND
1. Measure the resistance between CV03, pin 04 (BR) and GROUND.
-> Yes
-> No
G256924t64 : CHECK THE LEFT-HAND REAR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between CR90, pin 08 (BR) and CV03, pin 04 (BR).
-> Yes
-> No

PRESSURE SENSOR SIGNAL CIRCUIT
FAULT
G256924t65 : CHECK THE PRESSURE SENSOR SIGNAL CIRCUIT FOR SHORT
TO GROUND
1. Disconnect the pressure sensor electrical connector, CR92. 2. Measure the resistance between
CR92, pin 02 (G) and GROUND.
-> Yes
-> No
G256924t66 : CHECK THE PRESSURE SENSOR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between CR92, pin 02 (G) and CR90, pin 14 (G).
-> Yes
-> No
INSTALL a new valve block,
Air Suspension Solenoid Valve Block CLEAR the DTC. TEST the system for normal operation.
C2305; AIR SPRING SUPPLY CIRCUIT
FAULT
G256924t67 : CHECK THE LEFT-HAND FRONT AIR SPRING SUPPLY CIRCUIT
FOR SHORT TO GROUND
1. Disconnect the left-hand front air spring electrical connector, EC47. 2. Measure the resistance
between EC47, pin 01 (WR) and GROUND.
-> Yes
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-> No
G256924t68 : CHECK THE LEFT-HAND FRONT AIR SPRING SUPPLY CIRCUIT

FOR SHORT TO B+
1. Measure the voltage between EC47, pin 01 (WR) and GROUND.
-> Yes
-> No
G256924t69 : CHECK THE RIGHT-HAND FRONT AIR SPRING SUPPLY

1. Disconnect the right-hand front air spring electrical connector, EC12. 2. Measure the resistance
between EC12, pin 01 (WU) and GROUND.
-> Yes
-> No
G256924t70 : CHECK THE RIGHT-HAND FRONT AIR SPRING SUPPLY

1. Measure the voltage between EC12, pin 01 (WU) and GROUND.
-> Yes
-> No
G256924t71 : CHECK THE LEFT-HAND REAR AIR SPRING SUPPLY CIRCUIT

FOR SHORT TO GROUND
1. Disconnect the left-hand rear air spring electrical connector, TL33. 2. Measure the resistance
between TL33, pin 01 (WG) and GROUND.
-> Yes
-> No
G256924t72 : CHECK THE LEFT-HAND REAR AIR SPRING SUPPLY CIRCUIT

FOR SHORT TO B+
1. Measure the voltage between TL33, pin 01 (WG) and GROUND.
-> Yes
-> No
G256924t73 : CHECK THE RIGHT-HAND REAR AIR SPRING SUPPLY CIRCUIT

FOR SHORT TO GROUND
1. Disconnect the right-hand rear air spring electrical connector, CR23. 2. Measure the resistance
between CR23, pin 01 (WB) and GROUND.
-> Yes
-> No
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G256924t74 : CHECK THE RIGHT-HAND REAR AIR SPRING SUPPLY CIRCUIT

FOR SHORT TO B+
1. Measure the voltage between CR23, pin 01 (WB) and GROUND.
-> Yes
-> No
CHECK for DTCs indicating a air spring fault. Contact dealer technical support for confirmation of

AIR SPRING SOLENOID
SUPPLY/DRIVE CIRCUIT FAULT
G256924t75 : CHECK THE AIR SPRING SOLENOID SUPPLY CIRCUIT FOR
SHORT TO GROUND
(YG) and GROUND.

-> Yes
-> No

SHORT TO B+
1. Measure the voltage between CR91, pin 01 (YG) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
1. Disconnect the air spring solenoid electrical connector, CR22. 2. Measure the resistance between
CR91, pin 01 (YG) and CR22, pin 06 (YG).
-> Yes
-> No
G256924t78 : CHECK THE LEFT-HAND FRONT AIR SPRING SOLENOID DRIVE

1. Measure the resistance between CR22, pin 01 (WR) and GROUND.
-> Yes
-> No

1. Measure the voltage between CR22, pin 01 (WR) and GROUND.
-> Yes
-> No
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1. Measure the resistance between CR22, pin 01 (WR) and CR91, pin 02 (WR).
-> Yes
-> No
G256924t81 : CHECK THE RIGHT-HAND FRONT AIR SPRING SOLENOID

DRIVE CIRCUIT FOR SHORT TO GROUND
1. Measure the resistance between CR22, pin 02 (WB) and GROUND.
-> Yes
-> No
DRIVE CIRCUIT FOR SHORT TO B+
1. Measure the voltage between CR22, pin 02 (WB) and GROUND.
-> Yes
-> No

DRIVE CIRCUIT FOR HIGH RESISTANCE
1. Measure the resistance between CR22, pin 02 (WB) and CR91, pin 03 (WB).
-> Yes
-> No
G256924t84 : CHECK THE LEFT-HAND REAR AIR SPRING SOLENOID DRIVE

1. Measure the resistance between CR22, pin 03 (WU) and GROUND.
-> Yes
-> No

1. Measure the voltage between CR22, pin 03 (WU) and GROUND.
-> Yes
-> No

1. Measure the resistance between CR22, pin 03 (WU) and CR91, pin 05 (WU).
-> Yes
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-> No
G256924t87 : CHECK THE RIGHT-HAND REAR AIR SPRING SOLENOID DRIVE

1. Measure the resistance between CR22, pin 04 (WG) and GROUND.
-> Yes
-> No

1. Measure the voltage between CR22, pin 04 (WG) and GROUND.
-> Yes
-> No

1. Measure the resistance between CR22, pin 04 (WG) and CR91, pin 06 (WG).
-> Yes
-> No
INSTALL a new valve block,
Air Suspension Solenoid Valve Block CLEAR the DTC. TEST the system for normal operation.

Removal
1 . Disconnect the battery ground cable.
For additional information, refer to Battery Disconnect and Connect

3 . Disconnect the electrical connector.

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4
. WARNING: Loosen the pipes no more than one full turn to allow the stored air
pressure to vent for a minimum of three seconds.
CAUTION: Using a suitable blanking plug, blank off the end of the air pipe to prevent
dirt ingress.
NOTE:
Make a note of the correct routing of the air pipe.
Release the air pipe.

Remove the nut.
6
. CAUTION: Make sure air feed pipe does not come detached from air compressor
mounting bracket.
Remove air feed pipe.
7.
CAUTION: Mounting bushes may fall out on removal of the compressor.
Remove the compressor.
Remove the 3 nuts.
Remove the compressor support brace.
Collect the 6 bushes.

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8 . Remove air pipe union.
1) Split, remove and discard olive.
2) Remove and discard brass nut.

Installation
1
. CAUTION: Make sure mounting bushes and springs are in the correct orientation.
Failure to follow this instruction will cause the compressor to become noisey and may
cause damage to the vehicle.
Locate compressor to mounting bracket.
Install compressor support brace.
Install the 3 nuts and tighten to 20 Nm.
2
. CAUTION: Make sure the air feed pipe is not restricted and is in the correct
orientation. Failure to carry out this instruction may cause damage to the vehicle.
CAUTION: Failure to check pipe can result in pipe being trapped and restricting air
flow to air suspension system.
Install air feed pipe to compressor filter.

3 . Connect the electrical connector.
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4 . NOTE:
Make sure the pipe is routed correctly.
Remove blanking plug from compressor.
Push air pipe firmly into union.

6 . Install the radiator splash shield.

7 . Connect the battery ground cable.

Air Suspension Control Module (60.32.03)
Removal
NOTE:
of the system remains the same.
NOTE:
The later module can be fitted in place of the four sensor module, but the right front sensor
must be left in place, even though the system will not use it.
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1
. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Disconnect the battery ground cable.


3 . NOTE:
1) Remove the luggage compartment side trim retaining clip.
2) Remove the luggage compartment side trim panel.
4 . Remove the luggage compartment front carpet.
1) Remove the fir tree clips
2) Disconnect the interior light electrical connector.
3) Remove the luggage compartment front carpet.
5 . Remove the rear seat backrest.

For additional information, refer to Rear Seat Backrest (76.70.38)
6 . Disconnect the air suspension control module electrical connectors.
7 . NOTE:
Clean the vehicle of any debris after the rivets have been removed.
Remove the air suspension control module.

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Using a suitable tool, remove the four rivets.
Installation
1
. CAUTION: Make sure the rivets are correctly seated and the riveting device is
positioned squarely onto the rivets before the rivets are secured. Failure to follow this

For additional information, refer to Battery Connect (86.15.15)
3 . Re-calibrate the air suspension control module using the Jaguar approved diagnostic system.
For additional information, refer to Ride Height Adjustments
Air Suspension Reservoir
Removal
1 . Using the Jaguar approved diagnostic system depressurize the air suspension system.
2 . Disconnect the battery ground cable. <<414-01>>

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4
. CAUTION: Before the spare wheel retainer is removed the lower locking nut should
be loosened.
Remove the spare wheel.

5 . Remove the reservoir insulator.
8
Remove the air pipes.
1) Detach the blue air pipe.
2) Detach the white air pipe.

3) Detach the yellow air pipe.
4) Detach the red air pipe.
5) Detach the brown air pipe.

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9 . Remove the reservoir.
10
. WARNING: Loosen the pipe no more than one full turn to allow the stored air
pressure to vent for a minimum of one minute.
Detach the pink air pipe.

11 . Remove the securing nuts.
Installation
Tighten to 5 Nm.
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5 . Connect the battery ground cable. <<414-01>>
6 Where required. Using the Jaguar approved diagnostic system pressurize the air suspension
. system.
7 . Start and run the engine for 2 minutes to make sure the vehicle has leveled.
Removal
4
. CAUTION: Before the spare wheel retainer is removed the lower locking nut should
be loosened.
Remove the spare wheel.

5 . Remove the reservoir insulator.

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8
Remove the air pipes.
1) Detach the blue air pipe.
2) Detach the white air pipe.

3) Detach the yellow air pipe.
4) Detach the red air pipe.
5) Detach the brown air pipe.
9
Detach the pink air pipe.
10 . Remove the solenoid valve block.

Installation
Tighten to 5 Nm.
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5 Where required. Using the Jaguar approved diagnostic system pressurize the air suspension
. system.
6 . Start and run the engine for 2 minutes to make sure the vehicle has leveled.
Removal

3 . NOTE:
Disconnect the air spring electrical connector if fitted.
4
. WARNING: Loosen the air pipe until the stored air pressure starts to vent. Wait for
at least one minute for the air pressure to escape completely before fully removing the air
pipe connector.
NOTE:
Detach the air pipe.
5 . NOTE:

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Remove the air spring retaining nuts.

For additional information, refer to Front Stabilizer Bar Link (60.10.02)
7 . Detach the front air suspension height sensor link rod.

8 . Detach the brake line from the inner fender securing clips
9
. CAUTION: Prevent the air spring from rotating. Do not use extension bars when
removing the air spring securing bolt. Failure to follow these instructions may result in
damage to the air spring.
NOTE:
10
. CAUTION: Prevent the upper ball joint ball pin hexagon from rotating. Failure to do
so may result in damage to the upper ball joint boot.
CAUTION: Make sure the wheel knuckle is supported. Failure to follow these
instructions may result in damage to the vehicle.
NOTE:

11 . Remove the air spring.
Installation
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WARNING: Do not install an air spring if the pressure retaining valve has been removed or
has become loose. Failure to follow this instruction may result in personal injury.
CAUTION: Do not install an air spring if the pressure retaining valve has been removed or
has become loose. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
New air springs have a shelf life of seven months from the date of manufacture. Do not install
the air spring if the date marking exceeds this date.
Tighten to 90 Nm.
2
. CAUTION: Prevent the air spring from rotating. Do not use extension bars when
tightening the air spring securing bolt. Failure to follow these instructions may result in
damage to the air spring.
NOTE:
Tighten to 175 Nm.
3 . NOTE:
Tighten to 25 Nm.
4
. CAUTION: Do not over tighten the air pipe union as it may result in the pressure
retaining valve coming loose if removed again.
NOTE:
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Tighten to 5 Nm.
5 NOTE:
.
Make sure the air suspension system is repressurized using the Jaguar approved
diagnostic system before lowering the vehicle to the ground.
Repressurize the air suspension system. For further information, refer to the Jaguar approved
diagnostic system.
Front Vertical Accelerometer (86.56.53)
Removal
1 . Remove the wheel and tire assemble. <<204-04>>
2 . Remove the right-hand side front fender splash shield. <<501-02>>
3 . Disconnect the front vertical accelerometer electrical connector.
4
. CAUTION: Make sure the vertical accelerometer is not dropped in transit as damage
will be caused to internal components.
Remove the front vertical accelerometer.

Installation
Tighten to 4 Nm.
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Rear Air Spring - VIN Range: G00442-
>G45703 (60.32.10)
Removal
1 . Using the Jaguar approved diagnostic system depressurize the air suspension.

4 . NOTE:

5 . NOTE:
Remove the air spring trim panel.

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6 . NOTE:
Disconnect the air spring electrical connector.
7 . NOTE:

8 . NOTE:

10 . NOTE:
Detach the rear fender splash shield.

11 . NOTE:
Remove the rear fender splash shield.

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12 . NOTE:
Remove the air spring bolt.

13 . NOTE:
Remove the air spring.
1) Displace the air spring lower mounting from the lower arm.
2) Displace the air spring from the upper mounting.
3) Position the air spring to the outside of the lower arm.
4) Remove the air spring.
Installation
NOTE:
1 . NOTE:
Install the air spring.
1) Install the air spring.
2) Position the air spring to the front of the lower arm.
3) Locate the air spring into the upper mount.
4) Locate the lower air spring mounting into the lower arm.
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2 . NOTE:
Install the air spring bolt.
Tighten to 133 Nm.

3 . NOTE:
Attach the rear fender splash shield.
4 . NOTE:
Install the rear fender splash shield.
5 . NOTE:
Install the rear air spring retaining nuts.
Tighten to 25 Nm.
6 . NOTE:
Attach the air pipe.
Tighten to 5 Nm.
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7 . NOTE:
Connect the air spring electrical connector.

8 . NOTE:
Install the air spring trim panel.
9 . NOTE:

12 NOTE:
.
Make sure that the air suspension system is repressurized using the Jaguar approved
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Repressurize the air suspension system. For further information, refer to the Jaguar
approved diagnostic system.

Rear Air Spring - VIN Range: G45704-
>G99999 (60.32.10)
Removal

4 . NOTE:

5 . NOTE:
Remove the air spring trim panel.

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6 . NOTE:
Disconnect the air spring electrical connector.
7 . NOTE:

8 . NOTE:

10 . NOTE:
Reposition the stabilizer bar link cover.

11 . NOTE:

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12 . NOTE:
Remove the air spring retaining bolt.
13 . NOTE:
Remove the air spring.

Installation
NOTE:
1 . NOTE:
Install the air spring.

2 . NOTE:
Tighten to 133 Nm.
3 . NOTE:
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Tighten to 48 Nm.
4 . NOTE:
Reposition the stabilizer bar link cover.

5 . NOTE:
Tighten to 25 Nm..
6 . NOTE:
Tighten to 5 Nm.
7 . NOTE:
Connect the air spring electrical connector.
8 . NOTE:

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Install the air spring trim panel.
9 . NOTE:


12 NOTE:
.
Make sure that the air suspension system is repressurized using the Jaguar approved
Repressurize the air suspension system. For further information, refer to the Jaguar

Rear Air Spring Lower Bushing (64.32.03)
Bushing Remover / installer

205-335
Bushing remover
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204-533
Bushing installer
204-534
Removal
1 . Remove the rear air spring.
For additional information, refer to Rear Air Spring - VIN Range: G00442->G45703 (60.32.10)
2 . NOTE:
With assistance make sure the tool is aligned.
Using the special tool, support the air spring.

3 . NOTE:
Position and align the special tool to the air spring bush.
4 . NOTE:
Using special tools slowly push the bush from the air spring.
Installation
1 . NOTE:
Make sure the bush is clean and free from oil or grease.
NOTE:
Use a suitable lubricant to allow the bush to locate into the special tool.
Locate the new bush in the special tool.

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2 NOTE:
.
Make sure the damper is clean and free from grease or oil and is not damaged prior to
pushing in the new bush.
NOTE:
Make sure the air spring and bush are placed in the correct orientation.
Using the special tools, align the bush to the air spring.
3 . NOTE:
Make sure correct alignment is maintained.
Slowly push the bush into the air spring until the tool reaches the stop.
4 . Install the rear air spring.

Rear Vertical Accelerometer (86.56.55)
Removal

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2 . Remove the luggage compartment side trim panel.
3 . Disconnect the rear vertical accelerometer electrical connector.

4
. CAUTION: Make sure the vertical accelerometer is not dropped in transit as damage
will be caused to internal components.
Remove the rear vertical accelerometer.
Installation
Tighten to 4 Nm.
Suspension Height Sensor (60.32.05)
Removal
NOTE:
of the system remains the same. There may be some early vehicles which will have four sensors
fitted, but which have the three-sensor module, making the right front sensor redundant. To
confirm the level of equipment, read the module part number from the special applications
menu in configuration on the Jaguar approved diagnostic system. Part numbers before 'BJ' are
four sensor, while 'BJ' and after are three sensor. If the Jaguar approved diagnostic system is not
available, remove the rear seat and sound deadening and read the part number from the
module.
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NOTE:
The later module can be fitted in place of the four sensor module, but the right front sensor
must be left in place, even though the system will not use it.
1 . Remove the wheel and tire assembles.

2
. CAUTION: Do not spray solvents or cleaning agents inside the height sensor. Failure
to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure the height sensor is thoroughly cleaned prior to disassembly.
For additional information, refer to General Service Information
NOTE:
Front shown, rear similar.
Disconnect the front air suspension height sensor electrical connector.

3 . NOTE:
This step is for front air suspension height sensors only.
Detach the wheel speed sensor harness.
4 . NOTE:
Detach the front air suspension height sensor link rod.

5 . NOTE:
Remove the front air suspension height sensor.
Remove the front air suspension height sensor retaining bolts.

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Installation
Tighten to 20 Nm.
2 NOTE:
.
To aid installation of the electrical connector, apply a small amount of silicone based oil
or grease to the connector seal.
NOTE:
Make sure the electrical connector latch is fully secured to the sensor.
Connect the front air suspension height sensor electrical connector.
3 . Re-calibrate the suspension height sensor using the Jaguar approved diagnostic system.
For additional information, refer to Ride Height Adjustments
205 : Driveline
205-00 : Driveline System – General Information
General procedures
Driveline Angle Inspection

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Alignment Tool
205-535
1. Raise and support the vehicle. <<100-02>>
2. Remove the exhaust system. <<309-00>>
3. Remove the support bracket.
4. Remove the driveshaft heat shield.

5. Loosen the driveshaft centre bearing retaining bolts two complete turns.
6.
CAUTION: Make sure the driveshaft centre bearing is correctly aligned to the driveshaft.
Failure to follow these instructions may result in damage to the vehicle.
Using the special tool, align the driveshaft centre bearing.
7. Install the driveshaft heat shield retaining bolts.
8. Install the support bracket.
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9. Install the exhaust system. <<309-00>>

Driveline System
The driveline transfers engine torque to the drive wheels. Power is transmitted through the
transmission to the driveshaft and then to the rear drive axle which is connected to the rear drive
halfshaft.
For additional information, refer to Halfshaft (205-05 Rear Drive Halfshafts)
For additional information, refer to Driveshaft (205-01 Driveshaft)
For additional information, refer to Axle Assembly (205-02 Rear Drive Axle/Differential)
The engine angle is built into the engine mounts. If the engine angle is out of specification, the
engine mounts must be inspected for damage.
Driveline Vibration
Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline
vibration is directly related to the speed of the vehicle and is usually noticed at various speed ranges.
Driveline vibration can be felt as a tremor in the floorpan or is heard as a rumble, hum, or boom.
Driveline vibration can exist in all drive modes, but may exhibit different symptoms depending upon
whether the vehicle is accelerating, decelerating, cruising, or coasting. Check the driveline angles if
the vibration is particularly noticeable during acceleration or deceleration, especially at lower
speeds. Check that the centre bearing washers between the body and bearing housing are 3mm
minimum and 8mm maximum thickness.
In order to diagnose vibrations in the driveshaft, refer to the Jaguar approved diagnostic system for
analysis/rectification.
Driveline Angle
Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft, and
the rear drive axle pinion. Factors determining driveline angularity include ride height, rear springs
and engine mounts.
An incorrect driveline (pinion) angle can often be detected by the driving condition in which the
vibration occurs.
• A vibration during coasting from 72 to 56 km/h (45 to 35 mph) is often caused by a high
pinion angle.
• A vibration during acceleration from 56 to 72 km/h (35 to 45 mph) may indicate a low pinion
angle.
When these conditions exist, check the driveline angles.
If the tires and driveline angle are not the cause, carry out the Noise, Vibration and Harshness (NVH)
tests to determine whether the concern is caused by a condition in the driveline. For additional
information, refer to Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness)
Rear Drive Axle Identification Tag

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Item Description
1 Part Number
2 Ratio and Vehicle Line
Rear Drive Axle Ratio
• A and E = 2.87 Ratio

3
• B and F = 3.07 Ratio
• C and G = 3.31 Ratio
• D = 2.69 Ratio
4 Time Built
5 Year Built
6 Month Built
7 Day Built
Plant Built
8 • C = Castle Bromwich
• B = Browns Lane
• G = German Specification
Engine capacity Transmission Axle Ratio
4.2L V8 Supercharger Automatic 2:87
4.2L V8 Automatic 2:87
3.5 V8 Automatic 3.07
3.0 V6 Automatic 3.31
The plant code denotes a particular rear drive axle design and specific ratio. In addition, the plant
code will not change as long as that particular rear drive axle never undergoes an external design
change. If, however, an internal design change takes place during the production life of the rear drive
axle and that internal change affects parts interchangeability, a dash and numerical suffix is added to
the plant code. This means that as an assembly both rear drive axles are interchangeable; however,
internally they are different. Therefore, each requires different internal parts at the time of repair.
Driveline System
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.
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4 . If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Rear Drive Axle Noise
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.
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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 G215971p1.

.
Noise is the same on drive or coast
Possible Source(s):
• Road.
• Wheel bearing.
Action(s) to take:
• Normal conditions.
• CHECK and INSTALL a new wheel bearing as necessary. For additional information,
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:
Noise is produced with the vehicle standing and

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

Engine - 3.0L/3.5L/4.2L
Possible Source(s):
• Transmission.
Action(s) to take:
Noise is more pronounced while turning
Possible Source(s):
• Differential side gears and pinion gears.
Action(s) to take:

Loud clunk in the driveline when shifting from reverse to forward

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Possible Source(s):
• Transmission out of calibration.
• Engine idle speed set too high.
• Engine mount.
Action(s) to take:
• Using the Jaguar approved diagnostic system, calibrate the transmission control module
(TCM).
• Check and adjust the idle speed as necessary. For additional information,
Electronic Engine Controls - VIN Range: G00442->G45703 or
• INSPECT and INSTALL new engine mounts as necessary.
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:
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 suspension components as necessary.
Clicking, popping, or grinding noises
Possible Source(s):
• Inadequate or contaminated lubrication in the rear drive halfshaft constant velocity (CV)
joint.
• Another component contacting the rear drive halfshaft.
• Wheel bearings, brakes or suspension components.
Action(s) to take:
• INSPECT, CLEAN and LUBRICATE with new grease as necessary.
• INSPECT and REPAIR as necessary.
• INSPECT and INSTALL new components as necessary.
Vibration at highway speeds
Possible Source(s):
• Out-of-balance wheels or tires.
Action(s) to take:
• INSTALL new 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):
• Propshaft centre bearing touching body mounting point.

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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.
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):
• Vent.
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:

EXCESSIVE DRIVELINE NOISE
G215971t1 : 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 at the same vehicle speed?
-> Yes
INSTALL a new final drive. TEST the system for normal operation.
-> No
REFER to Engine - 3.0L/3.5L/4.2L
205-01 : Driveshaft
Specifications
Specifications

Centre bearing retaining bolts 48 36 -
Transmission flexible joint retaining bolts 108 80 -
Rear drive axle CV joint retaining bolts 73 54 -
Driveshaft heat shield retaining bolts 7 - 62
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General Procedures
Driveshaft Runout and Balancing

1. For additional information, refer to the Jaguar Approved Diagnostic System.
Driveshaft
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1 — Transmission flexible joint retaining nut
2 — Transmission flexible joint washer
3 — Transmission flexible joint retaining bolt
4 — Centre bearing spacers
5 — Universal joint
6 — Centre bearing retaining bolts
7 — Rear drive axle flexible joint
8 — Rear drive axle flexible joint retaining bolt
9 — Rear drive axle flexible joint washer
10 — Rear drive axle flexible joint retaining nut
11 — Rear drive axle flexible joint balance nut
12 — Rear driveshaft tube
13 — Collapsible front driveshaft tube
14 — Transmission flexible joint
CAUTION: To preserve 'drive line' refinement, individual parts, other than fixings, MUST
NOT be renewed. In the event of any balance or driveshaft component related concern, the
complete assembly must be renewed. Under no circumstances may the flexible coupling be
removed from the driveshaft (or its fixings be loosened). Do not drop or subject the driveshaft to
damage.
NOTE:
All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft,
universal joints and the rear drive axle shafts to prevent over-spray of the undercoating material.
The driveshaft consists of the following:
• A two piece welded steel tube with a splined center slip joint.
• A universal joint.
• A center bearing.
• Two flexible joints.
Universal Joint
The universal joint is:
• a lubed-for-life design and requires no lubrication in service.

Driveshaft
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Driveshaft (47.15.01)
Removal
For additional information, refer to Lifting
2 . Remove the exhaust system.

For additional information, refer to Exhaust System - 3.0L/3.5L/4.2L
3 . Remove the support bracket.
4 . Remove the driveshaft heat shield.
5
loosened or removed from the driveshaft.
Detach the driveshaft from the transmission flange.
Mark the position of the driveshaft in relation to the transmission flange.
Mark the position of each nut and bolt in relation to the transmission
flexible joint.
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6
(if fitted).
flexible joint.
7.
CAUTION: Support the driveshaft front and rear sections.
NOTE:
Note the position of the driveshaft centre bearing spacers.
Remove the driveshaft.
Remove the driveshaft centre bearing spacers.
Installation
1 NOTE:
.
If a new driveshaft is installed, refer to Jaguar approved diagnostic system to establish
the correct location for the balance nut if required.
NOTE:
Do not fully tighten the driveshaft centre bearing retaining bolts.
Tighten to 40 Nm.
Install the driveshaft centre bearing spacers.

Tighten to 88 Nm.
If a balance nut is fitted, install onto the original bolt position.
Tighten to 12 Nm.
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3 . Attach the driveshaft to the transmission flange.
Tighten to 108 Nm.

4
. CAUTION: Make sure the driveshaft centre bearing is correctly aligned to the
driveshaft. Failure to follow these instructions may result in damage to the vehicle.
Carry out the Driveline Angle Inspection.

For additional information, refer to Driveline Angle Inspection
5 . Install the driveshaft heat shield retaining bolts.
Tighten to 7 Nm.
6 . Install the support bracket.
Tighten to 9 Nm.
7 . Install the exhaust system.

For additional information, refer to Exhaust System - 3.0L/3.5L/4.2L

205-02 : Rear Drive Axle / Differential
Specifications
Specifications
Item Specification
Differential fluid type M2C192A synthetic
Differential fluid capacity 1.3 liters
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Axle front retaining bolt 90 55 –
Axle rear retaining bolts A – –
Driveshaft flexible joint 88 65 –
A = refer to the procedure for correct torque sequence.


1 — Differential bearing shim
2 — Differential bearing cup
3 — Differential bearing
4 — Ring gear
5 — Differential side gear
6 — Differential pinion shaft
7 — Differential pinion thrust washer
8 — Differential pinion gear
9 — Differential gear case
10 — Pinion
11 — Differential bearing cap
12 — Rear axle pinion bearing cup
13 — Output shaft oil seals
14 — Differential pilot bearing
15 — Differential housing
16 — Differential drive pinion cup
17 — Differential drive pinion collapsible spacer
18 — Pinion bearing
19 — Pinion flange
20 — Pinion nut
21 — Dust shield
22 — Rear axle drive pinion seal
23 — Rear axle pinion shaft oil slinger
24 — Pinion Bearing
25 — Drive pinion bearing adjustment shim
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.
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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 - Vehicles Without:

Differential Drain Plug (51.25.13)
Powertrain Assembly Jack.

HTJ1200-2
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Replacer - Mounting Bolts Final Drive To Subframe.

204-477
Removal
1 . Remove both halfshafts.
For additional information, refer to Rear Halfshaft (47.10.13)

For additional information, refer to Front Muffler - 3.0L/3.5L/4.2L (30.10.18)
3
Detach the driveshaft from the differential flange.
Mark the position of the driveshaft in relation to the differential flange.

Mark the position of the balance nut in relation to the differential flange (if
fitted).
Mark the position of each nut and bolt in relation to the driveshaft flexible
joint.
4
. CAUTION: When supporting the axle assembly, use a suitable packing material to
prevent damage to the axle assembly.
Using the special tool HTJ1200-02, support the axle assembly.
5 . Remove the axle assembly front retaining bolt.
6 NOTE:
.
The axle assembly rear retaining bolts do not have to be fully removed for the axle
assembly to be removed, slacken the rear retaining bolts alternately until the rear axle
assembly is released.
Remove the axle assembly.

Installation
1 . NOTE:
Loosely tighten the axle assembly rear retaining bolts.

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Install the axle assembly.
2 . NOTE:
Make sure the axle front retaining bolt washer and spacer are correctly installed.
Install the axle assembly front retaining bolt.

3
. CAUTION: When supporting the axle assembly, use a suitable packing material to
prevent damage to the axle assembly.
Remove the special tool HTJ1200-02, supporting the axle assembly.
5
. CAUTION: Make sure the axle rear retaining bolts are tightened to the correct
torque specification. Failure to follow this instruction may result in damage to the vehicle.
Using the special tool and a torque wrench, tighten the axle rear retaining bolts.
Tighten to 200 Nm.
To make sure the axle rear retaining bolts are torqued to the correct
specification, using the special tool and a torque wrench the following
calculation steps must be followed.
Step 1. Multiply 200 Nm by the effective length of the torque wrench

(1).
Step 2. Add the effective length of the special tool (2) to the effective
length of the torque wrench (1).
Step 3. Divide the total of step 1 by the total of step 2.
Step 4. Set the torque wrench to the figure arrived at in step 3.

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7 . NOTE:
Make sure the driveshaft nuts and bolts are correctly installed.
Tighten to 88 Nm.

For additional information, refer to Front Muffler - 3.0L/3.5L/4.2L (30.10.18)
9 . Install both halfshafts.

Axle Assembly - Vehicles With: Differential
Drain Plug (51.25.13)
No data
Axle Housing Bushing (64.25.30)
Forcing screw remover and installer

204-274
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Forcing screw remover and installer

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 . Remove the axle assembly.
2 . Using the special tools, remove the axle housing bushing.
Installation
1 The bushing should be installed with the raised molding at 45 degrees to the centre line of
. the pinion shaft.
2 . Using the special tools, install the axle housing bushing.
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3 . Install the axle assembly.

Drive Pinion Seal (51.20.01)
Flange holding tool

205-053
Pinion seal installer

204-264
Flange remover/replacer plate

204-265
Flange remover/replacer boss

204-266
Flange remover/replacer shaft center

204-267
Flange remover/replacer forcing screw
204-269
Removal
1 . Remove the driveshaft.
For additional information, refer to Driveshaft (47.15.01)
2
. CAUTION: The following step must be carried out to make sure the correct drive
pinion flange retaining nut torque is achieved.
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CAUTION: Only use a paint mark to match mark the drive pinion and flange.
Remove the drive pinion flange nut.
Match mark the drive pinion nut to the drive pinion flange.
Match mark the drive pinion flange to the drive pinion shaft.
Loosen the drive pinion flange nut 180°.
Tighten the drive pinion flange nut to the match mark.
Note the force required to tighten to the match mark.
Remove the drive pinion flange nut.

3 . Using the special tools, remove the drive pinion flange.
4 . Remove the drive pinion seal dust cover.
5 . Using a suitable tool, remove the drive pinion seal.
Installation
1
. CAUTION: If the drive pinion seal becomes misaligned during installation, remove it
and install a new one.
NOTE:
Check the rear drive axle pinion flange, rear axle housing and drive pinion splines for
damage.
Using the special tool, install the drive pinion seal.

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2 . Install the drive pinion seal dust cover.
3.
CAUTION: Only use the correct special tools to install the drive pinion flange.
Using the special tools, install the drive pinion flange.
4 . Install a new drive pinion flange nut.
Tighten the drive pinion flange nut to the force noted on removal.
Tighten the drive pinion flange nut to a further 10%.

5
. CAUTION: Axle fluid should flow from the filler plug threaded hole when full. Failure
to follow this instruction may result in damage to the axle.
Check and top up the axle assembly fluid level as required.
Tighten to 34 Nm.
6 . Install the driveshaft.

For additional information, refer to Driveshaft (47.15.01)
205-05 : Rear Drive Halfshaft
Specifications
Specifications
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Constant velocity (CV) grease Olistamoly LN 584 LO
Torque Specification
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Anti-lock brake sensor retaining nut 9 – 80
Lower arm to wheel knuckle retaining nut 150 111 –
Outer tie rod ball joint retaining nut 55 41 –
Upper wish bone ball joint retaining nut 90 66 –
Wheel hub nut 300 221 –
Fill Capacities
Description Vehicle Grams

Vehicles without supercharger 100
Grease for inner CV joint boot
Vehicles with supercharger -
Grease for inner CV joint
Vehicles with supercharger 100
Grease for outer CV joint boot
Vehicles with supercharger -
Grease for outer CV joint
Vehicles with supercharger 100

1 — Outer constant velocity (CV) joint
2 — Anti-lock brake system (ABS) ring
3 — Outer CV joint boot
4 — Inner CV joint boot
5 — Spring clip
6 — Inner CV joint
7 — Halfshaft
The rear drive halfshafts are of unequal lengths and both inner and outer joints are of the CV type.
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 halfshaft. The inner CV joints are retained in the
rear drive axle with the aid of a spring clip.
Handling Rear Drive Halfshafts

The following points should be observed when handling rear drive halfshafts:
• Do not pull on the CV joints or the bar shaft.

• Do not allow the CV joints to exceed 18 degrees of travel.
• Check polished surfaces and splines for damage.
• Do not allow the CV joint boots to come into contact with sharp edges, hot vehicle
components or the exhaust system.
• Do not drop the rear drive halfshafts, this may cause damage to the splined sections of the
CV joints, the threaded sections of the CV joints or the interior of the boots which may not be
visible.
• Do not support the rear drive halfshaft by holding the CV joint alone.
Underbody Protection and Corrosion Prevention

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The CV joint boots should be covered during application of underbody protection or corrosion
prevention. Foreign matter on the CV boots may cause premature ageing of the material. Foreign
material on the rear drive halfshafts may cause imbalance.

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

Halfshaft splitter handle

307-443
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Halfshaft splitter
307-442
Halfshaft oil seal installer

205-532
Halfshaft seal protector

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

204-269
Removal
1 . Loosen the wheel hub nut.

G00442->G45703 (70.10.11)
Range: G00442->G45703 (70.10.11)
3 . Detach the anti-lock brake system (ABS) sensor.

4 . Detach the outer tie rod.
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5 . Detach the lower arm from the wheel knuckle.
6 . Remove the wheel hub nut.
7 . Using the special tools, detach the halfshaft.

8 . Remove the wheel knuckle assembly.
9
. CAUTION: To avoid damage to the halfshaft constant velocity (CV) joints and boots,
do not allow the CV joints to exceed 18 degrees of travel.
NOTE:
The halfshaft is retained in the axle assembly by a retaining clip.
Using the special tools, remove the halfshaft.
Remove and discard the retaining clip.

10 . Remove the halfshaft seal.
Installation
CAUTION: The final tightening of the rear suspension components must be carried out with
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the vehicle on its wheels.
1 . Using the special tool, install the halfshaft seal.
2 . Install a new retaining clip.

3
. CAUTION: The next four steps must be carried out within 5 minutes of applying the
sealant.
CAUTION: Install the halfshaft within 5 minutes of applying the sealant.
Apply a 3mm diameter bead of Loctite WSK-M2G349-A4 or equivalent meeting Jaguar

specification to the halfshaft splines.
4
. CAUTION: Do not damage the axle shaft seal.
CAUTION: To avoid damage to the halfshaft CV joints and boots, do not allow the
CV joints to exceed 18 degrees of travel.
CAUTION: Make sure no damage occurs to the halfshaft seal when installing the
halfshaft.
NOTE:
Do not fully engage the halfshaft into the axle assembly.
Install the halfshaft.
1) Install the special tool to the halfshaft seal.

2) Install the halfshaft.

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6
. CAUTION: To avoid damage to the halfshaft CV joints and boots, do not allow the
CV joints to exceed 18 degrees of travel.
CAUTION: Make sure no damage occurs to the halfshaft seal when installing the
halfshaft.
NOTE:
Make sure the retaining clip is correctly seated.
Attach the halfshaft.

7
. CAUTION: Axle fluid should flow from the filler plug threaded hole when full. Failure
to follow this instruction may result in damage to the axle.
Check and top up the axle assembly fluid level as required.
Tighten to 34 Nm.
8 . Install the wheel knuckle assembly.
9 . NOTE:
Using the old wheel hub nut, tighten to 150 Nm.
Attach the wheel knuckle to the halfshaft.

10 . Install the lower arm to the wheel knuckle.
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11 . Install the outer tie rod retaining nut.
12 . Install the ABS sensor.
Tighten to 9 Nm.
13 Install the brake disc.
G00442->G45703 (70.10.11)
Range: G00442->G45703 (70.10.11)
For additional information, refer to Brake Disc - VIN Range: G45704->G99999 (70.10.11) or
14 . Remove and discard the old wheel hub nut, install a new wheel hub nut.
Tighten to 300 Nm.
15
Tighten to 150 Nm.

16
Tighten to 55 Nm.
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Inner Constant Velocity (CV) Joint Boot
(47.10.33)
Removal
1 . Remove the halfshaft.
2.
CAUTION: Use suitable protective covers to protect the halfshaft.
Using a suitable clamp, secure the halfshaft.
3
. CAUTION: Make sure the inner constant velocity (CV) joint is not separated from
the halfshaft.
Remove and discard the inner CV joint boot retaining clip.
4.
CAUTION: Make sure the CV joint ball bearings do not drop out of the CV joint.
Using a suitable tool, remove the inner CV joint.

5 . Remove the inner CV joint boot.

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Installation
All vehicles
1 . Install the inner CV joint boot.
Install a new retaining clip.
Using a suitable tool, install the retaining clip.

Vehicles without supercharger
2.
NOTE:
Use a CV grease meeting Jaguar specification.
Fit the inner CV joint.
Fill the CV joint with 40 grams of grease.
Fill the CV joint boot with 100 grams of grease.
Vehicles with supercharger

3.
NOTE:
Fit the inner CV joint.

All vehicles
4.
CAUTION: Make sure the CV joint is not separated from the halfshaft.
NOTE:
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Make sure enough air is present in the CV boot.
5 . Install a new retaining clip.

6 . Remove the halfshaft from the clamp.
7 . Install the halfshaft.

Outer Constant Velocity (CV) Joint Boot
(47.10.32)
Removal
1 . Remove the Halfshaft.
2.
CAUTION: Use suitable protective covers to protect the halfshaft.
Using a suitable clamp, secure the halfshaft.

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3 . Remove the outer constant velocity (CV) joint boot retaining clip.
4.
CAUTION: Do not damage the bearing retainer.
NOTE:
The outer CV joint is retained to the shaft by a spring clip.
Using a suitable brass drift, remove the outer CV joint.

5 . Remove the retaining clip.
6 . Remove the outer CV joint boot.

Installation
All vehicles
1 . Install the outer CV joint boot.
Install the new retaining clip.

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2 . Install the new retaining clip.

3.
NOTE:
Fit the outer CV joint.

Fill the CV joint boot with 65 grams of grease.

4.
NOTE:
Fit the outer CV joint.
All vehicles
5 . NOTE:
Make sure enough air is present in the CV boot.
Install the new retaining clip.

6 . Remove the halfshaft from the clamp.
7 . Install the halfshaft.

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206 : Brake System
206-00 : Brake System – General Information
Specifications
Specifications
CAUTION: Do not use brake fluid ITT Super Dot 4 on 2006my vehicles onwards.
Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Brake fluid ITT Super Dot 4 has now been superseded by Shell ESL Super Dot 4 which is
the Jaguar recommended brake fluid. Shell ESL Super Dot 4 can be used on all model
years.
Item Specification
Brake fluid ITT Super Dot 4
Brake fluid Shell ESL Super Dot 4
Brake Lining and Disc Specifications
Item Specification
Front brake disc diameter - Vehicles with 4.2L engine 320 mm (12.8 in)
Front brake disc diameter - Vehicles with Brembo brakes 365 mm (14.6 in)
New front brake disc nominal thickness - Vehicles with 3.0L,
30 mm (1.2 in)
3.5L or 4.2L engine
New front brake disc nominal thickness - Vehicles with Brembo
32 mm (1.28 in)
brakes
Worn brake disc discard thickness - Vehicles with 3.0L, 3.5L or
28 mm (1.14 in)
4.2L engine
Worn front brake disc discard thickness - Vehicles with Brembo
30 mm (1.2 in)
brakes
Rear brake disc diameter - Vehicles with 3.0L, 3.5L or 4.2L
288 mm (11.52 in)
engine
Rear brake disc diameter - Vehicles with Brembo brakes 330 mm (13.2 in)
New rear brake disc nominal thickness - Vehicles with 3.0L, 3.5L
20 mm (0.8 in)
or 4.2L engine
New rear brake disc nominal thickness - Vehicles with Brembo
15 mm (0.6 in)
brakes
Worn rear brake disc minimum thickness - Vehicles with 3.0L,
18 mm (0.72 in)
3.5L or 4.2L engine
Worn rear brake disc minimum thickness - Vehicles with Brembo
13 mm (0.52 in)
brakes
Maximum front and rear brake disc runout (installed) - Vehicles
0.076 mm ( 0.003 in)
with 3.0L, 3.5L or 4.2L engine
Maximum front brake disc runout (installed) - Vehicles with
0.070 mm ( 0.002 in)
Brembo brakes
Maximum rear brake disc runout (installed) - Vehicles with
0.070 mm ( 0.002 in)
Brembo brakes
Maximum new front and rear brake disc thickness variation - 0.005 mm ( 0.0002 in) in
Vehicles with 3.0L, 3.5L or 4.2L engine 360°
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Maximum new front brake disc thickness variation - Vehicles 0.010 mm (0.0003 in) in
with Brembo brakes 360°
Maximum new rear brake disc thickness variation - Vehicles with 0.010 mm (0.0003 in) in
Brembo brakes 360°
Maximum used front and rear brake disc thickness variation - 0.009 mm (0.0004 in) in
Vehicles with 3.0L, 3.5L or 4.2L engine 360°
Maximum front and rear hub face runout (installed) - Vehicles
0.05 mm ( 0.002 in)
with 3.0L, 3.5L or 4.2L engine
Maximum front hub face runout (installed) - Vehicles with
0.05 mm ( 0.002 in)
Brembo brakes
Maximum rear hub face runout (installed) - Vehicles with
0.05 mm ( 0.002 in)
Brembo brakes
Front brake caliper piston diameter - twin piston - Vehicles with 38 mm (1.52 in) and 45
3.0L, 3.5L or 4.2L engine mm (1.8 in)
Rear brake caliper piston diameter - Vehicles with 3.0L, 3.5L or
43 mm (1.72 in)
4.2L engine
Front brake caliper piston diameter - twin piston - Vehicles with 38 mm (1.52 in) and 44
Brembo brakes mm (1.8 in)
Rear brake caliper piston diameter - twin piston - Vehicles with 28 mm (1.12 in) and 30
Brembo brakes mm (1.2 in)
Specifications
CAUTION: Do not use brake fluid ITT Super Dot 4 on 2006MY vehicles
onwards. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
years.
Item Specification
Brake fluid Shell ESL
Brake Lining and Disc Specifications
Item Specification
Front brake disc diameter - Vehicles with standard brakes 326 mm (12.8 in)
Front brake disc diameter - Vehicles with high performance brakes 355 mm (14.0 in)
New front brake disc nominal thickness - Vehicles with standard brakes 30 mm (1.18 in)
New front brake disc nominal thickness - Vehicles with high
32 mm (1.28 in)
performance brakes
Worn brake disc discard thickness - Vehicles with standard brakes 28 mm (1.14 in)
Worn front brake disc discard thickness - Vehicles with high
30 mm (1.18 in)
performance brakes
Rear brake disc diameter 326 mm (12.8 in)
New rear brake disc nominal thickness 20 mm (0.79 in)
Worn rear brake disc minimum thickness 18 mm (0.72 in)
Maximum front brake disc runout (installed) - Vehicles with standard 0.090 mm ( 0.004
brakes in)
Maximum front brake disc runout (installed) - Vehicles with high 0.090 mm ( 0.004
performance brakes in)
0.075 mm ( 0.003
Maximum rear brake disc runout (installed)
in)
0.015 mm ( 0.0006
Maximum front hub face runout (installed)
in)
Maximum rear hub face runout (installed) 0.05 mm ( 0.002 in)
Front brake caliper piston diameter 60 mm (2.36 in)
Rear brake caliper piston diameter 45 mm (1.77 in)
Brake Lining and Disc Specifications – Armoured XJ
Item Specification
Front brake disc diameter 380 mm (14.96 in)
New front brake disc nominal thickness 36 mm (1.42 in)
Worn front brake disc discard thickness 33.6 mm (1.32 in)
Front brake pad discard thickness (including backing plate) 7.7 mm (0.30 in)
Rear brake disc diameter 330 mm (12.99 in)
New rear brake disc nominal thickness 28 mm (1.10 in)
Worn rear brake disc minimum thickness 25.6 mm (1.00)
Rear brake pad discard thickness (including backing plate) 7.7 mm (0.30 in)
Maximum front brake disc runout (installed) 0.090 mm ( 0.004 in)
Maximum rear brake disc runout (installed) 0.075 mm ( 0.003 in)
Maximum front hub face runout (installed) 0.015 mm ( 0.0006 in)
Maximum rear hub face runout (installed) 0.05 mm ( 0.002 in)
Front brake caliper piston diameter
 30.2 mm (1.18 in)
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 Brake caliper piston 1 and 2  34.9 mm (1.37 in)

 Brake caliper piston 3 and 4  38.1 mm (1.50 in)
 Brake caliper piston 5 and 6
Rear brake caliper piston diameter 31.80 mm (1.25 in)

General procedures
Brake Disc Runout Check

Check
1. Remove the wheel and tire. For additional information, refer to <<204-04>>.
2. NOTE:
For vehicles with Brembo brakes, detach the parking brake caliper.
Detach the front or rear brake caliper.
3. Install all wheel nuts and tighten equally to 20 Nm.

• Make sure that the brake disc is fully seated against the hub face.
4. Install a dial test indicator gauge and holding fixture to a suitable mounting point.
5. 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.
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.
6. If a front hub runout check is required, remove the front brake disc. For additional
information, refer to <<206-03>>. If a rear hub runout check is required, remove the rear
brake disc. For additional information, refer to <<206-04>>.
7. NOTE:
The hub surface should be free from dirt and corrosion. Do not use abrasive cloths to
clean hub faces.
Using the dial test indicator, measure the hub face runout.
1. Position the gauge so that it contacts the mounting tube between the stud and the
chamfer.
2. Slowly rotate the hub and note the runout. For additional information, refer to the
specification chart.
• If the front hub runout exceeds the specifications, install a new hub, brake disc and
recheck. For additional information, refer to <<204-01>>. If the rear hub runout exceeds
the specifications, install a new hub, brake disc and recheck. For additional information,
refer to <<204-02>>.
8. If the front hub face is within specification, install a new brake disc. For additional
information, refer to <<206-03>>. If the rear hub face is within specification, install a new
disc. For additional information, refer to <<206-04>>.
9. Install the wheel and tire. For additional information, refer to <<204-04>>.
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Brake System Bleeding - VIN Range:
G00442->G45703 (70.25.03)
WARNING: Brake Fluid contains polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands thoroughly after handling, as prolonged contact may
cause irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold
water or eyewash solution and seek medical attention. If taken internally do not induce
vomiting, seek immediate medical attention. Failure to follow these instructions may
CAUTION: Make sure that the vehicle is standing on a level surface or supported
on a wheel free lift.
CAUTION: If brake fluid comes into contact with the paintwork, the affected
area must be immediately washed down with cold water.
NOTE:
The system consists of separate circuits for each front and diagonally opposite rear wheel.
Each front to rear circuit and each wheel circuit can be bled individually of each other.
NOTE:
The service ABS hydraulic control unit is supplied pre-filled with brake fluid. Therefore,
a conventional bleed procedure should be adequate to remove all the air from the brake
system.
1.
CAUTION: Make sure that the brake master cylinder reservoir filler cap does
not become contaminated.
Remove the brake master cylinder reservoir filler cap.

2. NOTE:
Always use fluid from a sealed container and dispose of used fluid safely.
Fill up the brake master cylinder reservoir to the MAX mark as necessary.
3. Install a bleed tube to the rear right-hand brake caliper bleed nipple.
4. Bleed the circuit.

• Make sure the bleed tube is firmly attached to the bleed nipple.
• Submerge the end of the bleed tube in a bleed jar containing a small quantity of
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approved brake fluid.

• Position the bleed jar base at least 300 mm (12 in) above the bleed nipple to maintain
fluid pressure and prevent air leaking past the bleed nipple threads.
• Open the bleed nipple half a turn.
• Slowly apply the brake pedal to its maximum travel (this forces brake fluid into the
bleed jar).
• Close the bleed nipple.
• Return the brake pedal to the rest position.
• Wait 2 seconds to allow the brake fluid to replenish the system.
• Fill up the brake master cylinder reservoir to the MAX mark as necessary.
• Continue to bleed the circuit until air-free brake fluid is pumped into the jar.
• Fully tighten the bleed nipple.
5. Repeat the procedure for the rear left, front right and front left-hand brake circuits.
6. Fill up the brake master cylinder reservoir to the MAX mark.

7. Install the brake master cylinder reservoir filler cap.
Additional Procedure to Bleed New

Calipers with Integral Park Brake
Mechanism
NOTE:
Due to the complexity of the fluid path within the integral park brake calipers, it may be
difficult to achieve a satisfactory result using the procedure above when new calipers
have been installed.
1. Using the Jaguar approved diagnostic system, put the park brake system into service mode.
2. Remove both rear wheels and tires. <<204-04>>
3. Bleed the braking system.
4. Disconnect the parking brake cable.

• Release the tension.
• Disconnect the park brake cable.
5. Detach the park brake cable.

1. Release the retaining tangs.
2. Detach the park brake cable.
6. Detach the brake caliper from the anchor bracket.

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7. NOTE:
The inner brake pad must have at least 7mm of friction material. If there is less then 7mm
a new pad must be used.
Remove the outer brake pad.
8. Attach the brake caliper with a protective cloth placed between the caliper fingers and the
disc.
9. Slowly apply the brake pedal until the piston is extended to the brake disc.
10. Detach the brake caliper from the anchor bracket.
11. Bleed the caliper.

• Position the brake caliper with the piston facing down and the bleed nipple at the top.
• Using the special tool, fully retract the caliper piston.
• Repeat the above procedure twice.
• Continue to bleed the caliper using the above procedure until air-free brake fluid is
pumped into the jar.
• Make sure the piston grooves are aligned to fit the brake pad peg when the caliper is
assembled.
12. Install the outer brake pad.

13. Install the brake caliper.
• Install new brake caliper guide pin retaining bolts.
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14. Attach the park brake cable.

• Attach the park brake cable.
• Fully seat the retaining tangs.
15. Connect the park brake cable.

• Release the tension.
• Connect the park brake cable.
16. Bleed the braking system.
17. Install the wheels and tires. <<204-04>>

Brake System Bleeding - VIN Range:
G45704->H99999 (70.25.03)
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with the eyes. Wash hands thoroughly after handling, as prolonged contact may cause
irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water
or eyewash solution and seek medical attention. If taken internally do not induce
CAUTION: Make sure that the vehicle is standing on a level surface or supported
on a wheel free lift.
CAUTION: If brake fluid comes into contact with the paintwork, the affected
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area must be immediately washed down with cold water.
NOTE:
The system consists of separate circuits for each front and diagonally opposite rear wheel.
Each front to rear circuit and each wheel circuit can be bled individually of each other.
NOTE:
The service anti-lock braking system (ABS) hydraulic control unit is supplied pre-filled
with brake fluid. Therefore, a conventional bleed procedure should be adequate to remove
all the air from the brake system.
1.

2. NOTE:

• Slowly apply the brake pedal to its maximum travel (this forces brake fluid into the
bleed jar).
• Return the brake pedal to the rest position.
• Wait 2 seconds to allow the brake fluid to replenish the system.
• Continue to bleed the circuit until air-free brake fluid is pumped into the jar.
5. Repeat the procedure for the rear left, front right and front left-hand brake circuits.
6. Fill up the brake master cylinder reservoir to the MAX mark.

NOTE:
Due to the complexity of the fluid path within the integral park brake calipers, it may be
difficult to achieve a satisfactory result using the procedure above when new calipers
have been installed. Therefore carry out the following steps to make sure that the system
is properly bled.
7. Remove both rear wheels and tires.

8. NOTE:
Remove the logo badge.

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9. NOTE:
Remove the anti-rattle spring.
10. NOTE:
Remove the brake caliper retaining bolt dust covers.

11. NOTE:
Detach the brake caliper.
12. NOTE:
The inner brake pad must have at least 7mm of friction material. If there is less then 7mm
a new pad must be used.
NOTE:
Remove the outer brake pad.
13. NOTE:
Attach the brake caliper with a protective cloth placed between the caliper fingers and the
disc.
14. Slowly apply the brake pedal until the piston is extended to the brake disc.
15. NOTE:

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16. Bleed the caliper.

• Position the brake caliper with the piston facing down and the bleed nipple at the top.
• Using a suitable tool, fully retract the caliper piston.
• Repeat the above procedure twice.
• Continue to bleed the caliper using the above procedure until air-free brake fluid is
pumped into the jar.
17. NOTE:
Install the outer brake pad.
18. NOTE:
Install the brake caliper.

19. NOTE:
Install the brake caliper retaining bolt dust covers.
20. NOTE:
Install the anti-rattle spring.

21. NOTE:
Install the logo badge.

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22. Install the wheels and tires.

23. NOTE:
24.
Install the brake master cylinder reservoir filler cap.

Brake System Bleeding (70.25.03) – Armoured Vehicles
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands
thoroughly after handling, as prolonged contact may cause irritation and dermatitis. If brake fluid contacts the eyes,
flush the eyes with cold water or eyewash solution and seek medical attention. If taken internally do not induce vomiting,
seek immediate medical attention. Failure to follow these instructions may result in personal injury.
CAUTION: Make sure that the vehicle is standing on a level surface or supported on a wheel free lift. Failure to
follow these instructions may result in damage to the vehicle.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately washed
down with cold water. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
The system consists of separate circuits for each front and diagonally opposite rear wheel. Each front to rear circuit and each
wheel circuit can be bled individually of each other.
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NOTE:
The front brake calipers and rear brake calipers have two bleed nipples each.
NOTE:
The service anti-lock braking system (ABS) hydraulic control unit is supplied pre-filled with brake fluid. Therefore, a
conventional bleed procedure should be adequate to remove all the air from the brake system.
1.
CAUTION: Make sure that the brake master cylinder reservoir filler cap does not become contaminated. Failure to
2. NOTE:
Fill the brake master cylinder reservoir to the MAX mark as necessary.
3. Remove the wheels and tires.
4.
CAUTION: Make a note of the position of the brake caliper bleed nipple shields. Failure to follow this instruction
may result in damage to the vehicle.
Reposition the brake caliper bleed nipple shields.
 Remove the bleed nipple rubber cover (s).

 Make sure the bleed tube is firmly attached to the bleed nipple.
 Submerge the end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
 Position the bleed jar base at least 300 mm (12 in) above the bleed nipple to maintain fluid pressure and prevent air leaking
past the bleed nipple threads.
 Open the bleed nipple half a turn.
 Slowly apply the brake pedal to its maximum travel (this forces brake fluid into the bleed jar).
 Close the bleed nipple.
 Return the brake pedal to the rest position.
 Wait 2 seconds to allow the brake fluid to replenish the system.
 Fill up the brake master cylinder reservoir to the MAX mark as necessary.
 Continue to bleed the circuit until air-free brake fluid is pumped into the jar.
 Tighten the bleed nipple to 14 Nm.
 Install the bleed nipple cover (s) and tighten to 5 Nm.
7.
CAUTION: Make sure that the fluid bleeding procedure is carried out on ALL of the brake caliper bleed nipples.
Repeat the procedure for the rear left, front right and front left-hand brake circuits.
8.
CAUTION: Make sure the brake caliper bleed nipple shields are correctly aligned. Failure to follow this instruction
Reposition the brake caliper bleed nipple shields.

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9. NOTE:
Fill up the brake master cylinder reservoir to the MAX mark.
10. Install the wheels and tires.

11.
CAUTION: Make sure that the brake master cylinder reservoir filler cap does not become contaminated.
Install the brake master cylinder reservoir filler cap.

Brake System - VIN Range: G00442-

>G45703
The braking system is a diagonally split, dual circuit design featuring front and rear disc
brakes.
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The hydraulic system provides separate circuits for each pair of diagonally opposed wheels
(left front, right rear and right front, left rear).
The standard front brake caliper has two retaining bolts that attach the brake caliper to the
anchor plate. These are of double, sliding piston type which makes sure equal effort is applied
through both brake pads. The anchor plate is attached to the wheel knuckle with two bolts.
The standard rear brake calipers are single pistoned floating caliper type, which also
incorporates the park brake mechanism. The standard brake disc is manufactured from cast
iron and is of the vented type. It is retained on the hub by two retaining clips and the wheel
studs.
The Brembo front and rear brake calipers have two retaining bolts that attach the brake caliper
to the wheel knuckle. These are four piston fixed type which makes sure that equal effort is
applied through both brake pads.The Brembo rear brakes have separate brake calipers for the
parking brake. The Brembo brake disc is manufactured from cast iron and is of the vented
type. It is retained on the hub by two retaining clips and the wheel studs. The brake pads in all
cases are asbestos free.
Braided steel brake hoses are now fitted to reduce expansion under braking pressure and are
of a light weight design.
The brake master cylinder is of a tandem design and is linked to a brake booster to reduce the
brake pedal effort. The tandem design will make sure that in the event of one brake circuit
failure the other will remain fully operational. The brake booster operating rod is connected
directly to the brake pedal.
The parking brake module is located in the luggage compartment behind the right-hand rear
luggage compartment trim panel and operates the rear brakes through a motor and cable
system.
Brake System - VIN Range: G45704-
>G99999
The braking system is a diagonally split, dual circuit design featuring front and rear disc
brakes.
The hydraulic system provides separate circuits for each pair of diagonally opposed wheels
(left front, right rear and right front, left rear).
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The standard front brake caliper has two retaining bolts that attach the brake caliper to the
anchor plate. These are of single, sliding piston type. The anchor plate is attached to the wheel
knuckle with two bolts. The standard brake disc is manufactured from cast iron and is of the
vented type. It is retained on the hub by two retaining clips and the wheel studs.
The high performance front brake caliper has two retaining bolts that attach the brake caliper
to the anchor plate. These are of single, sliding piston type. The anchor plate is attached to the
wheel knuckle with two bolts. The high performance brake disc is manufactured from cast
iron and is of the vented type. It is retained on the hub by two retaining clips and the wheel
studs.
The rear brake calipers are single pistoned floating caliper type, which also incorporates the
park brake mechanism. In addition, the high performance caliper has a logo badge which has
to be removed when changing the brake pads. The brake disc is manufactured from cast iron
and is of the vented type. It is retained on the hub by two retaining clips and the wheel studs.
The brake pads in all cases are asbestos free.
Braided steel brake hoses are fitted to reduce expansion under braking pressure and are of a
light weight design.
The brake master cylinder is of a tandem design and is linked to a brake booster to reduce the
brake pedal effort. The tandem design will make sure that in the event of one brake circuit
failure the other will remain fully operational. The brake booster operating rod is connected
directly to the brake pedal.
The parking brake module is located in the luggage compartment behind the right-hand rear
luggage compartment trim panel and operates the rear brakes through a motor and cable
system.
Brake System
Principles of Operations
The brake system operates by transferring effort applied to the brake pedal, by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is assisted using
a vacuum brake booster that reduces pedal effort for a given hydraulic pressure. The parking brake
operates on the rear wheels and is applied using a pull/push switch mounted on the floor console.
The adjustable pedal system allows adjustment of the throttle, brake and clutch pedals by a switch
fitted on the steering column shroud.
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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 manufacture. Replace the damaged wheel or excessively worn tire. For additional
information, refer to <<204-04>>.
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. For additional information, refer to <<204-00>>.
Road Test

Brake master cylinder Parking brake actuator

Brake caliper piston(s) Parking brake module
Parking brake caliper piston(s) Parking brake switch
Brake discs Damaged or corroded wiring harness
Wheel bearings Brake master cylinder fluid level switch
Brake pads Adjustable pedal motor
Power brake booster Adjustable pedal switch
Brake pedal linkage
Brake booster vacuum hose
Tires
Debris
Adjustable pedal drive cables
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.
Brakes noisy
Possible Source(s):
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• 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 bush wear or failure.
• Steering bush 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 bushes 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

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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. For additional information, refer to
<<206-06>>.
Possible Source(s):
• Parking brake control.

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Action(s) to take:
• For additional information,<<206-05>>
Possible Source(s):
• Electrical circuit.
Action(s) to take:
• For additional information,<<206-05>>
Slow or incomplete brake pedal return
Possible Source(s):
• Brake pedal binding.
Action(s) to take:
• GO to Pinpoint Test K.
PINPOINT TEST G189234p1 : BRAKES
NOISY
G189234t1 : 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. For additional information,
refer to <<206-03>>. CLEAN the rear brake pads or INSTALL new rear brake pads if necessary. For
additional information, refer to <<206-04>>. Test vehicle for presence of brake squeal.
G189234t2 : 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. For additional information, refer to <<206-03>>.
INSTALL new rear brake discs and brake pads. For additional information, refer to <<206-04>>. TEST
the system for normal operation.
-> No
Vehicle is OK.

VIBRATION WHEN BRAKES ARE
APPLIED
G189234t3 : 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. For additional information, refer to <<100-04>>. REPEAT road
test if necessary.
-> No
G189234t4 : 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 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 G189234t5.
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-> No
Vehicle is OK.
G189234t5 : 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 bushes. For additional information, refer to <<211-02>>. CHECK
for wear or failure of steering ball joints. For additional information, refer to <<211-03>>. CHECK for
wear or failure of front wheel bearings, suspension bushes and ball joints. For additional information,
refer to <<204-01>>. CHECK for wear or failure of rear wheel bearings, suspension bushes and ball
joints. For additional information, refer to <<204-02>>.
-> No
Vehicle is OK.
PINPOINT TEST G189234p3 : 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.
G189234t7 : INSPECT TIRE 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.
G189234t8 : CHECK CALIPERS

1. Check the front brake caliper pistons for binding, leaking or sticking. For additional information,
refer to <<206-03>>. Check the rear brake caliper pistons for binding, leaking or sticking. For
additional information, refer to <<206-04>>.
• Do the disc brake caliper pistons and pins bind, leak or stick?
-> Yes
INSTALL new brake calipers as necessary. TEST the system for normal operation.
-> No
G189234t9 : INSPECT BRAKE DISCS

1. Check the brake discs for excessive damage, thickness variation or runout. For additional
information, refer to General Procedures.
• Does excessive damage or runout exist?
-> Yes
INSTALL new brake discs and brake pads as necessary. TEST the system for normal operation.
-> No
G189234t10 : INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY
1. Check the front hub and wheel bearing assembly. For additional information, refer to <<204-00>>.
• Are the wheel bearings OK?
-> Yes
-> No
INSTALL new wheel bearings. For additional information, refer to <<204-01>>. TEST the system for
normal operation.
G189234t11 : CHECK SUSPENSION BUSHES AND BALL JOINTS.

1. Check all suspension bushes and ball joints.
• Are the suspension bushes and ball joints OK?

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-> Yes
-> No
INSTALL new front suspension bushes and ball joints as required. For additional information, refer to
<<204-01>>. INSTALL new rear suspension bushes and ball joints as required. For additional
information, refer to <<204-02>>.
G189234t12 : CHECK VEHICLE ALIGNMENT

1. Check the vehicle alignment. For additional information, refer to <<502-00>>.
• Is the alignment within specification?
-> Yes
Vehicle is OK.
-> No
Adjust the alignment as necessary. For additional information, refer to <<502-00>>.

PEDAL FEELS SPONGY
G189234t13 : 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
G189234t14 : 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. For additional information, refer to General Procedures. TEST the system
for normal operation.
G189234t15 : 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. For additional information, refer to <<206-07>>.
G189234t16 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level.
• Is the fluid level OK?
-> Yes
BLEED the brake system. For additional information, refer to General Procedures. TEST the system
-> No
CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake
Master Cylinder in this section. ADD fluid and BLEED the brake system. For additional information,
refer to General Procedures. TEST the system for normal operation. REPEAT road test if necessary.

PEDAL GOES DOWN FAST
1. Road test and apply the brake pedal.
-> Yes
Vehicle is OK.
-> No
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• Is the fluid level within specification?
-> Yes
-> No
CHECK the brake master cylinder reservoir sealing points. For additional information, refer to Brake
Master Cylinder Component Test in this section. ADD fluid and BLEED brake system. For additional
information, refer to General Procedures. TEST the system for normal operation. REPEAT road test if
necessary.
G189234t19 : 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
BLEED the brake system. Refer to the General Procedures. TEST the system for normal operation.
REPEAT road test. For additional information, refer to <<206-06>>
-> No
G189234t20 : CHECK FOR BRAKE SYSTEM LEAKS
1. Check for external brake system leaks. For additional information, refer to Brake master cylinder in
this section.
• Are leaks found?
-> Yes
REPAIR as necessary, ADD fluid and BLEED brake system. For additional information, refer to General
Procedures. TEST the system for normal operation. REPEAT road test.
-> No
System is OK.

PEDAL GOES DOWN SLOWLY
G189234t21 : 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
G189234t22 : CHECK FOR BRAKE SYSTEM LEAKS

1. Check for external brake system leaks. For additional information, refer to Brake master cylinder in
this section.
• Are there any external brake system leaks?
-> Yes
REPAIR as necessary. ADD fluid and BLEED the brake system. For additional information, refer to
General Procedures. TEST the system for normal operation.
-> No
G189234t23 : 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. For additional
information, refer to General Procedures. TEST the system for normal operation.
-> No
System is OK.

EXCESSIVE BRAKE PEDAL EFFORT
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G189234t24 : 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. For additional
information, refer to <<206-03>>. INSTALL the rear brake pads correctly or INSTALL new rear brake
pads if necessary. For additional information, refer to <<206-04>>. REPEAT road test.
-> No
G189234t25 : CHECK VACUUM

1. Disconnect the vacuum booster 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 40.5kPa (12 in-Hg) or greater?
-> Yes
-> No
LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.
G189234t26 : 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
G189234t27 : CHECK POWER BRAKE BOOSTER VALVE

1. Check the brake booster valve. For additional information, refer to Brake Booster in this section.
• Is the power brake booster valve OK?
-> Yes
CHECK the brake booster. For additional information, refer to Brake Booster in this section. INSTALL a
new brake booster if necessary. TEST the system for normal operation.
-> No
INSTALL a new brake booster valve. TEST the system for normal operation.
PINPOINT TEST G189234p8 : BRAKE

LOCKUP DURING LIGHT BRAKE
PEDAL FORCE
G189234t28 : TEST BRAKE LOCKUP
1. Road test the vehicle and apply the brake pedal lightly.
• Do the brakes lockup?
-> Yes
-> No
Vehicle is OK.
G189234t29 : INSPECT BRAKE PADS

1. Inspect brake pads for contamination, correct installation, damage and type.
-> Yes
CHECK the front brake pads. For additional information, refer to <<206-03>>. CHECK the rear brake
pads. For additional information, refer to <<206-04>>. INSTALL new brake pads as necessary. REPEAT
road test.
-> No
G189234t30 : INSPECT BRAKE CALIPERS

1. Inspect brake calipers for binding, leaking or sticking.
-> Yes
CHECK the front brake calipers. For additional information, refer to <<206-03>>. CHECK the rear
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brake calipers. For additional information, refer to <<206-04>>. INSTALL the brake calipers correctly
or INSTALL new brake calipers as necessary. TEST the system for normal operation. REPEAT road test
if necessary.
-> No
Vehicle is OK.
PINPOINT TEST G189234p9 : BRAKES

DRAG
1. Road test the vehicle and apply the brakes.
• Are the brakes functioning correctly?
-> Yes
Vehicle is OK.
-> No
G189234t32 : CHECK BRAKE CALIPERS

1. Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to
<<206-03>>. Check the rear caliper pistons for binding, leaking or sticking. For additional information,
refer to <<206-04>>.
• 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. Road
test vehicle.
-> No
G189234t33 : CHECK BRAKE BOOSTER

1. Check the brake booster connecting rod alignment and travel. For additional information, refer to
<<206-07>>.
• Is the connecting rod OK?
-> Yes
Vehicle is OK.
-> No
INSTALL a new brake booster. For additional information, refer to <<206-07>>. TEST the system for
normal operation.

EXCESSIVE/ERRATIC BRAKE PEDAL
TRAVEL
G189234t34 : TEST ON ROUGH ROAD
1. Road test the vehicle on rough road conditions. 2. Apply the brakes slowly.
-> Yes
Vehicle is OK.
-> No

• Is the fluid level OK?

-> Yes
-> No
CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake
master cylinder in this section. ADD brake fluid and BLEED the brake system. For additional
information, refer to General Procedures. TEST the system for normal operation. REPEAT road test if
necessary.
G189234t36 : CHECK BRAKE PEDAL RESERVE

1. Engine is idle. 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?
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-> Yes
-> No
CHECK the vacuum to the brake booster. For additional information, refer to <<206-07>>.
G189234t37 : CHECK THE FRONT HUB AND BEARING ASSEMBLY

1. Check the front hub and bearing assembly. For additional information, refer to <<204-00>>
• Are the front wheel bearings loose?
-> Yes
INSTALL a new front wheel bearing if damaged. For additional information, refer to<<204-00>> TEST
-> No
CHECK the front brake discs for thickness variances. For additional information, refer to General
Procedures.
PINPOINT TEST G189234p11 : SLOW

OR INCOMPLETE BRAKE PEDAL
RETURN
G189234t38 : CHECK FOR BRAKE PEDAL RETURN
1. Run the engine at fast 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
G189234t39 : CHECK FOR BRAKE PEDAL BINDING

1. Check the brake pedal to make sure it is operating freely.
• Is the brake pedal operating freely?
-> Yes
INSTALL a new brake booster. For additional information, refer to <<206-07>>. TEST the system for
normal operation.
-> 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 transmission in PARK (automatic transmissions) or in NEUTRAL (manual transmissions),

stop the engine and apply the parking brake. Pump the brake pedal several times to exhaust all
vacuum in the system.
4 . 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.
5 . 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 transmission in PARK or
NEUTRAL. 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.
6 . 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
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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.
• New 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
NOTE:
Prior to carrying out any diagnosis, make sure the brake system warning indicator is functional.
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:
• 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 condition may be caused by two
types of none pressure external leaks.
Type 1: An external leak may be occur at the brake master cylinder reservoir cap because of incorrect
positioning of gasket and cap. Reposition cap and gasket.
Type 2: An external leak may occur at the brake master reservoir mounting seals. Repair such a leak
by installing new seals and make sure that the brake master reservoir retaining bolt is correctly
installed.
Type 3: An external leak may occur in the manual transmission clutch operating system. For
additional information, refer to <<308-00>>.
206-03 : Front Disc Brake
Specifications
Specifications
Lubricants, Fluids, sealers and Adhesives
NOTE:
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years.
Item Specification
Brake caliper slide pin grease Klueber GLK1

Brake caliper anchor plate - Vehicles with 3.0L, 3.5L or 4.2L engine 103 76 -
Brake caliper retaining bolts - Vehicles with Brembo brakes 212 156 -
Brake caliper retaining bolts - Vehicles with 3.0L, 3.5L or 4.2L engine 34 25 -
Brake hose retaining bolt 35 26 -
Specifications
No data
Front Disc Brake - VIN Range: G00442-

>G45703
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1 — Brake disc
2 — Brake caliper guide pin retaining bolt
3 — Brake caliper anchor plate
4 — Brake caliper
5 — Brake pads
6 — Brake disc retaining clips
7 — Brake disc shield retaining rivets
8 — Brake disc shield

9 — Brake caliper anchor plate retaining bolts
For vehicles without Brembo brakes, the brake system consists of the following components:
• Brake pads
• Double piston, floating calipers
• Brake discs
• Brake caliper anchor plates
• Steel braided brake hoses
The brake caliper has two retaining bolts that attach the brake caliper to the anchor plate. These are
of double, sliding piston type which makes sure equal effort is applied through both brake pads. The
anchor plate is attached to the wheel knuckle with two bolts. The hydraulic system provides separate
circuits for each pair of diagonally opposed wheels (i.e. left front, right rear and right front, left rear).
The brake disc is manufactured from cast iron and is of the vented type. It is retained on the hub by
two retaining clips and the wheel studs.
1 — Brake pads
2 — Brake pad anti-rattle spring
3 — Brake pad retaining pins

5 — Brake caliper retaining bolts
8 — Brake disc
9 — Brake caliper
For vehicles with Brembo brakes, the brake system consists of the following components:
• Brake pads
• Four piston, fixed calipers
• Drilled brake discs
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The brake caliper has two retaining bolts that attach the brake caliper to the wheel knuckle. These
are of four piston fixed type which makes sure that equal effort is applied through both brake pads.
The hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e. left
front, right rear and right front, left rear).
Front Disc Brake - VIN Range: G45704-
>G99999
Vehicles with standard brakes
3 — Brake caliper retaining bolt dust covers
5 — Brake caliper
6 — Anti-rattle spring
7 — Brake pads
8 — Brake disc
For vehicles with standard brakes, the brake system consists of the following components:
• Brake pads
• Single piston, floating calipers
• Brake discs
of single, sliding piston type. The anchor plate is attached to the wheel knuckle with two bolts. The
hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e. left front,
right rear and right front, left rear).
Vehicles with high performance brakes

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5 — Brake caliper
7 — Brake pads
8 — Brake disc
For vehicles with high performance brakes, the brake system consists of the following components:
• Brake pads
• Single piston, fixed calipers
• Brake discs
of single, sliding piston type. The anchor plate is attached to the wheel knuckle with two bolts. The
hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e. left front,
right rear and right front, left rear).
Front Disc Brake
STANDARD BRAKES - COMPONENT LOCATION
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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

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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.

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Front Disc Brake – Armoured Vehicles

1 — Brake pads
3 — Brake caliper
CAUTION: The brake caliper is aligned / centralized to the brake disc when the vehicle is built. The vehicle may
have shims fitted between the brake caliper anchor plate and the wheel knuckle. Care must be taken not to disturb this
alignment. When removing the caliper; remove only the bolts that secure the brake caliper to the brake caliper anchor
plate. DO NOT loosen any other caliper bolts. This alignment / centralization MUST be checked / set when the wheel
knuckle is replaced. Failure to follow this instruction may result in damage to the vehicle.
The front disc brake system consists of the following components:
 Brake pads
 Six piston, apposed brake calipers
 Ventilated brake discs
 Brake caliper anchor plates
 Steel braided brake hoses
 Tamper proof brake bleeding screw shields
The brake caliper has two retaining bolts that attach the brake caliper to the brake caliper anchor plate. The
brake caliper anchor plate is attached to the wheel knuckle with two bolts. The hydraulic system provides
separate circuits for each pair of diagonally opposed wheels (i.e. left front, right rear and right front, left
rear).
The brake disc is manufactured from cast iron and is of the grooved vented type. It is retained on the hub by
Each brake caliper features two brake bleeding screws, which are fitted with tamper proof brake bleeding
screw shields, these shields must be fitted correctly to prevent unauthorized access when the wheels and
tires are installed.
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Front Disc Brake

Brake Caliper - Vehicles With: Standard

Brakes, VIN Range: G00442->G45703
(70.55.02)
Brake pedal hold-down tool

JDS 9013
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Removal
1 . Remove the brake pads.
2
. CAUTION: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after handling, as prolonged contact may cause irritation
and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention. If taken internally do not induce vomiting, seek
immediate medical attention. Failure to follow these instructions may result in personal
injury.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area
must be immediately washed down with cold water.

CAUTION: Cap the brake hose to prevent loss of fluid and dirt ingress.
NOTE:
To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to
hold the brake pedal down 40 mm (1.6 in).
Detach the brake hose.
Remove and discard the sealing washers.
3 . Remove the brake caliper.
Remove and discard the brake caliper upper retaining bolt.
Installation
1
. CAUTION: If brake fluid comes into contact with the paintwork, the affected area
Install a new brake caliper upper retaining bolt.
Tighten to 34 Nm.
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2 . Attach the brake hose.
Install new sealing washers.
Tighten to 35 Nm.
3 . Remove the brake pedal hold-down tool.
4 . Install the brake pads.

5 . Bleed the brake system.

(70.55.02)

JDS 9013
Removal
1 . Remove both front wheels and tires.
2 . NOTE:
3
. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or
eyewash solution and seek medical attention. If taken internally do not induce vomiting,
seek immediate medical attention. Failure to follow these instructions may result in
personal injury.
NOTE:
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NOTE:
4 . NOTE:

5 . NOTE:
Remove the brake caliper retaining bolts.
6 . NOTE:
Remove the brake caliper.
7
. CAUTION: Do not allow the brake caliper to hang on the hydraulic hose, as this will
damage the hose. Failure to follow this instruction will result in damage to the hose.
NOTE:
Remove the brake pad from the caliper piston.

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8 . NOTE:
Remove the brake pad.
Installation
1.
WARNING: Do not use compressed air to disperse brake dust into the atmosphere.
CAUTION: Brake pads must always be replaced in axle sets.

CAUTION: Make sure the brake disc faces are clean before installation.
NOTE:
Install the brake pad.
Using a suitable tool, fully retract the brake caliper piston.
2 . NOTE:
Make sure the brake pad is correctly installed to the caliper piston.
NOTE:
Install the brake pad to the caliper piston.

3 . NOTE:
4 . NOTE:
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Install the brake caliper retaining bolts.
Tighten to 28 Nm.
5 . NOTE:

6 . NOTE:
Attach the brake hose.
Tighten to 35 Nm.
7 . NOTE:

9 Bleed the brake system.

. For additional information, refer to Brake System Bleeding - VIN Range: G45704->H99999
(70.25.03)
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10 . Install both front wheels and tires.

Brake Caliper - Vehicles With: High
Performance Brakes, VIN Range: G00442-
>G45704 (70.55.02)

JDS 9013
Removal
1 Remove the brake pads.
. For additional information, refer to Brake Pads - Vehicles With: High Performance Brakes, VIN
Range: G00442->G45703 (70.40.02)
2
injury.
NOTE:
NOTE:
Cap the brake hose to prevent loss of fluid and prevent dirt ingress.

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Installation
1 . Install the brake caliper.
Tighten to 212 Nm.
Tighten to 35 Nm.
4 Install the brake pads.

Range: G00442->G45703 (70.40.02)

. For additional information, refer to Brake System Bleeding - VIN Range: G00442->G45703
(70.25.03)
>G99999 (70.55.02)

JDS 9013
Removal
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2 . NOTE:
3
personal injury.
NOTE:
NOTE:
4 . NOTE:
5 . NOTE:

6 . NOTE:
7
NOTE:

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8 . NOTE:

Installation
1.
NOTE:
Install the brake pad.
Using a suitable tool, fully retract the brake caliper piston.
2 . NOTE:
Make sure the brake pad is correctly installed to the caliper piston.
NOTE:

Install the brake pad to the caliper piston.
3 . NOTE:

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4 . NOTE:
Tighten to 58 Nm.
5 . NOTE:

6 . NOTE:
Tighten to 35 Nm.
7 . NOTE:

(70.25.03)
10 . Install both front wheels and tires.

Brake Caliper (70.55.02) – Armoured Vehicles

JDS 9013
Removal
alignment. When removing caliper; remove only the bolts that secure the brake caliper to the brake caliper anchor plate.
DO NOT loosen any other caliper bolts. This alignment / centralization MUST be checked / set when the wheel knuckle is
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replaced. Failure to follow this instruction may result in damage to the vehicle.

For additional information, refer to Brake Pads (70.40.02)
2
.
CAUTION: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash
hands thoroughly after handling, as prolonged contact may cause irritation and dermatitis. If brake fluid contacts
the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. If taken internally do not
induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal
injury.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately
washed down with cold water.
CAUTION: Do not allow the brake caliper to hang on the hydraulic hose, as this will damage the hose.
Failure to follow this instruction will result in damage to the hose.
NOTE:
To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40
mm (1.6 in).
NOTE:

3
.
CAUTION: The brake caliper is aligned to the brake disc when it is first installed to the vehicle, therefore,
care must be taken not to disturb this alignment. When removing the caliper; remove the bolts that secure the
brake caliper to the brake caliper anchor plate only. DO NOT loosen any other caliper bolts. Failure to follow this
injury.
NOTE:
mm (1.6 in).
NOTE:

Installation

Tighten to 101 Nm.

Tighten to 35 Nm.
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Brake Disc - Vehicles With: Standard
(70.10.10)
Removal
2.
Detach the brake caliper and brake caliper anchor plate and secure to one side.
3 NOTE:
.
If the same brake disc is to be installed, the tip of a hub must be marked with a
corresponding part of the brake disc for alignment.
Remove the brake disc.
Remove and discard the brake disc retaining clips.

Installation
Tighten to 103 Nm.

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(70.10.10)
Removal
. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes, VIN Range:
G45704->G99999 (70.40.02)
2 . NOTE:
Remove the brake caliper anchor plate.
Remove and discard the brake caliper anchor plate retaining bolts.
3 NOTE:
.
NOTE:

Installation
1.
CAUTION: Brake discs must always be replaced in axle sets.
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NOTE:
Tighten to 115 Nm.

Brake Disc - Vehicles With: High
>G45703 (70.10.10)
Removal
Range: G00442->G45703 (70.40.02)
2.
3 NOTE:
.

Installation
Tighten to 212 Nm.

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>G99999 (70.10.10)
Removal
Range: G45704->G99999 (70.40.02)
2 . NOTE:
3 NOTE:
.
NOTE:

Installation
1.
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NOTE:
Tighten to 115 Nm.

Brake Disc (70.10.10) – Armoured Vehicles
Removal
CAUTION: Brake discs must be renewed in axle sets. Failure to follow this instruction may result in damage to the
vehicle.
CAUTION: If new brake discs are installed, new brake pads must also be installed. Failure to follow this instruction

2 NOTE:
. If the same brake disc is to be installed, the tip of a hub must be marked with a corresponding part of the brake disc
for alignment.

Installation

Brake Disc Shield - Vehicles With: Standard
Brakes (70.10.18)
Removal
1 Remove the front brake disc.
G00442->G45703 (70.10.10)
For additional information, refer to Brake Disc - Vehicles With: Standard Brakes, VIN Range:
G45704->G99999 (70.10.10)
2 . Remove the brake disc shield.
Remove and discard the brake disc shield retaining rivets.

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Installation
Install new brake disc shield retaining rivets.

Brake Disc Shield - Vehicles With: High
Performance Brakes (70.10.18)
Removal
1 . Remove the wheel bearing and wheel hub.
For additional information, refer to Front Wheel Bearing and Wheel Hub (60.25.03)
2 . Remove the brake disc shield.
Remove and discard the brake disc shield retaining rivets.
Installation
Install new brake disc shield retaining rivets.

Brake Pads - Vehicles With: Standard
(70.40.02)
Removal
1 . Remove both front wheels and tires. <<204-04>>
2 . Detach the anti-lock brake (ABS) sensor wiring harness from the retaining clips.
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3 . Rotate the brake caliper upwards.
1) Remove and discard the brake caliper lower retaining bolt.
2) Rotate the brake caliper upwards.

Installation
1
. WARNING: Do not use compressed air to disperse brake dust into the atmosphere.
CAUTION: If the pistons are pushed back into the housing, brake fluid will be forced
back into the brake fluid reservoir.
Using a suitable tool, fully retract the brake caliper pistons.
Install a new brake caliper lower retaining bolt.
Tighten to 34 Nm.
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(70.40.02)
Removal
2 . NOTE:
3 . NOTE:

4
NOTE:

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5
NOTE:
6
NOTE:
7 . NOTE:
Installation
1
NOTE:
Make sure that the inboard brake pad is correctly installed to the caliper piston.
NOTE:
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Tighten to 28 Nm.
Brake Pads - Vehicles With: High
>G45703 (70.40.02)
Removal
1 . Raise front of vehicle and support on stands.
For additional information, refer to Jacking
2 . Remove front wheels.

3
. CAUTION: Remove brake fluid spillage immediately from paint work, with clean
water.
Loosen brake fluid reservoir-cap.
Position a cloth around the reservoir to collect any fluid spillage.
4 . Remove brake pads from caliper.
1) Remove 'R' clips.
2) Withdraw pins from caliper.
3) Remove anti-rattle spring.

4) Discard brake pads.
5 . Clean all mating surfaces and remove brake dust, see WARNING above.
6 . Repeat above procedure to remove opposite side brake pads.

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Installation
1
. CAUTION: Make sure grease does not contact brake-pad friction surface or brake
disc.
To prevent brake squeal apply grease to the shoulders of the brake-pad backplate.
For additional information, refer to Specifications
Apply a uniform layer of grease to backplate shoulders, making sure the

whole shoulder is covered.
2
. CAUTION: Make sure the brake pads are fitted with the direction arrow following
the direction of wheel rotation.
Make sure the brake pads are fitted with the direction arrow following the direction of wheel
rotation.
3
. CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow.
Remove brake fluid spillage immediately from paint work, with clean water.
CAUTION: Make sure the brake pads are installed to the correct orientation.
CAUTION: Make sure the brake pads are fitted with the direction arrow following
CAUTION: Note condition of pins and 'R' clips and replace if necessary.
Install brake pads into caliper.
Slowly retract caliper pistons into caliper.
2) Install pads.
3) Position anti-rattle spring.
4) Install pins.
5) Install 'R' clips.
4 . Repeat above procedure to install opposite side brake pads.
5 . Fit wheels.
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6 . Remove stands and lower vehicle.

7
water.
Check brake fluid level.
Check brake fluid level is at the maximum mark.
Remove cloth.
Fit cap.
8 . Remove paint work protection covers, and close engine compartment.
9 . Start the engine and repeatedly press the brake pedal until brake pressure is evident.
>G99999 (70.40.02)
Removal
2 . NOTE:

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3 . NOTE:

4 . NOTE:
5
NOTE:
6
NOTE:
7 . NOTE:

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Installation
1
NOTE:
Make sure that the inboard brake pad is correctly installed to the caliper piston.
NOTE:
Tighten to 58 Nm.
Brake Pads (70.40.02) – Armoured Vehicles
Removal
WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A
VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.
CAUTION: Brake pads must always be replaced in axle sets. Failure to follow this instruction may result in damage
to the vehicle.
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2
.
CAUTION: Remove brake fluid spillage immediately from paint work, with clean water. Failure to follow
this instruction may result in damage to the vehicle.
Loosen brake fluid reservoir cap.

3
.
NOTE:

4
.
NOTE:
Remove the brake pads from the brake caliper.
Installation
1
.
WARNING: Do not use compressed air to disperse brake dust into the atmosphere. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure that the anti-rattle spring is correctly installed. Failure to follow this instruction may
CAUTION: If the brake caliper pistons are pushed back into the housing, brake fluid will be forced back
into the brake fluid reservoir. Remove brake fluid spillage immediately from paint work, with clean water. Failure
to follow this instruction may result in personal injury.
CAUTION: Make sure the brake disc faces are clean before installation. Failure to follow this instruction
CAUTION: Brake pads must always be replaced in axle sets. Failure to follow this instruction may result in
NOTE:

Tighten to 101 Nm.

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206-04 : Rear Disc Brake
Specifications
Specifications
Lubricants, Fluids, sealers and Adhesives
NOTE:
years.
Item Specification
Brake caliper slide pin grease Klueber GLK1

Brake hose to brake caliper - Vehicles with 3.0L, 3.5L or 4.2L engine 35 26 -
Brake hose to brake caliper - Vehicles with Brembo brakes 35 26 -
Brake caliper anchor plate - Vehicles with 3.0L, 3.5L or 4.2L engine 103 76 -
Brake caliper retaining bolts - Vehicles with Brembo brakes 70 51 -
Brake caliper retaining bolts - Vehicles with 3.0L, 3.5L or 4.2L engine 34 25 -
Specifications
No data
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Rear Disc Brake - VIN Range: G00442-

>G45703
1 — Brake caliper anchor plate retaining bolts
2 — Brake caliper guide pin retaining bolt
3 — Brake caliper
4 — Brake pads
7 — Brake disc

For vehicles without Brembo brakes, the brake system consists of the following components:
• Brake pads
• Brake discs
of single, sliding piston type which makes sure equal effort is applied through both brake pads. The
anchor plate is attached to the wheel knuckle with two bolts. The hydraulic system provides separate
circuits for each pair of diagonally opposed wheels (i.e. left front, right rear and right front, left rear).
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The rear brake caliper incorporates the parking brake of which is self adjusting according to brake
pad wear.
2 — Brake pads
3 — Brake caliper
5 — Brake disc
6 — Brake pad anti-rattle spring
7 — Brake pad retaining pins
For vehicles with Brembo brakes, the brake system consists of the following components:
• Brake pads
• Four piston, fixed calipers
• Brake discs
The brake caliper has two retaining bolts that attach the brake caliper to the wheel knuckle. These
are of four piston fixed type which makes sure that equal effort is applied through both brake pads.
The hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e. left
front, right rear and right front, left rear).
The brake disc is manufactured from cast iron and is of the solid type. It is retained on the hub by
Rear Disc Brake - VIN Range: G45704-
>G99999
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1 — Brake caliper
6 — Brake disc
8 — Brake pads
9 — Logo badge retaining screws (if equipped)
10 — Logo badge (if equipped)
The brake system consists of the following components:
• Brake pads
• Brake discs
The brake caliper has two retaining bolts that attach the brake caliper to the anchor plate.
These are of single, sliding piston type. In addition, the high performance caliper has a logo
bagde which has to be removed when changing the brake pads.The anchor plate is attached to
the wheel knuckle with two bolts. The hydraulic system provides separate circuits for each
pair of diagonally opposed wheels (i.e. left front, right rear and right front, left rear).
The brake disc is manufactured from cast iron and is of the vented type. It is retained on the
hub by two retaining clips and the wheel studs.
The rear brake caliper incorporates the parking brake of which is self adjusting according to
brake pad wear.
Rear Disc Brake
COMPONENT LOCATION
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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 )
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Repairs
CAUTION: Whilst carrying out rear parking brake related service procedures, the tension on
the rear parking brake release actuator will need to be released. Failure to follow this instruction
may result in the parking brake functioning incorrectly or becoming inoperative.
Before carrying out any work on the rear brakes, the Jaguar approved diagnostic system must be
connected and the 'parking brake un-jam' 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 )
Rear Disc Brake – Armoured Vehicles

1 — Brake pads
3 — Brake caliper
The rear disc brake system consists of the following components:
 Brake pads
 Four piston, apposed brake calipers
 Ventilated brake discs
 Brake caliper anchor plates
 Steel braided brake hoses
 Tamper proof brake bleeding screw shields
The brake caliper has two retaining bolts that attach the brake caliper to the brake caliper anchor plate. The
brake caliper anchor plate is attached to the wheel knuckle with two bolts. The hydraulic system provides
separate circuits for each pair of diagonally opposed wheels (i.e. left front, right rear and right front, left
rear).
The brake disc is manufactured from cast iron and is of the grooved vented type. It is retained on the hub by
Each brake caliper features two brake bleeding screws, which are fitted with tamper proof brake bleeding
screw shields, these sheilds must be fitted correctly to prevent unauthorised access when the wheels and tires
are installed.
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Rear Disc Brake


(70.55.03)

JDS 9013
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Removal
1 Carry out the parking brake cable tension release procedure.
. For additional information, refer to Parking Brake Cable Tension Release - VIN Range:
G00442->G45703
2 . Remove both rear wheels and tires.

3 . Detach the parking brake cable.
1) Reposition the brake caliper lever.
2) Detach the parking brake cable.

1) Release the retaining tangs.
5
injury.
CAUTION: Cap the brake hose to prevent loss of fluid and prevent dirt ingress.
NOTE:

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6 . NOTE:
1) Remove and discard the brake caliper retaining bolts.
2) Remove the brake caliper.
Installation
1
Install new brake caliper upper retaining bolts.
Tighten to 34 Nm.
Tighten to 35 Nm.
3 . Attach the parking brake cable.

1) Reposition the brake caliper lever.
2) Attach the parking brake cable.

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(70.25.03)
7 . Install both rear wheels and tires.

>G45703 (70.55.03)

JDS 9013
Removal
Range: G00442->G45703 (70.40.03)
2
injury.
NOTE:
NOTE:

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Installation
Tighten to 70 Nm.
Tighten to 35 Nm.
4 Install the brake pads.

Range: G00442->G45703 (70.40.03)

(70.25.03)
Brake Caliper - VIN Range: G45704-
>G99999 (70.55.03)

JDS 9013
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Crankshaft pulley/damper remover

303-588
Brake caliper piston retractor tool

206-080

206-081
Removal
All vehicles
1 Carry out the parking brake cable tension release procedure.
G45704->G99999

3 . NOTE:
Detach the parking brake cable.

4 . NOTE:
Remove the logo badge.

All vehicles
5 . NOTE:
6
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injury.
CAUTION: Cap the brake hose to prevent loss of fluid and prevent dirt ingress.
NOTE:
NOTE:

7 . NOTE:
8 . NOTE:
1) Remove the brake caliper retaining bolts.
2) Remove the brake caliper.

9 . NOTE:
Remove the brake pads.

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Installation
All vehicles
1
NOTE:
Make sure that the brake pad with the anti-rattle spring is installed to the inboard side
of the brake disc.
NOTE:
Install the brake pads.
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.
NOTE:
Only the extraction bolt from special tool 303-588 is used.
NOTE:
Only the forcing plate from special tool 206-080 is used.
NOTE:

Using the special tools, fully retract the brake caliper piston.
3 . NOTE:

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1) Install the brake caliper.
2) Tighten to 28 Nm.
4 . NOTE:

5 . NOTE:
Tighten to 35 Nm.
6 . NOTE:

7 . NOTE:
Install the logo badge.

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Tighten to 5 Nm.
All vehicles


Brake Caliper (70.55.03) – Armoured Vehicles

JDS 9013
Removal
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2
.
injury.
NOTE:
mm (1.6 in).
NOTE:

3
.
injury.
NOTE:
mm (1.6 in).
NOTE:

Installation
1
.

Tighten to 101 Nm.

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Tighten to 35 Nm.


(70.10.11)
Removal
. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes, VIN Range:
G00442->G45703 (70.40.03)
2.
Detach brake caliper anchor plate.
3 NOTE:
.

Installation
Install new brake disc retaining clips.

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>G45703 (70.10.11)
Removal
1 . Remove the parking brake pads. <<206-05>>
1) Remove the brake pad retaining pins.
2) Remove the brake pad anti-rattle spring plate.
3) Remove the brake pads.
3.

4 NOTE:
.

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Installation
1 . NOTE:
Tighten to 103 Nm.

Brake Disc - VIN Range: G45704->G99999
(70.10.11)
Removal
For additional information, refer to Brake Pads - VIN Range: G45704->G99999 (70.40.03)
2.
NOTE:

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3 NOTE:
.
NOTE:

Installation
1.
NOTE:
Tighten to 103 Nm.

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Brake Disc (70.10.11) – Armoured Vehicles
Removal
CAUTION: Brake discs must be renewed in axle sets. Failure to follow this instruction may result in damage to the
vehicle.
CAUTION: If new brake discs are installed, new brake pads must also be installed. Failure to follow this instruction

2 NOTE:
. If the same brake disc is to be installed, the tip of a hub must be marked with a corresponding part of the brake disc
for alignment.

Installation

(70.40.03)

206-080
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303-588
Removal
1
. CAUTION: Whilst carrying out rear parking brake related service procedures, the
tension on the rear parking brake release actuator will need to be released. Failure to
follow this instruction may result in the parking brake to function incorrectly or become
inoperative.
Carry out the parking brake cable tension release.

For additional information, refer to Parking Brake - VIN Range: G00442->G45170

3 . NOTE:
2) Detach the brake caliper.
4.
NOTE:
Using a suitable tie strap, secure the caliper to one side.
5 . NOTE:
Remove the brake pad anti-rattle spring plates.

Installation
1
CAUTION: Make sure that the brake disc faces are clean before installation.
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NOTE:
Remove the forcing screw from the crankshaft pulley/damper remover and install to the
brake caliper piston retractor tool.
NOTE:
2 NOTE:
.
Make sure the brake caliper piston location mark is in the correct position so that the locator
pin on the brake pad locates correctly into the brake caliper piston.
3 NOTE:
.
Remove the forcing screw from the brake caliper piston retractor tool and install to the
crankshaft pulley/damper remover.
NOTE:
Install new brake pads.
Install the brake pad anti-rattle spring plates.
4.
NOTE:
Remove the tie strap.
5 . NOTE:
Attach the caliper.
Install new brake caliper lower retaining bolts.
Tighten to 34 Nm.
7
. CAUTION: Calibrate the electric park brake using Jaguar approved diagnostic system.
If the Jaguar approved diagnostic system is not available disconnect the battery for
approximately 30 seconds, the vehicle will then prompt the driver to carry out the
calibration procedure as per the vehicle hand book on re-connection.
Calibrate the electric parking brake module using the Jaguar approved diagnostic system.
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8 NOTE:
.
Do not start the engine or operate the electronic park brake before depressing the
brake pedal.
Repeatedly depress the brake pedal until brake pressure is evident.

>G45703 (70.40.03)
Removal
1
inoperative.

2
. WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS
REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO
DISPERSE BRAKE DUST INTO THE ATMOSPHERE. Failure to follow this instruction may result
in personal injury.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used
on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut
or bolt can be used.
For additional information, refer to General Service Information
CAUTION: The High performance brake caliper is aligned to the brake disc when it is
first installed to the vehicle, therefore, care must be taken not to disturb this alignment.
When removing the caliper; remove the bolts that secure the anchor bracket to the vertical
link only. DO NOT loosen any other caliper bolts.
Open engine compartment and fit paint work protection covers to fenders.
3 . Raise rear of vehicle and support on stands.

4 . Remove rear wheels.

5
water.
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Loosen brake fluid reservoir-cap.
6 . Remove brake pads from caliper.
1) Withdraw pins from caliper.
2) Remove anti-rattle spring.
3) Remove brake pads.

7 . Clean all mating surfaces and remove brake dust, see WARNING above.
8 . Repeat above procedure to remove opposite side brake pads.
Installation
1
. CAUTION: Make sure grease does not contact brake-pad friction surface or brake
disc.
To prevent brake squeal apply grease to the shoulders of the brake-pad backplate.
Apply a uniform layer of grease to backplate shoulders, making sure the

whole shoulder is covered.
2
. CAUTION: Make sure the brake pads are fitted with the direction arrow following
Make sure the brake pads are fitted with the direction arrow following the direction of wheel
rotation.
3
. CAUTION: Retracting the caliper piston may cause the fluid reservoir to over-flow.
Remove brake fluid spillage immediately from paint work with clean water.
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CAUTION: Make sure the brake pads are installed to the correct orientation.
CAUTION: Make sure the brake pads are fitted with the direction arrow following
CAUTION: Note the condition of pins and replace if necessary.
NOTE:
Slowly retract caliper pistons.
Install brake pads.
1) Install pads.
2) Position anti-rattle spring.
3) Install pins - make sure pin collets are fully engaged into caliper.
4 . Repeat above procedure to install opposite side brake pads.
5 . Fit wheels.
6 . Remove stands and lower vehicle.

7
water.
Check brake fluid level.
Check brake fluid level is at the maximum mark.
Remove cloth.
Fit cap.
8 . Remove paint work protection covers, and close engine compartment.
9
10 . Start the engine and repeatedly press the brake pedal until brake pressure is evident.
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Brake Pads - VIN Range: G45704->G99999
(70.40.03)

303-588

206-080

206-081
Removal
All vehicles
1
inoperative.


3 . Remove the logo badge.
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All vehicles
4 . NOTE:
5 . NOTE:

6.
NOTE:
1) Remove the brake caliper retaining bolts.
2) Detach the brake caliper.
7 . NOTE:

Installation
1
. 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.
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NOTE:
Only the extraction bolt from special tool 303-588 is used.
NOTE:
Only the forcing plate from special tool 206-080 is used.
NOTE:
2
NOTE:
Make sure that the brake pad with the anti-rattle spring is installed to the inboard side
of the brake disc.
NOTE:
Tighten to 28 Nm.
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4
5 NOTE:
.
Do not start the engine or operate the electronic park brake before depressing the
brake pedal.
Repeatedly depress the brake pedal until brake pressure is evident.

Brake Pads (70.40.03) – Armoured Vehicles
Removal
WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A
VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.
CAUTION: Brake pads must always be replaced in axle sets. Failure to follow this instruction may result in damage
to the vehicle.
1 . Remove both rear wheel and tires.

2
.
CAUTION: Remove brake fluid spillage immediately from paint work, with clean water. Failure to follow
Loosen brake fluid reservoir cap.

3
.
NOTE:

4
.
NOTE:
Remove the brake pads from the brake caliper.

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Installation
1
.
WARNING: Do not use compressed air to disperse brake dust into the atmosphere. Failure to follow this
CAUTION: Make sure that the anti-rattle spring is correctly installed. Failure to follow this instruction may
CAUTION: If the brake caliper pistons are pushed back into the housing, brake fluid will be forced back
into the brake fluid reservoir. Remove brake fluid spillage immediately from paint work, with clean water. Failure
CAUTION: Make sure the brake disc faces are clean before installation. Failure to follow this instruction
CAUTION: Brake pads must always be replaced in axle sets. Failure to follow this instruction may result in
NOTE:
Tighten to 101 Nm.

206-05 : Parking brake and Actuation
Specifications
Specifications
Parking brake caliper retaining bolts - vehicles with Brembo brakes 70 52 -
Parking brake module retaining nuts 4 - 35
Parking brake release actuator retaining bolts 20 15 -
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Specifications – Armoured XJ

)*+,-./ÿ0+*,1ÿ2*3-41+ÿ56ÿ78113ÿ890ÿ+15*-.-./ÿ0635:ÿ ;<ÿ=>ÿ?
)*+,-./ÿ0+*,1ÿ2*3-41+ÿ06@Aÿ+15*-.-./ÿ0635:ÿ ÿ B<ÿ=Cÿ?
Specifications
No data
General procedures
Parking Brake Cable Tension Release - VIN

Range: G00442->G45703
Electric parking brake release tool

206-082
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CAUTION: The warranty of the electric parking brake release tool will be invalidated if the
casing has been removed.
1.
WARNING: Always use the Jaguar Approved Diagnostic System to release the parking brake
cable tension, when carrying out repair operations on the electric park brake which require the
cable tension to be released.
Connect the Jaguar approved diagnostic system to release the parking brake cable tension.
WARNING: The procedure below should only be used in emergency situations, to release
the electric parking brake. All calibration of the parking brake system will be lost, and the parking
brake will need to be re-calibrated to function correctly.
NOTE:
The tool shown must only be used in the event of an emergency.
2. Move the selector lever to the ' P' position.
3. Release the parking brake.

4. Remove the luggage compartment floor covering.
5. NOTE:
6. Disconnect the parking brake module electrical connector
7. Connect the special tool to the parking brake module wiring harness electrical connector.
8. NOTE:
Operate the parking brake release tool until an audible noise is heard from the parking brake
release actuator.
Release the parking brake cable tension.

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9. Remove the special tool and carry out any necessary repair to the system.
10. Connect the parking brake module electrical connector.
11. NOTE:

13. NOTE:
The brake pedal must be applied when calibrating the parking brake switch.
Apply the parking brake.
14.
CAUTION: Calibrate the electric park brake using Jaguar approved diagnostic system. If the
Jaguar approved diagnostic system is not available disconnect the battery for approximately 30
seconds, the vehicle will then prompt the driver to carry out the calibration procedure as per the
vehicle hand book on re-connection.
Range: G45704->G99999

206-082
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206-082-01
CAUTION: The warranty of the electric parking brake release tool will be invalidated if the
casing has been removed.
1.
WARNING: Always use the Jaguar Approved Diagnostic System to release the parking brake
cable tension, when carrying out repair operations on the electric park brake which require the
cable tension to be released.
Connect the Jaguar approved diagnostic system to release the parking brake cable tension.
WARNING: The procedure below should only be used in emergency situations, to release
the electric parking brake. All calibration of the parking brake system will be lost, and the parking
brake will need to be re-calibrated to function correctly.
NOTE:
The tool shown must only be used in the event of an emergency.
2. Move the selector lever to the ' P' position.
3. Release the parking brake.
5. Remove the luggage compartment side trim panel.
6. Detach the rear electronic module (REM).
7.
CAUTION: Disconnect the parking brake module electrical connectors in the sequence
shown. Failure to follow this instruction may result in diagnostic trouble codes being stored in the
module.
Disconnect the parking brake module electrical connectors.
8. Connect the special tools to the parking brake module wiring harness electrical connectors.
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9. NOTE:
Operate the parking brake release tool until an audible noise is heard from the parking brake
release actuator.
Release the parking brake cable tension.
10. Remove the special tool and carry out any necessary repair to the system.
11. Disconnect the special tools from the parking brake module wiring harness electrical connectors.
12.
CAUTION: Connect the parking brake module electrical connectors in the sequence shown.
Failure to follow this instruction may result in diagnostic trouble codes being stored in the module.
Connect the parking brake module electrical connectors.
13. Attach the REM.
14. Install the luggage compartment side trim panel.

15. Install the luggage compartment floor covering.
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16. NOTE:
The brake pedal must be applied when calibrating the parking brake switch.
Apply the parking brake.
17.
CAUTION: Calibrate the electric park brake using Jaguar approved diagnostic system. If the
Jaguar approved diagnostic system is not available disconnect the battery for approximately 30
seconds, the vehicle will then prompt the driver to carry out the calibration procedure as per the
vehicle hand book on re-connection.
Parking Brake - VIN Range: G00442-

>G45703
1 — Parking brake actuator
2 — Parking brake cable
3 — Parking brake switch
4 — Parking brake caliper (vehicles without Brembo brakes)

5 — Parking brake caliper (vehicles with Brembo brakes)
6 — Parking brake module
Electric Park Brake

The electric park brake (EPB) system is operated by a floor console mounted switch. The rear calipers
are activated by cables from an electric motor and actuator unit which is mounted on the rear
subframe. Overall control of the EPB is from a control module which is located in the luggage
compartment behind the right-hand rear luggage compartment trim panel. On vehicles with Brembo
brakes separate parking brake calipers are fitted.
EPB Operation
To apply the parking brake, pull the parking brake switch upwards and release. The switch will then
return to the neutral position and the parking brake low fluid warning light will illuminate on the
instrument cluster. To release the parking brake set the ignition switch to position 2 or with the
engine running, apply the footbrake and press the parking brake switch down. The parking brake is
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automatically released when the selector is moved from the ‘P’ position.
If the vehicle is stationary and the gear selector is in ‘D’ or ‘R’ and the parking brake is applied, then
the parking brake will automatically release when the accelerator pedal is depressed.
The parking brake is automatically applied when the key is removed from the ignition switch. If the
parking brake is required to be permanently released press and hold the parking brake switch down
and at the same time remove the key. If the parking brake is operated while the vehicle is in motion
the message ‘PARKBRAKE ON’ will be displayed on the message centre. The warning lamp in the
instrument cluster will be illuminated and a warning chime will sound.
If the battery has been discharged or disconnected a message ‘APPLY PARKBRAKE’ will be displayed
when the ignition is next switched on. Apply the footbrake and pull the parking brake switch up to
apply the parking brake. This is required to reset the parking brake system which will now function
correctly.
>G99999
1 — Parking brake actuator
2 — Parking brake cable
3 — Parking brake switch
4 — Brake caliper
5 — Parking brake module

Electric Park Brake
The electric park brake (EPB) system is operated by a floor console mounted switch. The rear calipers
are activated by cables from an electric motor and actuator unit which is mounted on the rear
subframe. Overall control of the EPB is from a control module which is located in the luggage
compartment behind the right-hand rear luggage compartment trim panel and above and behind the
rear electronic module (REM).
EPB Operation
To apply the parking brake, pull the parking brake switch upwards and release. The switch will then
return to the neutral position and the parking brake low fluid warning light will illuminate on the
instrument cluster. To release the parking brake set the ignition switch to position 2 or with the
engine running, apply the footbrake and press the parking brake switch down. The parking brake is
automatically released when the selector is moved from the ‘P’ position.
If the vehicle is stationary and the gear selector is in ‘D’ or ‘R’ and the parking brake is applied, then
the parking brake will automatically release when the accelerator pedal is depressed.
The parking brake is automatically applied when the key is removed from the ignition switch. If the
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parking brake is required to be permanently released press and hold the parking brake switch down
and at the same time remove the key. If the parking brake is operated while the vehicle is in motion
the message ‘PARKBRAKE ON’ will be displayed on the message centre. The warning lamp in the
instrument cluster will be illuminated and a warning chime will sound.
If the battery has been discharged or disconnected a message ‘APPLY PARKBRAKE’ will be displayed
when the ignition is next switched on. Apply the footbrake and pull the parking brake switch up to
apply the parking brake. This is required to reset the parking brake system which will now function
correctly.
Parking Brake – Armoured Vehicles
CAUTION: The spacer must be correctly aligned to the parking brake caliper. Failure to follow this instruction may

1 Parking brake caliper
2 Spacer
3 Parking brake pad retaining spring
4 Parking brake caliper
5 Parking brake caliper body retaining bolt
6 Parking brake pad retaining pin
7 Parking brake caliper body retaining bolt
8 Spacer
Parking Brake Caliper Modification
The parking brake caliper has been modified to include additional spacers. The spacers are installed between
the two halves of the parking brake caliper body. If a new parking brake caliper is to be installed a new
parking brake caliper spacer kit must also be installed.

>G45170
Parking brake cable Fuse(s)
Parking brake actuator Wiring harness/electrical connectors

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Parking brake caliper Check for bent/corroded pins
Parking brake pads Parking brake switch
Drop link caps Parking brake module
4 . If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use
a suitable code reader to retrieve any fault codes before proceeding to the Diagnostic Trouble Code
(DTC) Index Chart (or the Symptom Chart if no DTCs are set), for actions to take.
Symptom Chart
Symptom Possible Sources Action
• Cables fouled, • Check the rear and primary cables for

trapped or damaged fouling, trapping or damage
The parking • Cables incorrectly • Check the cable routing between caliper and
routed or fixed subframe mountings. Make sure the cables
brake will not
• Rear lining wear sit above the rear anti-roll bar drop link
engage or • Service brake caps, and that the drop link caps are not
release incorrectly adjusted damaged
following lining • Check that the rear cable end fitting
change connector is correctly fitted into the caliper
• Caliper malfunction bracket, and is not damaged
• Actuator malfunction • Check that the rear cable end fitting
connector is correctly fitted into the
subframe bracket and is not damaged
• Check the 'C' clip between the cable and the
subframe for fit/damage
• Check that the cable is correctly located into
the reaction and connector brackets
• Inspect the rear brake linings (parkbrake
caliper linings for vehicles with
supercharger) for wear
• Check the parkbrake cable for correct
adjustment
• Fully retract the cables. Pump the brake
pedal hard five times
• Check the condition of the rear caliper
(parkbrake caliper for vehicles with
supercharger). Make sure the caliper return
spring is correctly fitted
• Check the actuator for damage and/or
excessive noise in normal operation
Range: G00442->G45703
Parking Brake Pads - Vehicles With: High
Parking Brake Module - VIN Range: G00442-
>G45703 (70.35.47)
Parking Brake Release Actuator - VIN Range:
G00001->G03445 (70.35.45)
Driver Information Chart

Warning Message Possible Source Action
Depress footbrake and apply

parkbrake at the same time (the
Yellow priority Apply
Parkbrake not calibrated parkbrake should now be correctly
light parkbrake
calibrated. Check for correct
function)
• Parkbrake Apply switch

Yellow priority circuit failure
light/Red, Parkbrake • Parkbrake Apply switch Check DTCs. Refer to the DTC index
flashing priority fault circuit short to ground for relevant pinpoint test
light • Parkbrake Release switch
circuit failure
• Parkbrake Release switch
circuit short to ground
• Parkbrake Apply and
Release switch contacts
energized simultaneously
• Parkbrake motor output
short to ground
open circuit
battery short to ground
Parkbrake Parkbrake applied with vehicle in

Warning chime Release parkbrake
on motion

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• Power supply to For EPB control module

module failure
power and ground tests,
B1342 Control module failure • Ground to module
failure GO to Pinpoint Test
• Control module failure G295394p1.
• Connector pin(s) bent

For EPB switch circuit
Parkbrake Apply switch circuit • Connector loose or
C1094 tests, GO to Pinpoint
failure corroded
• Harness fault Test G295394p2.

Parkbrake Apply switch circuit short • Connector loose or
to ground corroded

Parkbrake Release switch circuit • Connector loose or
failure corroded

Parkbrake Release switch circuit • Connector loose or
short to ground corroded
Parkbrake Apply and Release switch • Connector pin(s) bent For EPB switch tests, GO
C1989
contacts energized simultaneously • Connector loose or
to Pinpoint Test
corroded
• Harness fault G295394p3.
• Fuse failure
• Connector pin(s) bent For EPB motor circuit
Parkbrake motor output short to
C1784 • Connector loose or tests, GO to Pinpoint
ground corroded Test G295394p4.
• Harness fault
• Fuse failure
Parkbrake motor output open
circuit corroded Test G295394p4.
• Harness fault
• Fuse failure
Parkbrake motor output battery
short to ground corroded Test G295394p4.
• Harness fault
• Hall effect circuit open For hall effect sensor

circuit circuit tests, GO to
C1799 Hall effect sensor circuit failure
• Hall effect circuit short Pinpoint Test
circuit to ground G295394p5.
• Cables fouled, trapped

or damaged
Greater than expected motor • Cables incorrectly
routed or fixed Refer to the symptom
current draw reached before
• Rear lining wear chart for actions
C1801 expected travel (motor current
• Service brake not regarding mechanical
draw compared to expected correctly adjusted operation
number of turns) following lining change
• Caliper malfunction
• Actuator malfunction
• Cables incorrectly
routed or fixed
Greater than expected travel for • Rear lining wear Refer to the symptom
measured current draw (motor • Service brake not chart for actions
C1802
current draw compared to expected correctly adjusted regarding mechanical
number of turns) following lining change operation
Less than expected travel for • Cables fouled, trapped Refer to the symptom
C1803 chart for actions
parkbrake release or damaged
• Cables incorrectly regarding mechanical
routed or fixed operation
• Rear lining wear
• Service brake not
correctly adjusted
following lining change
Pinpoint Tests
NOTE:
Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
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NOTE:
NOTE:
PINPOINT TEST G295394p1 : DTC

B1342; CONTROL MODULE FAILURE
G295394t1 : CHECK THE POWER SUPPLY TO THE EPB CONTROL MODULE
1. Disconnect the EPB control module electrical connector, CR50. 2. Measure the voltage between
CR50, pin 01 (NW) and GROUND.
• Is the voltage less than 10 volts?
-> Yes
REPAIR the circuit between the EPB control module and battery. This circuit includes the battery
junction box (fuse 32). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
-> No
G295394t2 : CHECK THE GROUND TO THE EPB CONTROL MODULE

1. Measure the resistance between CR50, pin 04 (B) and GROUND.
-> Yes
-> No
Contact dealer technical support for advice on possible EPB control module failure.

C1094, C1769, C1782, C1783; PARK
BRAKE APPLY SWITCH CIRCUIT
FAILURE/SHORT TO GROUND, PARK
BRAKE RELEASE SWITCH CIRCUIT
FAILURE/SHORT TO GROUND
G295394t3 : CHECK THE SIGNAL GROUND TO THE EPB SWITCHPACK
1. Measure the resistance between TL82, pin 02 (BK) and GROUND.
-> Yes
-> No
G295394t4 : CHECK THE SIGNAL GROUND CIRCUIT TO THE EPB
SWITCHPACK FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the EPB control module electrical
connector, CR32. 3. Measure the resistance between TL82, pin 06 (WU) and CR32, pin 12 (WU).
-> Yes
-> No
G295394t5 : CHECK THE VOLTAGE FROM THE EPB CONTROL MODULE TO

THE SWITCHPACK
1. Reconnect the battery negative terminal. 2. Reconnect the EPB control module electrical
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connector, CR32. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between
TL82, pin 08 (WU) and GROUND. 5. Measure the voltage between TL82, pin 04 (RW) and GROUND.
• Is either voltage less than 3 volts?
-> Yes
-> No
Check the EPB switch function. CLEAR the DTC. TEST the system for normal operation.
G295394t6 : CHECK THE EPB CONTROL MODULE TO SWITCHPACK CIRCUITS

FOR HIGH RESISTANCE
connector, CR32. 3. Measure the resistance between TL82, pin 08 (WU) and CR32, pin 05 (WU). 4.
Measure the resistance between TL82, pin 04 (RW) and CR32, pin 06 (RW).
-> Yes
-> No
G295394t7 : CHECK THE EPB CONTROL MODULE TO SWITCHPACK CIRCUITS
FOR SHORT TO GROUND
1. Reconnect the battery negative terminal. 2. Measure the resistance between TL82, pin 08 (WU)
and GROUND. 3. Measure the resistance between TL82, pin 04 (RW) and GROUND.
• Is either resistance less than 10,000 ohms?
-> Yes
-> No

C1989; PARK BRAKE APPLY AND
RELEASE SWITCH CONTACTS
ENERGIZED SIMULTANEOUSLY
G295394t8 : CHECK PARK BRAKE APPLY SWITCH FUNCTION
1. Disconnect the EPB switchpack electrical connector, TL82. 2. Connect an ohmmeter between pins
06 and 08 of the switch. 3. Operate the switch to the Apply position.
• Does the ohmmeter switch between open and closed circuit as the switch is operated?
-> Yes
-> No
INSTALL a new switchpack.
Parking Brake Switch (70.35.46) CLEAR the DTC. TEST the system for normal operation.
G295394t9 : CHECK PARK BRAKE RELEASE SWITCH FUNCTION

1. Connect an ohmmeter between pins 04 and 06 of the switch. 2. Operate the switch to the Release
position.
• Does the ohmmeter switch between open and closed circuit as the switch is operated?
-> Yes
-> No
G295394t10 : CHECK THE PARK BRAKE SWITCH FOR SHORT CIRCUIT

1. Connect an ohmmeter between pins 04 and 08 of the switch.
-> Yes
-> No
Recheck DTCs. Contact dealer technical support for advice on possible EPB control module failure.

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C1784, C1785, C1786; EPB MOTOR

OUTPUT OPEN/SHORT CIRCUIT
G295394t11 : CHECK THE EPB MOTOR + CIRCUIT FOR OPEN CIRCUIT
1. Disconnect the battery negative terminal. 2. Disconnect the EPB motor electrical connector, CV07.
3. Disconnect the EPB control module electrical connector, CR50. 4. Measure the resistance between
CV07, pin 01 (RW) and CR50, pin 03 (RW).
-> Yes
-> No
G295394t12 : CHECK THE EPB MOTOR - CIRCUIT FOR OPEN CIRCUIT

1. Measure the resistance between CV07, pin 06 (GW) and CR50, pin 02 (GW).
-> Yes
-> No
G295394t13 : CHECK THE EPB MOTOR + CIRCUIT FOR SHORT TO GROUND

1. Reconnect the battery negative terminal. 2. Measure the resistance between CV07, pin 01 (RW)
and GROUND.
-> Yes
-> No
G295394t14 : CHECK THE EPB MOTOR - CIRCUIT FOR SHORT TO GROUND

1. Measure the resistance between CV07, pin 06 (GW) and GROUND.
-> Yes
-> No
G295394t15 : CHECK THE EPB MOTOR + AND - FOR SHORT CIRCUIT TO

EACH OTHER
1. Measure the resistance between CV07, pins 06 (GW) and 01 (RW).
-> Yes
-> No
G295394t16 : CHECK THE EPB MOTOR FOR OPEN CIRCUIT
1. Check for continuity between pins 01 and 06 of the motor.
• Is the circuit continuous?
-> Yes
-> No
INSTALL a new EPB motor.
Parking Brake Release Actuator - VIN Range: G00001->G03445 (70.35.45) CLEAR the DTC. TEST the
system for normal operation.

C1799; HALL EFFECT SENSOR
FAILURE
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G295394t17 : CHECK THE HALL EFFECT SENSOR POWER SUPPLY

1. Disconnect the EPB motor electrical connector, CV07. 2. Measure the voltage between CV07, pin
03 (Y) and GROUND.
-> Yes
-> No
G295394t18 : CHECK THE HALL EFFECT SENSOR POWER SUPPLY CIRCUIT

FOR HIGH RESISTANCE
connector, CR32. 3. Measure the resistance between CV07, pin 03 (Y) and CR32, pin 10 (Y).
-> Yes
-> No
G295394t19 : CHECK THE HALL EFFECT SENSOR SIGNAL GROUND

1. Reconnect the battery negative terminal. 2. Measure the resistance between CV07, pin 05 (WU)
and GROUND.
-> Yes
-> No
G295394t20 : CHECK THE HALL EFFECT SENSOR SIGNAL GROUND CIRCUIT

FOR HIGH RESISTANCE
1. Measure the resistance between CV07, pin 05 (WU) and CR32, pin 12 (WU).
-> Yes
-> No
G295394t21 : CHECK THE HALL EFFECT SENSOR INPUT CIRCUIT FOR HIGH
RESISTANCE
1. Measure the resistance between CV07, pin 04 (YB) and CR32, pin 04 (YB).
-> Yes
-> No
INSTALL a new hall effect sensor. (The hall effect sensor is not available separately).
Parking Brake Release Actuator - VIN Range: G00001->G03445 (70.35.45) CLEAR the DTC. TEST the
system for normal operation. If the DTC is repeated, contact dealer technical support for advice on
possible EPB module failure.
>G99999
Principles of Operation
For a detailed description of the Parking Brake and Actuation, refer to the relevant Description and
Operation sections in the workshop manual.

• Parking brake cable

• Fuses/Relays
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• Parking brake actuator

• Damaged, Loose or Corroded Connector(s)
• Parking brake caliper
• Damage to Wiring Loom/Incorrect Location, Stretched or
• Parking brake pads
Taught
• Drop link caps
retrieve the fault codes before proceeding to the diagnostic trouble code (DTC) Index.
Symptom Chart
Symptom Possible Sources Action
• Check the rear and primary cables for

• Cables fouled, fouling, trapping or damage
trapped or damaged • Check the cable routing between caliper and
• Cables incorrectly subframe mountings. Make sure the cables
The parking routed or fixed sit above the rear anti-roll bar drop link
• Rear lining wear caps, and that the drop link caps are not
brake will not
• Service brake damaged
engage or incorrectly adjusted • Check that the rear cable end fitting
release following lining connector is correctly fitted into the caliper
change bracket, and is not damaged
• Caliper malfunction • Check that the rear cable end fitting
• Actuator malfunction connector is correctly fitted into the
subframe bracket and is not damaged
• Check the 'C' clip between the cable and the
subframe for fit/damage
• Check that the cable is correctly located into
the reaction and connector brackets
• Inspect the rear brake linings (parking brake
caliper linings for vehicles with
supercharger) for wear
• Check the parking brake cable for correct
adjustment
• Fully retract the cables. Pump the brake
pedal hard five times
• Check the condition of the rear caliper
(parking brake caliper for vehicles with
supercharger). Make sure the caliper return
spring is correctly fitted
• Check the actuator for damage and/or
excessive noise in normal operation
Range: G45704->G99999
Parking Brake Module - VIN Range: G45704-
>G99999 (70.35.47)
Parking Brake Release Actuator - VIN Range:
G03446->H99999 (70.35.45)
DTC index
tests, use the adaptor kit, part number 3548-1358-00
NOTE:
If the control module/component is suspect and the vehicle remains under manufacturer
warranty, refer to the Warranty Policy and Procedures manual (section B1.2), or determine if
any prior approval program 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 5 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:
three decimal places and with a current calibration certificate. When testing resistance, always
NOTE:
Check and rectify basic faults before beginning diagnostic routines that involve pinpoint tests.
NOTE:
NOTE:
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If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an
terminals.
DTC Description Possible cause Action
• Parking brake module -

supply voltage high
Refer to electrical circuit diagrams
(above 18 volts)
B131700 Battery Voltage High and check parking brake module
Generator voltage is
regulated by the engine power circuit for fault
control module

supply voltage low
(below 8 volts)
B131800 Battery Voltage Low and check parking brake module
Generator voltage is
regulated by the engine power and ground circuit for fault
control module
Suspect the module, check and

install a parking brake module as
B134200 ECU is defective required, refer to the new module
internal fault
installation note at the top of the
DTC Index
• Parking brake module,
Ignition Key-In ignition key-in circuit
B135264 and check parking brake module,
Circuit Failure fault (Failed plausibility
check with CAN data) ignition key-in circuit for fault
The module can be configured

Module • Parking brake module -
B247700 using the new module
Configuration Failure configuration failure
configuration procedure
Carry out any pinpoint tests

associated with this DTC using the
• Parking brake module, manufacturer approved diagnostic
Park Brake Apply primary park brake apply system. Refer to electrical circuit
C109400
Switch Circuit Failure switch - short to power diagrams and check, parking
or open circuit brake module, primary park brake
apply switch for short to power or
open circuit

Park Brake Release
park brake release system. Refer to electrical circuit
C140800 Switch Circuit Out of switch - voltage out of diagrams and check park brake
Range range release switch circuit, for primary
release switch circuit tests, GO to
Pinpoint Test G531320p8.

manufacturer approved diagnostic
Park Brake Apply • Primary apply switch system. Refer to electrical circuit
C140900 Switch Circuit Out of circuit - short to power diagrams and check primary apply
Range or high resistance switch circuit for short to power
or high resistance, for primary
apply switch circuit tests, GO to

Park Brake Apply manufacturer approved diagnostic
• Primary apply switch
C176900 Switch Circuit Short system. Refer to electrical circuit
circuit - short to ground
to Ground diagrams and check primary apply
switch circuit for short to ground,
for primary apply switch circuit
tests, GO to Pinpoint Test
G531320p10.

system. Refer to electrical circuit
• Primary release switch
Park Brake Release diagrams and check primary
C178200 circuit - short circuit to
Switch Circuit Failure power or open circuit release switch circuit for short
circuit to power or open circuit,
for primary release switch circuit
G531320p29.

Park Brake Release system. Refer to electrical circuit
• Primary release switch
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C178300 Switch Short to diagrams and check primary

circuit - short to ground
Ground release switch circuit for short
circuit to ground, for primary
release switch circuit tests, GO to

Electric Park Brake
• Park brake motor output system. Refer to electrical circuit
C178400 Motor Output Short
circuit - short to ground diagrams and check park brake
to Ground
motor output for short circuit to
ground, GO to Pinpoint Test
G531320p13.

Electric Park Brake manufacturer approved diagnostic
• Park brake motor output
C178500 Motor Output Open system. Refer to electrical circuit
circuit - open circuit
Circuit diagrams and check park brake
motor output for open circuit, GO
to Pinpoint Test G531320p24.

Electric Park Brake
• Park brake motor output associated with this DTC using the
C178600 Motor Output Power
- short circuit to power manufacturer approved diagnostic
Short to Ground system. Refer to electrical circuit
diagrams and check park brake
motor output for short circuit to
power, GO to Pinpoint Test
G531320p16.

• Hall effect sensor - circuit
diagrams and check hall effect
Hall Effect Circuit fault
C179900 sensor for circuit fault, for hall
Failure • Hall effect sensor -
mechanical fault effect sensor tests, GO to Pinpoint
Test G531320p17.
Refer to the symptom chart for
actions regarding mechanical
operation faults.
• Cables fouled, trapped or

damaged
• Cables incorrectly routed
Motor Engage or fixed
Current Reached • Rear lining wear
C180100 actions regarding mechanical
Before Full Apply • Service brake not
correctly adjusted operation faults.
Travel Distance
• Cables incorrectly routed

or fixed
Motor Engage • Rear lining wear
Current Not Reached • Service brake not
C180200 actions regarding mechanical
or Travelled Too Far correctly adjusted
Apply following lining change operation faults.
• Cables fouled, trapped or

damaged
• Cables incorrectly routed associated with this DTC using the
or fixed manufacturer approved diagnostic
Less than expected
• Rear lining wear system. For motor release tests,
C180300 travel for parking
• Service brake not GO to Pinpoint Test G531320p19.
brake release correctly adjusted Refer to the symptom chart for
actions regarding mechanical
• Actuator malfunction operation faults.
Park Brake Apply • Park brake apply and manufacturer approved diagnostic
and Release Switch release switch contacts system. Refer to electrical circuit
C198900
Contacts Energized energized diagrams and check park brake
Simultaneously simultaneously apply and release switch circuits
for fault GO to Pinpoint Test
G531320p21.
Suspect park brake switch

Park Brake Apply
C1D0062 • Park brake switch - fault mechanism fault, check operation,
Switch
replace as required
Suspect park brake switch

Park Brake Apply
C1D0064 • Park brake switch - fault mechanism fault, check operation,
Switch
replace as required

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and check park brake apply and

• Park brake switch - fault release switch circuits for fault.
(More then 30 Applies suspect park brake switch
Park Brake Apply and 30 Releases initiated mechanism fault, check operation,
C1D0066 in a 60 second time
Switch replace as required.(Park Brake
period while in static Switch Fault, will be entered to
mode)
lock out further abuse of the
system. Full functionality will be
restored upon ignition reset)

• Parking brake module system. Refer to electrical circuit
Secondary Park
C1D0711 secondary apply switch diagrams and check, secondary
Brake Apply Switch circuit - short to ground apply switch circuit for short to
ground, for secondary apply
switch tests, GO to Pinpoint Test
G531320p5.

• Parking brake module associated with this DTC using the
Secondary Park secondary apply switch manufacturer approved diagnostic
C1D0715 system. Refer to electrical circuit
Brake Apply Switch circuit - short to power
or open circuit diagrams and check, secondary
apply switch circuit for short to
power or open circuit, for
secondary apply switch tests, GO

• Parking brake module manufacturer approved diagnostic
Secondary Park secondary apply switch system. Refer to electrical circuit
C1D071C
Brake Apply Switch circuit - voltage out of diagrams and check, secondary
range apply switch circuit for fault, for
secondary apply switch tests, GO

• Parking brake module
Secondary Park secondary release switch
C1D0811 diagrams and check, secondary
Brake Release Switch circuit - short circuit to
ground release switch circuit for short
circuit to ground, for secondary
release switch tests, GO to

• Parking brake module
Secondary Park secondary release switch
C1D0815 diagrams and check, secondary
Brake Release Switch circuit - short circuit to
power or open circuit release switch circuit for short to
power or open circuit For
secondary release switch tests,
GO to Pinpoint Test G531320p18.

• Parking brake module system. Refer to electrical circuit
Secondary Park secondary release switch diagrams and check, secondary
C1D081C
Brake Release Switch circuit - voltage out of release switch circuit for short
range circuit to power or high
resistance, for secondary release
switch tests, GO to Pinpoint Test
G531320p4.
C1D1000 FET Over Suspect the module, check and

Current/Over install a parking brake module as
Temperature internal fault required, refer to the new module
installation note at the top of the
DTC Index
Suspect parking brake switch

Park Brake Release • Parking brake switch -
C1D1162 mechanical fault, check and install
Switch internal fault
a parking brake switch as required
Suspect parking brake switch

Park Brake Release • Parking brake switch - mechanical failure, check and
C1D1164
Switch internal fault install a parking brake switch as
required
• Parking brake module - Refer to electrical circuit diagrams

C1D1464 Ignition Status ignition status circuit and check, parking brake module
fault ignition status circuit for fault

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brake switch circuit fault system. Refer to electrical circuit
C1D1564 Brake Switch Status
(Failed plausibility check diagrams and check footbrake
with CAN data) switch circuit for fault, for
footbrake switch tests, GO to

and check parking brake module
• High power feed circuit -
High Power Battery high power feed circuit for short
C1D1614 short to ground or high
Feed resistance circuit to ground or high
resistance, for power feed tests,
• Key-Out-Apply after
implausible vehicle
speed (Implausible
vehicle speed is defined
Check DSC (ABS) module for
C1D2092 Vehicle Deceleration as a change from High
Speed Dynamic Mode to stored fault codes
Static Mode without
passing through Low
Speed Dynamic Mode)
High Speed CAN • Parking brake module -

U000100 Communication Bus Refer to electrical circuit diagrams
CAN Bus circuit fault
- Can
Transmit/Receive CAN Bus circuit fault
Error
High Speed CAN Refer to electrical circuit diagrams

U000188 Communication Bus and check parking brake module
CAN Bus circuit fault
- CAN Bus off CAN Bus circuit fault

Lost Communication • Parking brake module - and check parking brake module
U010000
With ECM/PCM CAN Bus circuit fault CAN Bus circuit to engine control
module for fault

Lost Communication • Parking brake module - and check parking brake module
U010100
with TCM CAN Bus circuit fault CAN Bus circuit to transmission
control module for fault

Lost Communication
With Anti-Lock Brake • Parking brake module -
U012100 CAN Bus circuit to (DSC) anti-lock
System (ABS) Control CAN Bus circuit fault
brake system control module for
Module
fault
Lost Communication Refer to electrical circuit diagrams

With Instrument • Parking brake module - and check parking brake module
U015500
Panel Cluster (IPC) CAN Bus circuit fault CAN Bus circuit to instrument
Control Module panel cluster for fault

CAN Bus circuit fault (At Refer to electrical circuit diagrams
Invalid Data
least one message from and check parking brake module
U040100 Received From
the ECM/PCM was CAN Bus circuit to engine control
ECM/PCM invalid for 250 ms or module for fault
longer)
Invalid Data • Parking brake module - Refer to electrical circuit diagrams

CAN Bus circuit fault (At
Received From and check parking brake module
U040200 least one message from
Transmission Control the TCM was invalid for CAN Bus circuit to transmission
Module 250 ms or longer) control module for fault
Invalid Data • Parking brake module - Refer to electrical circuit diagrams

CAN Bus circuit fault (At
Received From Anti- and check parking brake module
U041500 least one message from
Lock Brake System the ABS was invalid for CAN Bus circuit to anti-lock brake
Control Module 250 ms or longer) system control module for fault
Pinpoint Tests
PINPOINT TEST G531320p1 : PRIMARY

PARKING BRAKE APPLY SWITCH
CIRCUIT FAILURE
G531320t1 : CHECK THE PRIMARY APPLY SIGNAL CIRCUIT FOR SHORT
CIRCUIT TO POWER
1. Key off. 2.
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Electric parking brake module connector 1 (CR50) disconnected. 3.
Electric parking brake module connector 2 (CR32) connector disconnected. 4. Key on, engine off. 5.
CR50, harness side Vehicle battery
Electric parking brake switch apply 1 - signal - Pin 10 Positive terminal
• Is the resistance greater than 100 Kohms?
-> Yes
-> No
G531320t2 : CHECK THE PRIMARY RELEASE SIGNAL CIRCUIT FOR SHORT

CIRCUIT TO POWER
CR50 connector, harness side Vehicle battery
-> Yes
-> No
G531320t3 : CHECK THE SECONDARY APPLY SIGNAL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G531320t4 : CHECK THE SECONDARY RELEASE SIGNAL CIRCUIT FOR SHORT

CIRCUIT TO POWER
Electric parking brake switch release 2 - signal - Pin 14 Positive terminal
-> Yes
-> No
G531320t5 : CHECK THE PRIMARY APPLY SIGNAL CIRCUIT FOR OPEN

CIRCUIT
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1.
Electric parking brake switch (TL82) connector disconnected. 2. Measure the resistance between:
CR50 connector, harness side TL82 connector, harness side
Electric parking brake switch apply 1 - signal - Pin Electric parking brake switch apply 1 - signal - Pin
10 08
• Is the resistance less than 10 ohms?
-> Yes
-> No
REPAIR the open circuit. For additional information, refer to the wiring diagrams.
G531320t6 : CHECK THE SWITCH RETURN CIRCUIT FOR OPEN CIRCUIT
Electric parking brake switch - switch return - Pin Electric parking brake switch - switch return - Pin
06 06
-> Yes
-> No
G531320t7 : CHECK THE ELECTRIC PARKING BRAKE SWITCH

TL82 connector, component side TL82 connector, component side
Electric parking brake switch apply 1 - signal - Pin Electric parking brake switch - switch return - Pin
08 06
• Is the resistance between 595 ohms - 611 ohms?
-> Yes
An intermittent fault may be present in the wiring harness. Visually check for chaffed wires or other
physical damage to the harness. If no fault is found in the circuit, suspect the following
component(s): - EPB Module - EPB module connector, CR50 - EPB module connector, CR32
-> No
INSTALL a new EPB switch.
G531320t8 : CHECK IF THE SHORT CIRCUIT IS IN THE HARNESS OR THE
SWITCH
1.

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-> Yes
-> No
REPAIR the short circuit. For additional information, refer to the wiring diagrams.

SWITCH
1.

-> Yes
-> No

SWITCH
1.
-> Yes
-> No
SWITCH
1.

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-> Yes
-> No

SECONDARY APPLY SWITCH CIRCUIT
VOLTAGE OUT OF RANGE
G531320t12 : CHECK THE SECONDARY SWITCH CIRCUIT RESISTANCE
1. Key off. 2.
Electric parking brake module connector 2 (CR32) disconnected. 3. Key on, engine off. 4. Measure the
resistance between:
CR32 connector, harness side CR32 connector, harness side
02 06
-> Yes
component(s): - EPB fault - EPB module connector, CR32
-> No

SECONDARY RELEASE SWITCH
CIRCUIT VOLTAGE OUT OF RANGE
G531320t21 : CHECK THE SECONDARY SWITCH CIRCUIT RESISTANCE
1. Key off. 2.
Electric parking brake connector 2 (CR32) disconnected. 3. Key on, engine off. 4. Measure the
resistance between:
Electric parking brake switch release 2 - signal - Pin Electric parking brake switch - switch return - Pin
14 06

-> Yes
component(s): - EPB module - EPB module connector, CR32
-> No

SECONDARY APPLY SWITCH CIRCUIT
SHORT CIRCUIT TO GROUND
CIRCUIT TO GROUND
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1. Key off. 2.
resistance between:
Electric parking brake switch apply 2 - signal - Pin 02 Negative terminal
-> Yes
-> No
SWITCH
1.
-> Yes
-> No

SECONDARY APPLY HARNESS SHORT
CIRCUIT TO BATTERY OR OPEN
CIRCUIT
CIRCUIT TO POWER
1. Key off. 2.

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resistance between:
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531320t34 : CHECK THE SECONDARY RELEASE SIGNAL CIRCUIT FOR

SHORT CIRCUIT TO POWER

-> Yes
-> No
G531320t35 : CHECK THE SECONDARY APPLY SIGNAL CIRCUIT FOR OPEN

CIRCUIT
1.
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Electric parking brake switch apply 2 - signal - Pin Electric parking brake switch apply 2 - signal - Pin
02 07
-> Yes
-> No
G531320t36 : CHECK THE SWITCH RETURN SIGNAL CIRCUIT FOR OPEN

CIRCUIT
06 06
-> Yes
-> No

07 06
-> Yes
component(s): - EPB module - EPB module connector, CR50 - EPB module connector, CR32
-> No

SWITCH
1.
-> Yes
-> No

SWITCH
1.
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-> Yes
-> No
SWITCH
1.
-> Yes
-> No

SWITCH
1.

-> Yes
-> No

RELEASE SWITCH CIRCUIT OUT OF
RANGE
G531320t42 : CHECK THE PRIMARY RELEASE SWITCH CIRCUIT RESISTANCE
1. Key off. 2.
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resistance between:
11 06

-> Yes
-> No

APPLY SWITCH CIRCUIT OUT OF
RANGE
G531320t43 : CHECK THE PRIMARY APPLY SWITCH CIRCUIT RESISTANCE
1. Key off. 2.
resistance between:
10 06

-> Yes
-> No

PRIMARY APPLY SWITCH CIRCUIT
CIRCUIT TO GROUND
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1. Key off. 2.
resistance between:
-> Yes
-> No
SWITCH
1.
-> Yes
-> No
PINPOINT TEST G531320p11 : HIGH

POWER BATTERY FEED CIRCUIT
SHORT CIRCUIT TO GROUND OR
OPEN CIRCUIT
G531320t46 : CHECK THE HIGH POWER SUPPLY CIRCUIT
1.
Electric parking brake module connector 2 (CR32) disconnected. 2. Measure the voltage between:
Electric parking brake module - battery supply - Pin 01 Negative terminal

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• Is the voltage between 9 volts - 15 volts?
-> Yes
component(s): - EPB module
-> No
No supply to the EPB circuit. check and repair the circuit as necessary. For additional information,
refer to the wiring diagrams.

PRIMARY RELEASE SWITCH CIRCUIT
TO GROUND
1. Key off. 2.
resistance between:
Electric parking brake switch release 1 - signal - Pin 11 Negative terminal
-> Yes
-> No

SWITCH
1.
-> Yes
-> No

PARKING BRAKE ACTUATOR OUTPUT
G531320t49 : CHECK THE ACTUATOR NEGATIVE SIGNAL CIRCUIT FOR
1. Key off. 2.
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Electric parking brake switch (TL82) connector disconnected. 3. Key on, engine off. 4. Measure the
resistance between:
Electric parking brake actuator - negative - Pin 07 Negative terminal
-> Yes
-> No
G531320t50 : CHECK THE ACTUATOR POSITIVE SIGNAL CIRCUIT FOR


Electric parking brake actuator - positive - Pin 14 Negative terminal
-> Yes
-> No

ACTUATOR
1.
EPB actuator connector disconnected. 2. Measure the resistance between:
Electric parking brake actuator - negative - Pin 07 Negative terminal
-> Yes
INSTALL a new EPB actuator.
-> No
ACTUATOR
1.
Electric parking brake actuator - positive - Pin 14 Negative terminal

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-> Yes
-> No
PINPOINT TEST G531320p15 : HIGH

POWER GROUND FEED OPEN
CIRCUIT
G531320t61 : CHECK THE MODULE GROUND CIRCUIT FOR CONTINUITY
1.
Electric parking brake module connector 2 (CR32) disconnected. 2. Measure the resistance between:
Electric parking brake module - ground - Pin 13 Negative terminal
-> Yes
component(s): - EPB Module
-> No

ACTUATOR OUTPUT SHORT CIRCUIT
TO BATTERY
G531320t62 : CHECK THE ACTUATOR NEGATIVE SIGNAL CIRCUIT FOR
1. Key off. 2.
resistance between:
Electric parking brake actuator - negative - Pin 07 Positive terminal
-> Yes
-> No
G531320t63 : CHECK THE ACTUATOR POSITIVE SIGNAL CIRCUIT FOR

Electric parking brake actuator - positive - Pin 14 Positive terminal

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-> Yes
-> No

ACTUATOR
1.
Electric parking brake actuator - negative - Pin 07 Positive terminal

-> Yes
-> No

ACTUATOR
1.
Electric parking brake actuator - positive - Pin 14 Positive terminal
-> Yes
-> No

ACTUATOR HALL EFFECT SENSOR
CIRCUIT FAILURE
G531320t66 : CHECK THE HALL EFFECT 5 VOLT SUPPLY CIRCUIT FOR
1. Key off. 2.

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resistance between:
Electric parking brake hall effect - signal - Pin 12 Negative terminal
-> Yes
-> No
G531320t67 : CHECK THE HALL EFFECT 5 VOLT SUPPLY CIRCUIT FOR


Electric parking brake hall effect - signal - Pin 12 Positive terminal
-> Yes
-> No
G531320t68 : CHECK THE ACTUATOR SIGNAL CIRCUIT FOR SHORT CIRCUIT

TO GROUND
Electric parking brake actuator - signal - Pin 10 Negative terminal
-> Yes
-> No
G531320t69 : CHECK THE ACTUATOR SIGNAL CIRCUIT FOR SHORT CIRCUIT

TO POWER

-> Yes
-> No
G531320t70 : CHECK THE SENSOR RETURN CIRCUIT FOR SHORT CIRCUIT

TO BATTERY
Electric parking brake hall effect - ground - Pin 13 Positive terminal

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-> Yes
-> No
G531320t71 : CHECK THE SENSOR RETURN CIRCUIT FOR OPEN CIRCUIT

1.
CR50 connector, harness side EPB actuator connector, harness side
Electric parking brake hall effect - ground - Pin 13 Electric parking brake hall effect - ground - Pin 05
-> Yes
-> No
G531320t72 : CHECK THE HALL EFFECT 5 VOLT SUPPLY CIRCUIT FOR OPEN
CIRCUIT
Electric parking brake hall effect - signal. - Pin 12 Electric parking brake hall effect - signal - Pin 03
-> Yes
-> No
G531320t73 : CHECK THE ACTUATOR SIGNAL CIRCUIT FOR OPEN CIRCUIT

Electric parking brake actuator - signal - Pin 10 Electric parking brake actuator - signal - Pin 04
-> Yes
component(s): - EPB module - EPB actuator - EPB module connector, CR50 - EPB module connector,
CR32 - EPB actuator connector
-> No

ACTUATOR
1.

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Electric parking brake hall effect - signal - Pin 12 Negative terminal
-> Yes
-> No

ACTUATOR
1.

Electric parking brake hall effect - signal - Pin 12 Positive terminal
-> Yes
-> No

ACTUATOR
1.
-> Yes
-> No
ACTUATOR
1.
Electric parking brake actuator - signal - Pin 10 Positive terminal

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-> Yes
-> No

ACTUATOR
1.
Electric parking brake hall effect - ground - Pin 13 Positive terminal

-> Yes
-> No

SECONDARY RELEASE HARNESS
SHORT CIRCUIT TO BATTERY OR
OPEN CIRCUIT
CIRCUIT TO POWER
1. Key off. 2.
resistance between:

-> Yes
-> No

CIRCUIT TO POWER

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-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

-> Yes
-> No
G531320t83 : CHECK THE SECONDARY RELEASE SIGNAL CIRCUIT FOR OPEN

CIRCUIT
1.
Electric parking brake switch release 2 - signal - Electric parking brake switch release 2 - signal -
Pin 14 Pin 05

-> Yes
-> No
G531320t84 : CHECK THE SWITCH RETURN SIGNAL CIRCUIT FOR OPEN

CIRCUIT
06 06
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-> Yes
-> No

05 06
-> Yes
-> No

SWITCH
1.
-> Yes
-> No

SWITCH
1.

-> Yes
-> No

SWITCH
1.
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-> Yes
-> No
SWITCH
1.
-> Yes
-> No

ACTUATOR DOES NOT FULLY
RELEASE
G531320t90 : CHECK THE HIGH CURRENT GROUND CIRCUIT FOR AN OPEN
CIRCUIT IN THE HARNESS
1. Key off. 2.
Electric parking brake connector 2 (CR32) disconnected. 3. Measure the resistance between:
Electric parking brake module - ground - Pin 13 Negative terminal
-> Yes
-> No

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SECONDARY RELEASE SWITCH

CIRCUIT SHORT CIRCUIT TO
GROUND
1. Key off. 2.
resistance between:

-> Yes
-> No

SWITCH
1.
Electric parking brake switch connector (TL82) disconnected. 2. Measure the resistance between:
-> Yes
-> No
PINPOINT TEST G531320p21 : APPLY

AND RELEASE SWITCH CONTACTS
ENERGIZED SIMULTANEOUSLY
G531320t93 : CHECK THE PRIMARY EPB APPLY AND RELEASE CIRCUIT FOR
SHORT CIRCUIT FAULTS
1. Key off. 2.
Electric parking brake connector 1 (CR50) disconnected. 3.

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Electric parking brake connector 2 (CR32) disconnected. 4. Make sure the parking brake switch is not
in the apply or release position. 5. Measure the resistance between:
Electric parking brake switch apply 1 - signal - Pin Electric parking brake switch release 1 - signal - Pin
10 11
• Is the resistance between 1.19 Kohms - 1.222 Kohms?
-> Yes
-> No
G531320t94 : CHECK THE SECONDARY EPB APPLY AND RELEASE CIRCUIT

FOR SHORT CIRCUIT FAULTS
1. Make sure the parking brake switch is not in the apply or release position. 2. Measure the
resistance between:
02 14
• Is the resistance between 1.19 Kohms - 1.222 Kohms?
-> Yes
-> No

SWITCH
1.
10 11
-> Yes
-> No
SWITCH
1.
02 14
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-> Yes
-> No

SWITCH INPUT STATUS PLAUSIBILITY
FAILURE
G531320t97 : CHECK THE BRAKE SWITCH CIRCUIT FOR SHORT CIRCUIT TO
POWER IN HARNESS
1. Key off. 2.
Electric parking brake module connector 2 (CR32) disconnected. 3. Key on, engine off. 4. Make sure
the brake pedal is not pressed. 5. Measure the resistance between:
Brake switch - signal - Pin 07 Positive terminal
-> Yes
-> No

GROUND IN THE HARNESS
Brake switch - signal - Pin 07 Negative terminal
-> Yes
The following items have not been fully tested : - EPB module - Brake switch - ECM
-> No
POWER IN THE HARNESS
1.
Brake pressure sensor (BPS) connector disconnected. 2. Measure the resistance between:
Brake switch - signal - Pin 07 Positive terminal

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-> Yes
INSTALL a new BPS.
-> No

ACTUATOR OUTPUT OPEN CIRCUIT
G531320t102 : CHECK THE ACTUATOR CIRCUIT RESISTANCE
1. Key off. 2.
resistance between:

Electric parking brake actuator - positive - Pin 14 Electric parking brake actuator - negative - Pin 07
• Is the resistance between 0.5 ohms - 1 ohms?
-> Yes
-> No
G531320t103 : CHECK THE ACTUATOR SIGNAL CIRCUIT FOR OPEN CIRCUIT

1.
Electric parking brake actuator - positive - Pin 14 Electric parking brake actuator - positive - Pin 01
-> Yes
-> No
G531320t104 : CHECK THE ACTUATOR RETURN CIRCUIT FOR OPEN CIRCUIT

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Electric parking brake actuator - negative - Pin 07 Electric parking brake actuator - negative - Pin 06
-> Yes
-> No
G531320t105 : CHECK THE ACTUATOR CIRCUIT RESISTANCE

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EPB actuator connector, component side EPB actuator connector, component side
Electric parking brake actuator - positive - Pin 01 Electric parking brake actuator - negative - Pin 06
• Is the resistance between 0.5 ohms - 1 ohm?
-> Yes
-> No

PRIMARY PARKING BRAKE RELEASE
SWITCH CIRCUIT FAULT
G531320t134 : CHECK THE PRIMARY RELEASE SWITCH SIGNAL CIRCUIT
FOR SHORT CIRCUIT TO POWER
1. Key off. 2.
resistance between:
Primary release switch signal 1 - pin 11 Positive terminal
-> Yes
-> No
G531320t135 : CHECK THE PRIMARY APPLY SWITCH SIGNAL CIRCUIT FOR


Primary apply switch signal 1 - pin 10 Positive terminal
-> Yes
-> No
G531320t136 : CHECK THE SECONDARY APPLY SWITCH SIGNAL CIRCUIT

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Secondary apply switch signal 2 - pin 02 Positive terminal
-> Yes
-> No
G531320t137 : CHECK THE SECONDARY RELEASE SWITCH SIGNAL CIRCUIT

Secondary release switch signal 2 - pin 14 Positive terminal

-> Yes
-> No
G531320t138 : CHECK THE PRIMARY RELEASE SWITCH SIGNAL CIRCUIT

FOR HIGH RESISTANCE
1.
Primary release switch signal 1 - pin 11 Primary release switch signal 1 - pin 04
-> Yes
-> No
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams.
G531320t139 : CHECK THE APPLY SWITCH RETURN CIRCUIT FOR HIGH

RESISTANCE
Switch return - pin 06 Switch return - pin 06

-> Yes
-> No
INSTALL a new parking brake switch.
G531320t140 : CHECK THE SWITCH RESISTANCE

Switch release signal 1 - pin 04 Switch return - pin 06

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• Is the resistance between 595 and 611 ohms?
-> Yes
component(s): - CR50 - CR32 - EPB module
-> No

SWITCH
1.
CR50 connector, component side Vehicle battery

Release switch signal 1 - pin 11 Positive terminal
-> Yes
-> No

SWITCH
1.
Apply switch signal 1 - pin 10 Positive terminal
-> Yes
-> No
SWITCH
1.
Apply switch signal 2 - pin 02 Positive terminal

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-> Yes
-> No

SWITCH
1.
Release switch signal 2 - pin 14 Positive terminal

-> Yes
-> No
arking Brake Module - VIN Range:

G00442->G45703 (70.35.47)
Removal
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3 . Disconnect the parking brake module electrical connector.
4 . Disconnect the parking brake module electrical connector.

5 . Remove the parking brake module.
Installation
1 NOTE:
.
If a new parking brake module is installed it must be configured using the Jaguar
Tighten to 4 Nm.
Parking Brake Module - VIN Range:
G45704->G99999 (70.35.47)
Removal
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3 . Detach the rear electronic module (REM).
4 . Disconnect the parking brake module electrical connectors.

5 . Detach the parking brake module.
6 . Remove the parking brake module.
Installation
1 NOTE:
.
If a new parking brake module is installed it must be configured using the Jaguar
Tighten to 4 Nm.
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Brake caliper piston retractor.

206-081
Removal
1 . Carry out the parking brake cable tension release.
2 . Remove both rear wheels and tires. <<204-04>>
1) Reposition the parking brake caliper lever.
4 . Remove the parking brake pads.
1) Remove the parking brake pad retaining pins.

2) Remove the parking brake pad anti-rattle spring plate.
3) Remove the parking brake pads.
5 . NOTE:
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Note using special tool 206-081 retract the parking brake caliper piston.
Remove the parking brake caliper.
Remove and discard the parking brake caliper retaining bolts.
Installation
1
. CAUTION: Make sure the brake disc faces are clean before installation.

CAUTION: Install new parking brake caliper retaining bolts.
CAUTION: After installing the parking brake caliper, manually operate the parking
brake caliper lever until the parking brake caliper piston is set to the correct position and
the clearances between the pads, discs and parking brake caliper piston have been
removed.
Removal
All vehicles
1 . Carry out the parking brake cable release.
2 . Remove both rear wheels and tires. <<204-04>>
1) For right-hand side connector bracket:

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reposition the retaining tang.
detach the parking brake cable.
2) For left-hand side reaction bracket, detach the parking brake cable.


5 . Remove the parking brake cable retaining tie strap.

All vehicles
7 . Remove the parking brake cable.
Detach the parking brake cable retaining tangs.

Remove the parking brake cable.
Installation
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Parking Brake Release Actuator - VIN
Range: G00001->G03445 (70.35.45)
Removal
1 Carry out the parking brake cable tension release.
G00442->G45703

3 . Disconnect the parking brake release actuator electrical connector.
reposition the retaining tang.
detach the parking brake cable.
5 . Remove the parking brake release actuator retaining bolts.
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6 . Detach the parking brake release actuator cable.
7 . Remove the parking brake release actuator.

Installation
1 . NOTE:
Make sure the parking brake cable is correctly routed.
Tighten to 20 Nm.
2
Parking Brake Release Actuator - VIN
Range: G03446->H99999 (70.35.45)

HTJ1200-02
Removal
1 Carry out the parking brake cable tension release.
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G45704->G99999
2 . Drain the fuel tank.

For additional information, refer to Fuel Tank Draining - VIN Range: G45704->G99999

4 . Disconnect the parking brake release actuator electrical connector.
5 . NOTE:

Detach the air springs.
6 . Detach the fuel tank filler pipe.
7 . NOTE:
Detach the muffler and tail pipe from the hanger insulator.

9 . NOTE:
Remove the noise, vibration and harshness brace retaining bolts.

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10 . NOTE:
Remove and discard the rear subframe rear retaining bolts.

11 . NOTE:
Remove the noise, vibration and harshness brace.
Remove and discard the rear subframe front retaining bolts.
12 . Lower the subframe to a maximum of 60 mm.
13 . Remove and discard the cross brace retaining bolts.
Reposition the cross brace.

14 . Remove the parking brake release actuator retaining bolts.

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Reposition the retaining tang.
17 . Remove the parking brake release actuator.
Installation
1 . NOTE:
Make sure the parking brake cable is correctly routed.
Install the parking brake release actuator.
Tighten to 20 Nm .
2 . Attach the parking brake release actuator cable.
Reposition the retaining tang.
3 . Reposition the cross brace.
Install new cross brace retaining bolts.
Tighten rear M8 to 35 Nm.
Tighten front M10 to 70 Nm.

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4 . Raise special tool and align subframe.
5 . NOTE:

Install the noise, vibration and harshness brace.
Tighten to 47 Nm
6 . NOTE:
Install, but do not fully tighten the new rear subframe front retaining bolts.
7 . NOTE:
Install and fully tighten the new rear subframe retaining bolts.
8 . Tighten rear subframe retaining bolts to 125 Nm.
9 . Remove the special tool supporting the rear subframe.

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10 . NOTE:
Attach the muffler and tailpipe to the hanger insulator.
11 . Attach the fuel tank filler pipe.

12 . NOTE:
Attach the rear air springs.
Tighten to 133 Nm.
13 . Connect the parking brake release actuator electrical connector.

15
. CAUTION: Calibrate the electric park brake using Jaguar approved diagnostic
system. If the Jaguar approved diagnostic system is not available disconnect the battery
for approximately 30 seconds, the vehicle will then prompt the driver to carry out the
16 . Refill the fuel tank.

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Installation
206-06 : Hydraulic Brake Actuation
Specifications
Specifications
NOTE:
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years.
Item Specification

Brake master cylinder to brake booster retaining nuts. 25 18 -
HCU to brake master cylinder brake tubes 17 13 -
Brake master cylinder reservoir retaining bolts 8 - 71
1 — Brake master cylinder
2 — Brake fluid reservoir
3 — Brake booster
4 — Rear brake caliper
5 — Brake lines
6 — Front brake caliper
7 — Hydraulic control unit
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the
eyes. Wash hands thoroughly after handling, as prolonged contact may cause irritation and
dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or eyewash solution and
seek medical attention. If taken internally, do not induce vomiting, seek immediate medical
attention. Failure to follow these instructions may result in personal injury.
The hydraulic brake system is of a pedal operated, diagonally split dual line brake system that
consists of the following components:
• A brake booster.
• A brake master cylinder.
• Front brake discs.
• Front brake disc calipers.
• Rear brake discs.
• Rear brake disc calipers.
• Brake tubes and hoses.
• Anti-lock brake system (ABS).
Brake Master Cylinder

The brake master cylinder is a dual piston type. The master cylinder operates as follows:
• When the brake pedal is applied, pressure is applied by mechanical linkage to the primary
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and secondary systems.

• Brake master cylinder pistons apply hydraulic pressure to the two circuits.
The master cylinder consists of the following components:
• Primary and secondary pistons.

• Brake master cylinder fluid reservoir with integral fluid level warning indicator.
Adjustable Pedals
The adjustable pedal system comprises of a throttle pedal assembly with an adjustment motor and
drive cables. The drive cables are attached to the brake and clutch adjustment mechanisms. The
pedals move forward and rearward together. Two seperate pedal positions can be set and stored in
the memory for driver recall. The pedal position adjustment is by a switch fitted on the steering
column shroud.
COMPONENT LOCATION
1 Brake master cylinder
2 Brake fluid reservoir
3 Brake booster
4 Rear brake caliper
5 Brake lines
6 Front brake caliper
7 Hydraulic control unit

OVERVIEW
The hydraulic brake system is of a pedal-operated, diagonally split dual line brake system that
consists of the following components:
• A brake booster
• A brake master cylinder
• Front brake discs
• Front brake disc calipers
• Rear brake discs
• Rear brake disc calipers
• Brake tubes and hoses
• Anti-lock brake system (ABS)
BRAKE MASTER CYLINDER

The brake master cylinder is a dual piston type. The master cylinder operates as follows:
• When the brake pedal is applied, pressure is applied by mechanical linkage to the primary
and secondary systems
• Brake master cylinder pistons apply hydraulic pressure to the two circuits
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The master cylinder consists of the following components:
• Primary and secondary pistons

• Brake master cylinder fluid reservoir with integral fluid level warning indicator
ADJUSTABLE PEDALS
The adjustable pedal system comprises of a throttle pedal assembly with an adjustment motor and
drive cables. The drive cables are attached to the brake adjustment mechanisms. The pedals move
forward and rearward together. Two separate pedal positions can be set and stored in the memory
for driver recall. The pedal position adjustment is by a switch fitted on the steering column shroud.

Brake Fluid Reservoir (70.30.16)

Removal
1
NOTE:
Make sure the brake fluid reservoir filler cap does not become contaminated.
Remove the brake fluid reservoir filler cap.

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2 . Disconnect the brake fluid level sensor electrical connector.
3 . Using a suitable suction device drain the brake fluid reservoir.

4 . NOTE:
Remove and discard the O-ring seals.
Remove the brake fluid reservoir from the master cylinder.
Installation
1 . NOTE:
Install new O-ring seals.

3 . After installation, bleed the brake system. <<206-00>>

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Brake Master Cylinder - 3.0L/3.5L/4.2L
(70.30.08)
Removal
1
NOTE:
Make sure that the brake fluid reservoir filler cap does not become contaminated.
Remove the brake fluid reservoir.

For additional information, refer to Brake Fluid Reservoir (70.30.16)
2 . Remove the brake booster/vacuum pipe.
3.
Disconnect the master cylinder brake pipes.

4 . Remove the dynamic stability control sensor electrical connector.
5 . Remove the dynamic stability control sensor.

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6 . Remove the brake master cylinder.
Remove and discard the O-ring seal.
Installation
Install a new O-ring seal.
Tighten to 25 Nm.
3 After installation, bleed the brake system.

(70.25.03)
For additional information, refer to Brake System Bleeding - VIN Range: G45704->H99999
(70.25.03)
Brake Master Cylinder - 2.7L Diesel
(70.30.08)
Removal
1 . Remove the brake fluid reservoir.
For additional information, refer to Brake Fluid Reservoir (70.30.16)
2 . Disconnect the brake booster vacuum pipe.

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3
NOTE:
Cap the exposed ports to prevent dirt ingress and loss of fluid.
Disconnect the brake master cylinder brake pipes.

Installation
Tighten to 25 Nm.
206-07 : Power Brake Actuation
Specifications
Specifications

Brake booster retaining nuts 25 18 -
Brake vacuum pump retaining bolts 23 17 -
Brake vacuum pump retaining stud 13 10 -
Brake vacuum pump retaining nut 13 10 -
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Brake Booster
or eyewash solution and seek medical attention. If taken internally, do not induce
Part
Item Description
Number
1 — Brake fluid level sensor
2 — Non return valve/vacuum supply
3 — Brake fluid reservoir cap
4 — Brake fluid reservoir
Brake master cylinder active booster solenoid (Vehicles built up to
5 —
VIN:G45703)
5 — Brake vacuum sensor (3.0L and 3.5L Vehicles built after VIN:G45704)
6 — Brake booster
7 — Brake master cylinder
8 — Brake pedal
9 — Brake pedal travel sensor
The diaphragm-type power brake booster:
• Is self contained.
• Is mounted on the engine side of the bulkhead.
• Uses engine intake manifold vacuum and atmospheric pressure for its assistance.
• Utilizes a non-return valve to preserve vacuum.
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Brake Booster
COMPONENT LOCATION
1 Brake fluid reservoir cap
2 Brake fluid level sensor
3 Brake fluid reservoir
4 Brake booster
5 Brake pedal
6 Brake vacuum sensor (3.0L and 3.5L)
7 Non return valve/vacuum supply
8 Brake master cylinder
OVERVIEW
The diaphragm-type power brake booster is self contained and is mounted on the engine side of the
bulkhead. It uses engine intake manifold vacuum and atmospheric pressure for its assistance and
utilizes a non-return valve to preserve vacuum.
Power Brake System

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Brake Booster (70.50.17)

Removal
All vehicles
For additional information, refer to Brake Master Cylinder - 3.0L/3.5L/4.2L (70.30.08)
Vehicles built up to VIN:G45703

2 Disconnect the brake booster pedal travel sensor and brake booster solenoid electrical
. connectors.
Vehicles built from VIN:G45704

NOTE:
Vehicles with 3.0L and 3.5L engines.
3 . Disconnect the brake booster vacuum sensor electrical connector.

All vehicles
4 . Remove the brake booster retaining nut.
5 NOTE:
.
The non-return valve and vacuum pipe assembly should be removed with the brake
booster.
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NOTE:
Remove and discard the brake booster/pedal box gasket.
Remove the brake booster.
Installation
1 NOTE:
.
When renewing the brake booster, the non-return valve and vacuum pipe assembly
should be installed prior to the brake booster installation.
NOTE:
Replace the brake booster/pedal box gasket.
Tighten to 25 Nm.
Brake Vacuum Pump
Removal
1 . Remove the oil filler cap.
2 . Remove the engine cover.

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3 . Install the engine oil filler cap to prevent foreign material entering the valve cover.
4 . Remove the injector sound proofing.
5
. CAUTION: Make a note of the connection orientation of the high and low pressure
hoses to the sensor ports. Make sure the hoses are located to the correct sensor port when
installed. Failure to follow these instructions may result in damage to the vehicle.
Detach the diesel particulate filter differential pressure sensor high-pressure and low-pressure
hoses.
6 . Detach the diesel particulate filter high-pressure and low-pressure pipes.
7 . Disconnect the pipes from the brake vacuum pump.
8 . Remove the right-hand catalytic converter.

For additional information, refer to Catalytic Converter - 2.7L Diesel (17.50.05)
9 Detach the diesel particulate filter high-pressure and low-pressure pipes from the
. transmission housing.
Detach the retaining clip.

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10 Detach the diesel particulate filter high-pressure and low-pressure pipes from the retaining
. bracket.
11 . Detach the transmission harness connector from the mounting bracket.

12 . Remove the crankcase vent oil seperator pipe retaining nut.
13 . Remove the brake vacuum pump retaining stud.
14 . Remove the crankcase vent oil seperator pipe retaining bolt.
15 . Remove the right-hand high pressure fuel pipe bracket retaining bolt.
16 . Remove the brake vacuum pump.
Remove the retaining bolts.
Installation
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1 Apply silicone gasket sealant or equivalent meeting Jaguar specification.

.
The application of sealant must be 10mm square in the two places shown.
Install the brake vacuum pump immediately after applying the sealant.
The brake vacuum pump should be fitted directly to the engine without
smearing the sealant.
2.
CAUTION: Make sure the drive coupling is aligned with the camshaft coupling.
Install the brake vacuum pump.

Tighten to 23 Nm.
3 . Install the right-hand high pressure fuel pipe bracket retaining bolt.
Tighten to 10 Nm.
4 . Install the crankcase vent oil seperator pipe retaining bolt.
Tighten to 10 Nm.
5 . Install the brake vacuum pump retaining stud.

Tighten to 13 Nm.
6 . Install the crankcase vent oil seperator pipe retaining nut.
Tighten to 13 Nm.
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7 . Attach the transmission harness connector to the mounting bracket.
8 . Attach the diesel particulate filter pressure pipes to the retaining bracket.
Tighten to 10 Nm.
9 . Attach the diesel particulate filter pressure pipes to the transmission housing.
Tighten to 10 Nm.
10 . Install the right-hand catalytic converter.

11 . Connect the pipes to the brake vacuum pump.

12 . Attach the diesel particulate filter pressure pipes.
Tighten to 10 Nm.
13
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. CAUTION: Make sure the high and low pressure hoses are fully installed and the
retaining clips are positioned in their original position.
Attach the diesel particulate filter differential pressure sensor high-pressure and low-
pressure hoses.
14 . Install the injector sound proofing.

15 . Remove the engine oil filler cap.
16 . Install the engine cover.
17 . Install the oil filler cap.

206-09 : Anti-Lock Control – Stability Assist
Specifications
Specifications
NOTE:
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years.
Item Specification

Brake master cylinder pressure transducer 30 22 –
Brake line connections to brake pressure control valve block 17 13 –
Yaw rate sensor retaining nuts 7 – 62
Hydraulic control unit (HCU) mounting bolts 9 – 80
Rear wheel speed sensor retaining bolt 9 – 80
Anti-Lock Control - Stability Assist - VIN

Range: G00442->G45703
1 — Engine control module
2 — Instrument cluster
3 — Steering wheel angle sensor
4 — Wheel speed sensor - rear

5 — Yaw/lateral rate sensor
6 — Wheel speed sensor - front
7 — Brake pedal switch
8 — Brake pedal travel sensor
9 — Brake master cylinder primary pressure transducer
10 — ABS/DSC hydraulic control modulator
11 — Master cylinder active booster solenoid
The anti-lock brake system (ABS) modulates brake pressure on each wheel independently to
maintain vehicle stability during braking. The ABS continually monitors the rotational velocity of each
wheel anytime the ignition switch is in the run position and determines if a tire is skidding when the
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brakes are applied. Only then does the ABS intervene to modulate the brake pressure to the skidding
wheel. The modulation continues until the wheel rotates freely. The brake pressure is then restored
and the modulate/restore cycle is repeated whenever skidding is detected. This cycle occurs at a rate
of several times per second.
The ABS module is capable of detecting the following system conditions:
• hydraulic valve failure

• wheel speed sensor failure
• ABS power relay short circuit
• interconnect failures to the ABS sensors, power and ground to the ABS module
• over/under voltage conditions
The ABS provides self-diagnostics and displays failure messages via the ABS indicator in the
instrument cluster. Failure of the ABS module, for whatever reason, will not compromise the normal
operation of the brake system.
The Dynamic Stability Control (DSC) system includes the:
• anti-lock brake system.

• yaw/lateral control.
• full speed traction control.
The DSC system manages the braking system to enhance the driver control of the vehicle.
The DSC system continually monitors the steering wheel angle, master cylinder brake pressure, front
and rear wheel speeds, vehicle yaw and lateral rate acceleration.
The yaw/lateral rate sensor supplies a signal to the DSC module, via a serial link, which monitors the
vehicles rate of acceleration from its central axis in a sideways direction, and also the vehicles
angular rotation around it's central axis.
The driver input parameters are continually monitored via the brake master cylinder dynamic
stability control sensor, the brake pedal travel sensor and the steering wheel angle sensor.
DSC is enabled/disabled via the traction control ON/OFF switch.
Self-diagnosis of the DSC system is provided via the instrument cluster message centre.
Traction control is an additional function added to the ABS/DSC system. The vehicles driven wheels
are continually monitored for wheel spin relative to the calculated reference speed and to each
other. If wheel spin is detected, the traction control function intervenes independently of the driver,
applying brake pressure to the slipping wheel and reducing the engine drive torque supply.
Meanwhile, brake pressure is modulated by the traction control until traction is re-established.
Traction control brake actuation is diminished above 40 km/h (25 mph). Above this speed traction
control relies primarily on engine torque reduction.
Traction control is enabled/disabled via the traction control ON/OFF switch. When the switch is in
the (OFF) position, the amber traction control warning lamp solidly illuminates within the instrument
cluster message centre. The traction control is automatically activated when the ignition is switched
on. Self-diagnosis of the traction control system is also provided via the instrument cluster message
centre.
The traction control brake intervention is automatically disabled whenever the brakes exceed a
temperature limit. The traction brake intervention will remain disabled until the brakes have cooled,
irrespective of ignition switch position or ignition switch cycling.
Brake Vacuum Assist (3.0L V6 and 3.5L V8 Vehicles Only)

Operation of Brake Vacuum Assist is possible at the start of an ignition cycle when the engine is cold
and low vacuum levels are generated by the engine. Its operation will result in vibrating pedal and
some modulator noise. This may appear to be similar to unexpected ABS (anti-lock brake system)
function, at lower than expected speed or light braking effort. As the engine warms up, Brake
Vacuum Assist operation should become less frequent, though it can be active in other circumstances
where vacuum levels are lower than required; for example, at higher altitudes or during frequent,
heavy braking.
Additionally, noise levels during Brake Vacuum Assist may be variable, with initial system activity
louder than normal activity. In some circumstances initial activity louder than normal may be
interpreted as a 'thump' noise, particularly if there is no significant Brake Vacuum Assist functionality
that immediately follows.
In these cases, this system behaviour is not unexpected, and should not be a cause for fault
investigation.
Range: G45704->G99999
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Part
Item Description
Number
1 — Engine control module (ECM)
2 — Instrument cluster and message centre
3 — Steering wheel rotation sensor
4 — Wheel speed sensor - rear
5 — Lateral/yaw rate sensor

6 — Wheel speed sensor - front
7 — Brake pedal switch
Anti-lock brake system (ABS)/Dynamic stability control hydraulic control

8 —
modulator (HCU)
The ABS modulates brake pressure on each wheel independently to maintain vehicle stability during
braking. The ABS continually monitors the rotational velocity of each wheel during driving and
determines if a tire is skidding when the brakes are applied. Only then does the ABS intervene to
modulate the brake pressure to the skidding wheel. The modulation continues until the wheel
rotates freely. The brake pressure is then restored and the modulate/restore cycle is repeated
whenever skidding is detected. This cycle occurs at a rate of several times per second.
The ABS/dynamic stability control module is capable of detecting the following system conditions:

• over/under voltage conditions.
The ABS provides self-diagnostics and displays failure messages through the ABS warning indicator in
the instrument cluster. Failure of the ABS module, for whatever reason, will not compromise the
normal operation of the brake system.
The dynamic stability control system includes the:
• anti-lock brake system

• lateral/yaw control
• full speed traction control.
The dynamic stability control system manages the braking system to enhance the driver control of
the vehicle.
The dynamic stability control system continually monitors the steering wheel angle, master cylinder
brake pressure, front and rear wheel speeds and vehicle lateral/yaw rate acceleration.
The dynamic stability control module supports speed control and stability assist functions.
The lateral/yaw rate sensor supplies a signal to the dynamic stability control module, via a serial link,
which monitors the vehicles rate of acceleration from its central axis in a sideways direction, and also
the vehicles angular rotation around it's central axis.
The driver input parameters are continually monitored by the steering wheel rotation sensor and the
HCU master cylinder pressure sensor.
Dynamic stability control is enabled/disabled through the traction control ON/OFF switch.
Self-diagnosis of the dynamic stability control system is provided through the instrument cluster and
message center.
Traction control is an additional function added to the ABS/dynamic stability control system. The
vehicles driven wheels are continually monitored for wheel spin relative to the calculated reference
speed and to each other. If wheel spin is detected, the traction control function intervenes
independently of the driver, applying brake pressure to the spinning wheel and reducing the engine
drive torque supply. Meanwhile, brake pressure is modulated by the traction control until traction is
re-established. Traction control brake actuation is diminished above 40 kph (25 mile/h). Above this
speed, traction control relies primarily on engine torque reduction.
Traction control is enabled/disabled through the traction control ON/OFF switch. When the switch is
in the OFF position, the amber traction control warning lamp solidly illuminates within the
instrument cluster message center. The traction control is automatically activated when the ignition
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is switched on. Self-diagnosis of the traction control system is also provided through the instrument
cluster and message center.
temperature limit. The traction brake intervention will remain disabled until the brakes have cooled.
Hydraulic Control Modulator Brake Tube Location - Left-hand Drive
1 — Secondary circuit
2 — Front left-hand
3 — Front right-hand
4 — Primary circuit
5 — Rear left-hand
6 — Rear right-hand
Hydraulic control Modulator Brake Tube Location - Right-hand Drive
1 — Secondary circuit
2 — Front left-hand
3 — Front right-hand
4 — Primary circuit
5 — Rear left-hand
6 — Rear right-hand

heavy braking.
investigation.
Anti-Lock Control - Stability Assist
COMPONENT LOCATION
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1 Engine Control Module (ECM)
2 Instrument cluster and message centre
3 Steering angle sensor
4 Wheel speed sensor - rear
5 Lateral/yaw rate sensor
6 Wheel speed sensor - front

7 Brake pedal switch
8 Anti-lock Brake System (ABS)/Dynamic Stability Control (DSC) module
INTRODUCTION
The ABS modulates brake pressure on each wheel independently to maintain vehicle stability during
braking. The ABS continually monitors the rotational velocity of each wheel during driving and
determines if a tire is skidding when the brakes are applied. Only then does the ABS intervene to
modulate the brake pressure to the skidding wheel. The modulation continues until the wheel
rotates freely. The brake pressure is then restored and the modulate/restore cycle is repeated
whenever skidding is detected. This cycle occurs at a rate of several times per second.
The ABS control module is capable of detecting the following system conditions:
• Hydraulic valve failure

• Wheel speed sensor failure
• Interconnect failures to the ABS sensors, power and ground to the ABS module
• Over/under voltage conditions
The ABS provides self-diagnostics and displays failure messages through the ABS warning indicator in
the instrument cluster. Failure of the ABS module, for whatever reason, will not compromise the
normal operation of the brake system.
The DSC system includes the:
• anti-lock brake system

• lateral/yaw control
• full speed traction control
The DSC system manages the braking system to enhance the driver control of the vehicle.
The DSC system continually monitors the steering wheel angle, master cylinder brake pressure, front
and rear wheel speeds and vehicle lateral/yaw rate acceleration.
The lateral/yaw rate sensor supplies a signal to the DSC module, via a serial link, which monitors the
vehicles rate of acceleration from its central axis in a sideways direction, and also the vehicles
angular rotation around its central axis.
The driver input parameters are continually monitored by the steering wheel rotation sensor and the
hydraulic control unit master cylinder pressure sensor.
The DSC is enabled/disabled through the traction control ON/OFF switch.
Self-diagnosis of the DSC system is provided through the instrument cluster and message center.
Traction control is an additional function added to the ABS/DSC system. The vehicles driven wheels
are continually monitored for wheel spin relative to the calculated reference speed and to each
other. If wheel spin is detected, the traction control function intervenes independently of the driver,
applying brake pressure to the spinning wheel and reducing the engine drive torque supply.
Meanwhile, brake pressure is modulated by the traction control until traction is re-established.
Traction control brake actuation is diminished above 40 kph (25 mile/h). Above this speed, traction
control relies primarily on engine torque reduction.
Traction control is enabled/disabled through the traction control ON/OFF switch. When the switch is
in the OFF position, the amber traction control warning lamp solidly illuminates within the
instrument cluster message center. The traction control is automatically activated when the ignition
is switched on. Self-diagnosis of the traction control system is also provided through the instrument
cluster and message center.
temperature limit. The traction brake intervention will remain disabled until the brakes have cooled.
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Hydraulic Control Modulator Brake Tube Location - Left-hand Drive
1 Secondary circuit
2 Front left-hand
3 Front right-hand
4 Primary circuit
5 Rear left-hand
6 Rear right-hand
Hydraulic control Modulator Brake Tube Location - Right-hand Drive
1 Secondary circuit
2 Front left-hand
3 Front right-hand
4 Primary circuit
5 Rear left-hand
6 Rear right-hand

heavy braking.
investigation.

Range: G00442->G45703
The anti-lock control - stability assist system includes the:
• anti-lock brake system (ABS)

• yaw/acceleration control
• emergency brake assist
• traction control
Anti-lock Brake System (ABS)

The anti-lock brake system (ABS) modulates brake pressure on each wheel independently to
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maintain vehicle stability during braking. The ABS continually monitors the rotational velocity of each
wheel anytime the ignition switch is in the run position and determines if a tire is skidding when the
brakes are applied. Only then does the ABS intervene to modulate the brake pressure to the skidding
wheel. The modulation continues until the wheel rotates freely. The brake pressure is then restored
and the modulate/restore cycle is repeated whenever skidding is detected. This cycle occurs at a rate
of several times per second.
The ABS module is capable of detecting the following system conditions:

• over/under voltage conditions
The ABS provides self-diagnostics and displays failure messages via the ABS indicator in the
instrument cluster. Failure of the ABS module, for whatever reason, will not compromise the normal
operation of the brake system.
Traction Control
Traction control is an additional function added to the anti-lock control - stability assist system. The
vehicles driven wheels are continually monitored for wheel spin relative to the calculated reference
speed and to each other. If wheel spin is detected, the traction control function intervenes, applying
brake pressure to the slipping wheel and reducing the engine drive torque supply. Meanwhile, brake
pressure is modulated by the traction control until traction is re-established. Traction control brake
actuation is diminished above 40 km/h (25 mph). Above this speed traction control relies primarily on
engine torque reduction.
temperature limit. The traction control brake intervention will remain disabled until the brakes have
cooled, irrespective of ignition switch position or ignition switch cycling.
Stability Assist
Dynamic stability control (DSC) maximizes vehicle stability under all conditions. The DSC system
compares actual vehicle course to that intended by the driver. If the intended course differs from the
actual course due to over steer or under steer conditions, the DSC system will brake individual
wheels and reduce engine torque to bring the vehicle back to the driver's intended direction. By
using a combined yaw rate sensor and lateral accelerometer, the vehicles rotational motion around
its vertical axis and centrifugal forces generated while cornering are calculated to determine the
vehicle's actual behavior. Using additional sensors for detecting steering wheel position and road
wheel speed enables the system to recognize the driver's intentions.
Dynamic stability control is enabled/disabled via the DSC ON/OFF switch. When the switch is in the
OFF position, the amber DSC warning lamp solidly illuminates within the instrument cluster message
center. The DSC is automatically activated when the ignition is switched on. The DSC also provides
failure messages via the instrument cluster message center.
Emergency Brake Assist

The emergency brake assist function allows the driver to enter ABS with greater speed and efficiency
so that maximum braking is achieved sooner. Using the information received from the wheel speed
sensors, brake pedal travel switch, master cylinder pressure transducer, master cylinder active
booster solenoid and the yaw rate sensor and accelerometer, the ABS module detects whether more
braking pressure can be applied in relation to how much braking pressure the driver is applying in an
emergency braking situation.

2 . Confirm if the ABS warning light was illuminated, or still is.
NOTE:
An intermittent fault may allow the warning light to go off. This does not necessarily mean the
fault is not present. Some warnings will appear to clear when the ignition is cycled. This is often
because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines
having run to detect the fault. If the same routine is not run when the ignition is switched ON,
the warning will not reflag until the routine does run.
• Brake fluid level • Warning light operation

• Vacuum system • Fuses (see table)
• Wheel speed sensor fitment • Wheel speed sensors
• Wheel speed sensor air gap • Connectors/Pins
• Wheel speed sensor tone ring(s) (missing or damaged • Harnesses
teeth/contamination) • Steering wheel angle sensor
• Yaw rate/lateral accelerometer sensor cluster fitment • Yaw/lateral rate sensor
• Incorrect wheel or tire size cluster
• ABS/DSC module
a fault code reader to retrieve the fault codes before proceeding to the diagnostic trouble code (DTC)
index chart.
Fuse Identification Table

Location Fuse Number Rating Circuit
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Engine bay fuse box 20 30 Amp ABS/Stability assist control pump battery supply
Engine bay fuse box 22 30 Amp ABS/Stability assist control module battery supply
Cabin fuse box 17 5 Amp ABS/Stability assist control module ignition supply
Primary junction box 44 5 Amp Brake light switch battery supply
Brake Pedal Position Switch Calibration

The brake pedal position switch procedure is under review. For further information, contact dealer
technical support.
Diagnostic Trouble Code (DTC) Index

Traction control disable • Traction control disable CAN For CAN module circuit tests,
C1093 message failure
CAN failure <<418-00>>
• Pump motor B+ power

supply circuit; high
For ABS/DSC module circuit
Pump motor circuit resistance, open circuit,
C1095 tests, GO to Pinpoint Test
failure short circuit to GROUND,
short circuit to B+ G307559p1.
• Pump motor failure
Left-hand front wheel
Refer to visual inspection
speed sensor tone ring • Damaged/ missing tooth on
C1141 chart. Inspect tone ring for
damaged/missing tone ring
damage.
tooth
Right-hand front wheel

damage.
tooth
Left-hand rear wheel

damage.
tooth
Right-hand rear wheel

damage.
tooth
• Wheel speed sensor circuit;

open circuit, short circuit
Right-hand front wheel • Wheel speed sensor to For right hand front WSS
C1145 speed sensor (WSS) control module circuit; high circuit tests, GO to Pinpoint
circuit failure resistance, open circuit, Test G307559p2.
short circuit to GROUND

Left-hand front wheel • Wheel speed sensor to For left hand front WSS circuit
C1155 speed sensor (WSS) control module circuit; high tests, GO to Pinpoint Test
circuit failure resistance, open circuit, G307559p3.

Right-hand rear wheel • Wheel speed sensor to For right hand rear WSS circuit
C1165 speed sensor (WSS) control module circuit; high tests, GO to Pinpoint Test
circuit failure resistance, open circuit, G307559p4.
• Wheel speed sensor circuit; For left -hand rear WSS circuit
C1175 Left-hand rear wheel
speed sensor (WSS) tests, GO to Pinpoint Test
• Wheel speed sensor to
circuit failure control module circuit; high G307559p5.
resistance, open circuit,
• Wheel speed sensor gap too Check the wheel speed sensor
Left-hand front wheel large
for correct fitment.
C1233 speed sensor (WSS) • Missing tone ring or sensor
• Incorrect tone ring Front Wheel Speed Sensor
signal failure
• Incorrect wheel size (70.60.03)
Right-hand front wheel large
• Incorrect tone ring Front Wheel Speed Sensor
signal failure
Right-hand rear wheel large
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• Incorrect tone ring Rear Wheel Speed Sensor
signal failure
Left-hand rear wheel large
• Incorrect tone ring Rear Wheel Speed Sensor
signal failure
• HF interference Contact dealer technical

• Supply voltages to valve support for advice on possible
ABS/DSC function solenoids or sensors out of ABS/DSC module failure. Refer
C1267 range
temporarily disabled to inspection and verification
• EEPROM read/write failure for information on warning
• ABS/DSC module failure
light behavior
• SA sensor circuit(s) open

circuit, short circuit, short
Steering angle sensor circuit to GROUND or B+
For SA sensor circuit tests, GO
C1277 (SA sensor) circuit A/B • SA sensor damaged
• Sensor wiring damaged to Pinpoint Test G307559p6.
failure
• Sensor loose, not mounted
correctly
• Yaw rate/lateral For lateral/yaw rate sensor

Yaw rate sensor circuit
C1279 accelerometer sensor circuit tests, GO to Pinpoint
failure cluster circuit(s) open/short Test G307559p7.
circuit, short circuit to
GROUND or B+
• Yaw rate/lateral
accelerometer sensor
cluster failure
• Sensor loose, not mounted Refer to visual inspection

correctly chart. Check sensor fitment.
Yaw rate sensor signal
C1280 • Yaw rate/lateral Refer to dealer technical
failure accelerometer sensor support for advice on possible
cluster failure sensor failure.
• Connector pins bent or

corroded
For lateral/yaw rate sensor
Lateral accelerometer • Sensor wiring damaged
C1281 circuit tests, GO to Pinpoint
sensor circuit failure • Yaw rate/lateral
accelerometer sensor Test G307559p7.
cluster failure
• Sensor loose, not mounted Refer to visual inspection

correctly chart. Check sensor fitment.
Lateral accelerometer
C1282 • Yaw rate/lateral Refer to dealer technical
sensor signal failure accelerometer sensor support for advice on possible
cluster failure sensor failure.
• Booster solenoid circuit

For booster solenoid circuit
Booster solenoid circuit open circuit, short circuit to
C1285 tests, GO to Pinpoint Test
failure GROUND
• Booster solenoid failure G307559p8.

• Brake light switch support for advice on brake
incorrectly calibrated pedal position switch
• Pedal force switch open calibration procedure. For
Booster mechanical pedal force switch tests, GO to
C1286 GROUND
failure • Pedal force switch failure Pinpoint Test G307559p10.
• Active brake booster Contact dealer technical
mechanical failure support for advice on possible
• ABS/DSC module failure active brake booster or
ABS/DSC module failure.
• Booster pedal force switch

open circuit, short circuit to For pedal force switch tests,
Booster pedal force
C1287 GROUND or B+ GO to Pinpoint Test
switch circuit failure • Booster pedal force switch G307559p10.
failure
• Brake pressure circuit open
GROUND or B+
Pressure sensor For pressure sensor circuit
C1288 main/primary input tests, GO to Pinpoint Test
corroded
circuit failure • Damaged harness/wiring G307559p11.
• Sensor failure
• Steering angle signal open

circuit, short circuit to For SA sensor circuit tests, GO
GROUND or B+, high
Steering angle sensor to Pinpoint Test G307559p6.
C1295 resistance
internal failure • Sensor loose Check sensor fitment, check
• Encoder ring contaminated encoder ring for debris.
• Sensor failure
Check for associated DTCs.

Steering angle sensor– • Steering angle sensor — no Reinitialize the sensor by
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C1306 no center found during center found within time turning the ignition to the OFF
initialization limits position, then back ON without
turning the steering wheel.
Check the security and

• Loose or damaged encoder condition of the steering angle
Steering wheel angle ring
sensor encoder ring. Check
C1307 sensor encoder ring • Steering angle sensor failure
• Signal wires shorted encoder ring for debris. For SA
failure
together sensor circuit tests, GO to
• Pressure sensor signal

circuit open circuit, short For pressure sensor circuit
Brake pressure sensor
C1440 circuit to GROUND or B+ tests, GO to Pinpoint Test
signal fault • Brake pressure sensor G307559p11.
failure
• Brake light switch signal For brake light switch circuit

Brake switch circuit
C1446 failure tests, GO to Pinpoint Test
failure • Mechanical switch failure G307559p12.
• Sensor supply voltage circuit For sensor power and

short circuit to GROUND or GROUND circuit tests,<<418-
Sensor supply voltage
C1730 B+ 00>> Contact dealer technical
out of range (+5 volt) • Defective sensor support for advice on possible
• ABS/DSC module failure ABS/DSC module failure.
CLEAR the DTC. TEST the
system for normal operation. If
• Mechanical failure in active the DTC is repeated, contact
Vacuum pressure
C1777 booster unit dealer technical support for
circuit failure • ABS/DSC module failure advice on possible active
booster or ABS/DSC module
failure.

DSC continuous • Yaw rate sensor cluster
C1994 support for advice on possible
operation fault failure
yaw rate sensor cluster failure.
• Booster solenoid
open/short circuit, short
circuit to GROUND or B+, For booster solenoid circuit
high resistance tests, GO to Pinpoint Test
Pressure controller • Booster solenoid failure G307559p8.
C1997
failure • Pressure sensor signal For pressure sensor circuit
open/short circuit, short tests, GO to Pinpoint Test
circuit to GROUND or B+,
G307559p11.
high resistance
• Pressure sensor failure
For lateral/yaw rate sensor

Yaw rate/Lateral • Sensor power supply circuit tests, GO to Pinpoint
accelerometer sensor voltage open circuit, short Test G307559p7.
C2778
cluster power supply circuit to GROUND or B+ Contact dealer technical
failure • ABS/DSC module failure support for advice on possible
ABS/DSC module failure.
• Incorrect yaw rate/lateral Contact dealer technical

C2783 Sensor cluster incorrect accelerometer sensor support for advice on possible
cluster fitted yaw rate sensor cluster failure.
Yaw rate/Lateral Contact dealer technical

• Yaw rate/Lateral
accelerometer support for advice on
C2785 accelerometer sensor
sensor(s) out of cluster not calibrated recalibration of the yaw rate
calibration sensor cluster.
• Check brake Carry out a full vehicle DTC

hydraulic/mechanical check. Check for DTC P1696 as
Longitudinal function/condition an indication of an ACC system
B1231 acceleration threshold • Pressure sensor failure
fault. For pressure sensor
exceeded • ACC failure
circuit tests, GO to Pinpoint
• Hydraulic unit failure
• Mechanical failure in Test G307559p11.
booster actuation unit For vacuum circuit tests refer
• Brake booster vacuum low to inspection and verification.
• Brake booster failure Contact dealer technical
support for further advice.
• Charging system failure Check the battery condition

Supply voltage out of
B1317 • ABS/DSC module GROUND and charging system, <<414-
range (HIGH) fault 00>> <<414-01>>
• Battery failure, loose

connections Check the battery condition
Supply voltage out of
B1318 • Charging system failure and charging system, <<414-
range (LOW) • ABS/DSC module positive 00>> <<414-01>>
supply fault

ABC/DSC module
B1342 • ABS/DSC module failure support for advice on possible
failure
ABS/DSC module failure
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• No or invalid vehicle
NVM configuration configuration information Reconfigure the ECM <<418-
B2141
failure received from the ECM and 00>>
stored in EEPROM
• Pedal travel sensor circuit:

open circuit, short circuit to For pedal travel sensor tests,
Pedal travel sensor
B2736 GROUND or B+, high GO to Pinpoint Test
circuit failure resistance, signal wires G307559p9.
short circuit to each other

corroded
• Pedal travel sensor signal
For pedal travel sensor tests,
Pedal travel sensor failure; open circuit, short
B2739 GO to Pinpoint Test
signal circuit failure circuit to GROUND or B+,
high resistance G307559p9.
• Pedal travel sensor failure
Yaw rate/Lateral • Yaw rate/Lateral Contact dealer technical

B2741 accelerometer sensor accelerometer sensor support for advice on possible
cluster fault cluster failure yaw rate sensor failure.
Local CAN yaw • Local CAN fault For CAN module circuit tests,
• Control module internal
U1901 rate/lateral <<418-00>> Contact dealer
local CAN failure
accelerometer sensor technical support for advice on
• Yaw rate/Lateral
cluster communication accelerometer sensor possible yaw rate sensor
fault cluster failure failure.
• CAN failure
Communication bus For CAN circuit tests, <<418-
U2012 • Control module internal
error CAN failure 00>>

Invalid configuration • ABS/DSC incorrectly
U2202 support for advice on
data received configured to VID block
reconfiguration of modules.
Missing message for • CAN message is not

For CAN module circuit tests,
U2515 adaptive cruise control received at specified rate or
is missing <<418-00>>
ACC
• CAN message is not

CAN message timeout For CAN module circuit tests,
U2522 received at specified rate or
from TCM is missing <<418-00>>
• CAN message is not

CAN message timeout For CAN module circuit tests,
U2523 received at specified rate or
from ECM is missing <<418-00>>
Local CAN transmit For CAN module circuit tests,

U2527 • Local CAN failure
error <<418-00>>
Pinpoint Tests
NOTE:
NOTE:
PUMP MOTOR FAULT
G307559t1 : CHECK THE BATTERY POWER SUPPLY (1) TO THE ABS/DSC
MODULE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ABS/DSC module electrical
connector EC30. 3. Measure the voltage between EC30, pin 01 (NR) and GROUND.
-> Yes
REPAIR the circuit. This circuit includes the engine compartment fuse box (fuse 20). For additional
information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
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G307559t3 : CHECK THE BATTERY POWER SUPPLY (2) TO THE ABS/DSC

MODULE
1. Measure the voltage between EC30, pin 32 (NW) and GROUND.
-> Yes
REPAIR the circuit. This circuit includes the engine compartment fuse box (fuse 22). For additional
-> No
G307559t7 : CHECK THE GROUND TO THE ABS/DSC MODULE

1. Measure the resistance between EC30, pins 16 and 47 (B) and GROUND.
-> Yes
-> No
Contact dealer technical support for advice on possible ABS/DSC module failure.
RIGHT HAND FRONT WHEEL SPEED
SENSOR (WSS) ELECTRICAL FAILURE
G307559t8 : CHECK THE WSS TO ABS/DSC MODULE SIGNAL CIRCUIT FOR
HIGH RESISTANCE
connector EC30. 3. Disconnect the WSS electrical connector EC15. 4. Measure the resistance
between EC30, pin 34 (WU) and EC15, pin 02 (WU).
-> Yes
-> No

SHORT TO GROUND
1. Measure the resistance between EC30, pin 34 (WU) and GROUND.
-> Yes
-> No
G307559t10 : CHECK THE WSS TO ABS/DSC MODULE SUPPLY CIRCUIT FOR

HIGH RESISTANCE
1. Measure the resistance between EC30, pin 33 (NG) and EC15, pin 01 (NG).
-> Yes
-> No

SHORT TO GROUND
1. Measure the resistance between EC30, pin 33 (NG) and GROUND.
-> Yes
-> No
INSTALL a new right-hand front wheel speed sensor.
Front Wheel Speed Sensor (70.60.03) CLEAR the DTC. TEST the system for normal operation. If the
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DTC is repeated, contact dealer technical support for advice on possible ABS/DSC module failure.

LEFT HAND FRONT WHEEL SPEED
HIGH RESISTANCE
connector EC30. 3. Disconnect the WSS electrical connector EC44. 4. Measure the resistance
between EC30, pin 45 (WG) and EC44, pin 2 (WG).
-> Yes
-> No

SHORT TO GROUND
-> Yes
-> No

HIGH RESISTANCE
1. Measure the resistance between EC30, pin 46 (NG) and EC44, pin 01 (NG).
-> Yes
-> No

SHORT TO GROUND
-> Yes
-> No
INSTALL a new left-hand front wheel speed sensor.
Front Wheel Speed Sensor (70.60.03) CLEAR the DTC. TEST the system for normal operation. If the

RIGHT HAND REAR WHEEL SPEED
HIGH RESISTANCE
connector EC30. 3. Disconnect the WSS electrical connector CV08. 4. Measure the resistance
between EC30, pin 43 (W) and CV08, pin 02 (W).
-> Yes
-> No

SHORT TO GROUND
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1. Measure the resistance between EC30, pin 43 (W) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
1. Measure the resistance between EC30, pin 42 (N) and CV08, pin 01 (R).
-> Yes
-> No
SHORT TO GROUND
1. Measure the resistance between EC30, pin 42 (N) and GROUND.
-> Yes
-> No
INSTALL a new right-hand rear wheel speed sensor.
Rear Wheel Speed Sensor (70.60.04) CLEAR the DTC. TEST the system for normal operation. If the

LEFT HAND REAR WHEEL SPEED
HIGH RESISTANCE
connector EC30. 3. Disconnect the WSS electrical connector CV06. 4. Measure the resistance
between EC30, pin 36 (WR) and CV06, pin 02 (W).
-> Yes
-> No

SHORT TO GROUND
1. Measure the resistance between EC30, pin 36 (WR) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
1. Measure the resistance between EC30, pin 37 (NR) and CV06, pin 01 (R).
-> Yes
-> No
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SHORT TO GROUND
1. Measure the resistance between EC30, pin 37 (NR) and GROUND.
-> Yes
-> No
INSTALL a new left-hand rear wheel speed sensor.
Rear Wheel Speed Sensor (70.60.04) CLEAR the DTC. TEST the system for normal operation. If the

C1295; STEERING ANGLE SENSOR (SA
SENSOR) 'A' AND 'B' CIRCUIT
FAILURE
G307559t20 : CHECK THE VOLTAGE SUPPLY TO THE STEERING ANGLE
SENSOR
1. Disconnect the steering angle sensor electrical connector IP37. 2. Turn the ignition switch to the
ON position. 3. Measure the voltage between IP37, pin 04 (R) and GROUND.
-> Yes
-> No
G307559t21 : CHECK THE STEERING ANGLE SENSOR VOLTAGE SUPPLY

connector EC30. 3. Measure the continuity between EC30, pin 07 (R) and IP37, pin 04 (R).
-> Yes
REPAIR the high resistance circuit. This circuit includes the splice IPS14. For additional information,
refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
G307559t22 : CHECK THE STEERING ANGLE SENSOR GROUND SUPPLY

CIRCUIT
1. Turn the ignition switch to the OFF position. 2. Reconnect the ABS/DSC module electrical
connector EC30. 3. Disconnect the yaw/lateral rate sensor electrical connector IP23. 4. Turn the
ignition switch to the ON position. 5. Measure the resistance between IP37, pin 01 (B) and GROUND.
-> Yes
-> No
G307559t23 : CHECK THE STEERING ANGLE SENSOR SIGNAL CIRCUIT ‘A’
FOR HIGH RESISTANCE
connector EC30. 3. Measure the resistance between EC30, pin 03 (Y) and IP37 pin 02 (Y).
-> Yes
-> No
G307559t24 : CHECK THE STEERING ANGLE SENSOR SIGNAL CIRCUIT ‘B’

FOR HIGH RESISTANCE
1. Measure the resistance between EC30, pin 06 (U) and IP37, pin 03 (U).
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-> Yes
-> No
G307559t25 : CHECK THE STEERING ANGLE SENSOR SIGNAL CIRCUIT ‘A’

FOR SHORT TO GROUND
1. Measure the resistance between IP37, pin 02 (Y) and GROUND.
-> Yes
-> No
G307559t26 : CHECK THE STEERING ANGLE SENSOR SIGNAL CIRCUIT ‘B’

FOR SHORT TO GROUND
1. Measure the resistance between IP37, pin 03 (B) and GROUND.
-> Yes
-> No
G307559t27 : CHECK THE STEERING ANGLE SENSOR SIGNAL CIRCUITS 'A'

AND 'B' FOR SHORT TO EACH OTHER
1. Measure the resistance between IP37, pin 03 (B) IP37, pin 02 (Y).
-> Yes
-> No
INSTALL a new steeering angle sensor. CLEAR the DTC. TEST the system for normal operation. If the

C1281, C2778, C2785, B2741;
LATERAL/YAW RATE CIRCUIT
FAILURE
G307559t28 : CHECK THE VOLTAGE SUPPLY TO THE LATERAL/YAW RATE
SENSOR
1. Disconnect the yaw/lateral rate sensor electrical connector IP23. 2. Turn the ignition switch to the
ON position. 3. Measure the voltage between IP23, pin 03 (R) and GROUND.
-> Yes
-> No
G307559t29 : CHECK THE YAW/LATERAL RATE SENSOR VOLTAGE SUPPLY
connector EC30. 3. Measure the resistance between IP23, pin 03 (R) and EC30, pin 07 (R).
-> Yes
-> No
G307559t30 : CHECK THE YAW/LATERAL RATE SENSOR VOLTAGE SUPPLY

1. Measure the resistance between IP23, pin 03 (R) and GROUND.
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-> Yes
REPAIR the short circuit. This circuit includes the splice IPS14. For additional information, refer to the
wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
G307559t4 : CHECK THE GROUND TO THE YAW/LATERAL RATE SENSOR

1. Measure the resistance between IP23, pin 05 (BK) and GROUND.
-> Yes
-> No
G307559t67 : CHECK THE YAW/LATERAL RATE SENSOR GROUND CIRCUIT

FOR HIGH RESISTANCE
connector EC30. 3. Measure the resistance between IP23, pin 05 (BK) and EC30, pin 05 (BK).
-> Yes
-> No
G307559t32 : CHECK THE YAW/LATERAL RATE SENSOR GROUND CIRCUIT

FOR SHORT TO B+
1. Measure the voltage between IP23, pin 05 (BK) and GROUND.
-> Yes
REPAIR the short circuit. This circuit includes the splice IPS10. For additional information, refer to the
-> No

ACTIVE BOOSTER SOLENOID
CIRCUIT FAILURE
G307559t33 : CHECK THE ACTIVE BOOSTER SOLENOID SUPPLY VOLTAGE
1. Disconnect the booster solenoid electrical connector, EC03. 2. Turn the ignition switch to the ON
position. 3. Measure the voltage between EC03, pin 04 (RW) and GROUND.
-> Yes
-> No
G307559t34 : CHECK THE ACTIVE BOOSTER SOLENOID SUPPLY CIRCUIT
FOR HIGH RESISTANCE
connector EC30. 3. Measure the resistance between EC03, pin 04 (RW) and EC30, pin 17 (RW).
-> Yes
-> No
G307559t35 : CHECK THE ACTIVE BOOSTER SOLENOID SUPPLY CIRCUIT

FOR SHORT TO GROUND
1. Measure the resistance between EC03 pin 04 (RW) and GROUND.
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-> Yes
-> No
G307559t36 : CHECK THE ACTIVE BOOSTER SOLENOID SIGNAL CIRCUIT FOR

HIGH RESISTANCE
1. Disconnect the ABS/DSC module electrical connector EC30. 2. Measure the resistance between
EC03, pin 03 (BW) and EC30, pin 31 (BW).
-> Yes
-> No
G307559t37 : CHECK THE ACTIVE BOOSTER SOLENOID SIGNAL CIRCUIT FOR

SHORT TO GROUND
1. Measure the resistance between EC03, pin 03 (BW) and GROUND.
-> Yes
-> No
Contact dealer technical support for advice on possible active booster failure. CLEAR the DTC. TEST
the system for normal operation. If the DTC is repeated, contact dealer technical support for advice
on possible ABS/DSC module failure.

C1286,C1287; PEDAL FORCE SWITCH
CIRCUIT FAILURE
G307559t31 : CHECK THE PEDAL FORCE SWITCH FUNCTION NORMALLY
CLOSED
1. Disconnect the brake pedal force switch electrical connector EC03. 2. With the brake pedal in the
rest position, measure the resistance between pins 02 and 05 of the switch.
-> Yes
-> No
G307559t68 : CHECK THE PEDAL FORCE SWITCH FUNCTION NORMALLY

OPEN
1. With the brake pedal depressed, measure the resistance between pins 03 and 05 of the switch.
-> Yes
-> No
G307559t38 : CHECK THE PEDAL FORCE SWITCH SUPPLY VOLTAGE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between EC03, pin 05 (WG)
and GROUND.
-> Yes
-> No
G307559t39 : CHECK THE PEDAL FORCE SWITCH SUPPLY CIRCUIT FOR

HIGH RESISTANCE
connector EC30. 3. Measure the resistance between EC03, pin 05 (WG) and EC30, pin 28 (wG).
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-> Yes
-> No
G307559t40 : CHECK THE PEDAL FORCE SWITCH SUPPLY CIRCUIT FOR

SHORT TO GROUND
1. Measure the resistance between EC03, pin 5 (WG) and GROUND.
-> Yes
-> No
G307559t41 : CHECK THE BRAKE PEDAL FORCE SWITCH SIGNAL (NC)

1. Measure the resistance between EC03, pin 02 (YR) and EC30, pin 30 (YR).
-> Yes
-> No
G307559t42 : CHECK THE BRAKE PEDAL FORCE SWITCH SIGNAL CIRCUIT

(NC) FOR SHORT TO GROUND
1. Measure the resistance between EC03, pin 02 (YR) and GROUND.
-> Yes
-> No

(NO) FOR HIGH RESISTANCE
1. Measure the resistance between EC03, pin 01 (YU) and EC30, pin 31 (YU).
-> Yes
-> No

(NO) FOR SHORT TO GROUND
1. Measure the resistance between EC03, pin 02 (YR) and GROUND.
-> Yes
-> No
the system for normal operation. If the DTC is repeated, contact dealer technical support for advice
on possible ABS/DSC module failure.

C1288, C1440, C1997; PRESSURE
SENSOR MAIN/PRIMARY 5 VOLT
SUPPLY CIRCUIT FAILURE
G307559t45 : CHECK THE PRESSURE SENSOR 5 VOLT SUPPLY
1. Turn the ignition switch to the OFF position. 2. Disconnect the pressure sensor electrical connector
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EC34. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between EC34, pin 01
(BG) and GROUND. 5. Measure the voltage between EC34, pin 03 (YU) and GROUND.
• Is either voltage less than 5 volts?
-> Yes
-> No
G307559t46 : CHECK THE PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT FOR

HIGH RESISTANCE
connector EC30. 3. Measure the resistance between the EC34, pin 03 (YU) and EC30, pin 18 (GU).
-> Yes
-> No
G307559t48 : CHECK THE PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT FOR
SHORT TO GROUND
1. Measure the resistance between EC34, pin 03 (YU) and GROUND.
-> Yes
-> No
G307559t6 : CHECK THE GROUND TO THE PRESSURE SENSOR

1. Measure the resistance between EC34, pin 01 (BG) and GROUND.
-> Yes
-> No
G307559t47 : CHECK THE PRESSURE SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
1. Measure the resistance between EC34, pin 01 (BG) and EC30, pin 19 (BG).
-> Yes
-> No
G307559t49 : CHECK THE PRESSURE SENSOR GROUND CIRCUIT FOR SHORT

TO B+
1. Measure the voltage between the pressure sensor electrical connector EC34, pin 01 (BG) and
GROUND.

-> Yes
REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
-> No
G307559t50 : CHECK THE PRESSURE SENSOR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
1. Measure the resistance between EC34, pin 02 (GU) and EC30, pin 20 (GU).
-> Yes
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-> No

TO GROUND
1. Measure the resistance between EC34, pin 02 (GU) and GROUND.
-> Yes
-> No

TO B+
1. Measure the voltage between EC34, pin 02 (GU) and GROUND.
-> Yes
-> No
INSTALL a new pressure sensor. CLEAR the DTC. TEST the system for normal operation. If the DTC is
repeated, contact dealer technical support for advice on possible ABS/DSC module failure.

B2736, B2739; PEDAL TRAVEL SENSOR
CIRCUIT FAILURE
G307559t53 : CHECK THE PEDAL TRAVEL SENSOR SUPPLY VOLTAGE
1. Disconnect the brake pedal travel sensor electrical connector EC10. 2. Turn the ignition switch to
the ON position. 3. Measure the voltage between EC10, pin 01 (G) and GROUND.
-> Yes
-> No
G307559t54 : CHECK THE PEDAL TRAVEL SENSOR SUPPLY CIRCUIT FOR

HIGH RESISTANCE
connector EC30. 3. Measure the resistance between EC10, pin 01 (G) and EC30, pin 26 (G).
-> Yes
-> No
G307559t55 : CHECK THE PEDAL TRAVEL SENSOR SUPPLY CIRCUIT FOR

SHORT TO GROUND
1. Measure the resistance between EC10, pin 01 (G) and GROUND.

-> Yes
-> No
G307559t56 : CHECK THE PEDAL TRAVEL SENSOR GROUND CIRCUIT FOR

HIGH RESISTANCE
1. Measure the resistance between EC10, pin 02 (B) and EC30, pin 24 (B).
-> Yes
-> No
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G307559t57 : CHECK THE PEDAL TRAVEL SENSOR GROUND SUPPLY

CIRCUIT
1. Turn the ignition switch to the OFF position. 2. Reconnect the ABS/DSC module electrical
connector EC30. 3. Turn the ignition switch to the ON position. 4. Measure the resistance between
EC10, pin 02 (B) and GROUND.
-> Yes
-> No
G307559t58 : CHECK THE PEDAL TRAVEL SENSOR GROUND CIRCUIT FOR

SHORT TO B+
1. Measure the voltage between EC10, pin 02 (B) and GROUND.
-> Yes
-> No
G307559t59 : CHECK THE PEDAL TRAVEL SENSOR SIGNAL CIRCUIT FOR

HIGH RESISTANCE
connector EC30. 3. Measure the resistance between EC10, pin 03 (U) and EC30, pin 40 (U).
-> Yes
-> No
G307559t60 : CHECK THE PEDAL TRAVEL SENSOR SIGNAL CIRCUIT FOR

SHORT TO GROUND
1. Measure the resistance between EC10, pin 03 (U) and GROUND.
-> Yes
-> No
G307559t61 : CHECK THE PEDAL TRAVEL SENSOR SIGNAL SIGNAL CIRCUIT

FOR SHORT TO B+
1. Measure the voltage between EC10, pin 03 (U) and GROUND.
-> Yes
-> No
Contact dealer technical support for advice on possible active booster failure. <<206-07>>CLEAR the
DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support
for advice on possible ABS/DSC module failure.

BRAKE LIGHT SWITCH CIRCUIT
FAILURE
G307559t62 : CHECK THE BRAKE LIGHT SWITCH OUTPUT VOLTAGE
1. Turn the ignition switch to the OFF position. 2. Disconnect the rear electronic module (REM)
electrical connector CR13. 3. Turn the ignition switch to the ON position. 4. Depress the brake pedal.
5. Measure the voltage between CR13, pin 13 (GO) and GROUND.
-> Yes
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-> No
INSTALL a new rear electronic module (REM). CLEAR the DTC. TEST the system for normal operation.
G307559t63 : CHECK THE BRAKE LIGHT SWITCH SUPPLY VOLTAGE

1. Disconnect the brake light switch electrical connector CR78. 2. Measure the voltage between
CR78, pin 01 (NG) and GROUND.
-> Yes
REPAIR the circuit between the battery and the brake light switch electrical connector CR78, pin 01
(NG). This circuit includes the primary junction box ( fuse 44). For additional information, refer to the
-> No
G307559t64 : CHECK THE CONTINUITY OF THE BRAKE LIGHT SWITCH

OUTPUT CIRCUIT
1. Measure the resistance between CR78, pin 02 (GO), and CR13, pin 13 (GO).
-> Yes
-> No
INSTALL a new brake light switch. CLEAR the DTC. TEST the system for normal operation.
Range: G45704->G99999
Overview
There are some changes for 2006 my, the most obvious of which when diagnosing the system is the
change to 7-digit diagnostic trouble codes (DTCs) from the familiar 5-digit.
Refer to the DTC index in this section for guidance on how to use these codes with the Jaguar
approved diagnostic system or a scan tool.
For information on the operation of the system,


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2 . Confirm if the ABS warning light was illuminated, or still is.
NOTE:
An intermittent fault may allow the warning light to go off. This does not necessarily mean the
fault is not present. Some warnings will appear to clear when the ignition is cycled. This is often
because the warning has flagged as a result of one of the vehicle's on-board diagnostic routines
having run to detect the fault. If the same routine is not run when the ignition is switched ON,
the warning will not reflag until the routine does run.
• Brake fluid level • Warning light operation

• Vacuum system • Fuses (see table)
• Wheel speed sensor (WSS) fitment • Wheel speed sensors
• WSS air gap • Connectors/Pins
• WSS ring(s) (missing or damaged • Harnesses
teeth/contamination) • Steering wheel rotation sensor
• Steering wheel rotation sensor • Yaw rate sensor and accelerometer
• Yaw rate sensor and accelerometer cluster cluster
fitment • Booster pressure sensor
• Incorrect wheel or tire size • Hydraulic control module (HCU)
retrieve the fault codes before proceeding to the DTC index chart.
Fuse Identification Table

Location Fuse Number Rating Circuit
Front power distribution fuse box 20 30 Amp HCU pump battery supply
Front power distribution fuse box 03 5 Amp HCU module battery supply
Front power distribution fuse box 22 15 Amp HCU valve battery supply
Primary junction fuse box 17 5 Amp HCU module ignition supply
DTC Index
NOTE:
Traction control
Refer to the warranty policy and
switch (TCS)
C000101 • Internal HCU fault procedures manual if a module is
control channel A
suspect.
valve 1
Traction control
switch (TCS)
control channel A
suspect.
valve 2
Traction control
switch (TCS)
control channel B
suspect.
valve 1
Traction control
C000401 switch (TCS) • Internal HCU fault Refer to the warranty policy and
procedures manual if a module is
control channel B
valve 2 suspect.

Left hand front
outlet control
suspect.

Left hand front
outlet control
suspect.
Check the brake fluid condition.

Left hand front • Fluid leak
C00117A Check the hydraulic system for
outlet control • Seal failure
leaks.

Right hand front
inlet control
suspect.
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Right hand front
outlet control
suspect.
Check the brake fluid condition.

Right hand front
C00157A • Internal HCU fault Check the hydraulic system for
outlet control
leaks.

Left hand rear
inlet control
suspect.

Left hand rear
outlet control
suspect.

Right hand rear
C001C01 • Internal HCU fault procedures manual if a module is
inlet control
suspect.

Right hand rear
C001D01 • Internal HCU fault procedures manual if a module is
outlet control
suspect.
• Power supply to pump

C002001 ABS pump motor motor: short circuit Refer to the warranty policy and
control - excessive • Power supply to pump procedures manual if a module is
motor: incorrect voltage
volt drop • Pump ground circuit fault suspect.
• Mechanical pump fault

motor: high resistance
ABS pump motor Refer to the warranty policy and
motor: short circuit
C00201C control - voltage procedures manual if a module is
• Pump ground circuit fault
out of range • Internal solid-state fault suspect.
caused by ground circuit
fault
For power supply circuit tests, GO to

• Power supply to pump Pinpoint Test G531322p3.
ABS pump motor motor: high resistance If the power and ground circuits are
C002071 control - actuator • Power supply to pump OK, refer to the warranty policy and
stuck motor: short circuit procedures manual if a module is
• Mechanical pump fault suspect. No physical test of the
pump is possible.
For a mechanical check of the

Brake booster • Vacuum circuit fault
C002201 vacuum booster function. GO to
fault • Booster fault
Check the WSS ring for

damage/contamination (the sensor
ring is part of the hub and can only
• Contamination or debris
Left hand front be inspected by removing the
on the WSS ring
C003007 wheel speed sensor).
• WSS ring distorted
sensor (WSS) ring • Excessive vibration Front Wheel Speed Sensor
(70.60.03) Check the steering and
suspension for excessive play which
could cause vibration.
Left hand front • WSS signal circuit: short

circuit to ground
wheel speed
• WSS signal circuit: short For left hand front WSS tests, GO to
C003101 sensor (WSS) -
circuit to power Pinpoint Test G531322p4.
signal current out • WSS signal circuit: high
of range resistance
Left hand front • WSS faulty/incorrectly Check the condition and fitment of
installed the WSS.
wheel speed
C003107 • WSS or ring
sensor (WSS) - Front Wheel Speed Sensor
missing/damaged
mechanical fault (70.60.03) Check the WSS ring for
• Excessive gap between
sensor and ring damage/contamination. Check the
• Incorrect ring (number of steering and suspension for
teeth) excessive play. Check the WSS ring
for correct specification.
Check the WSS ring for

damage/contamination (the sensor
ring is part of the hub and can only
• Contamination or debris
Right hand front be inspected by removing the
on the WSS ring
C003307 wheel speed sensor).
• WSS ring distorted
sensor ring • Excessive vibration Front Wheel Speed Sensor
(70.60.03) Check the steering and
suspension for excessive play which
could cause vibration.
Right hand front • WSS signal circuit: short

circuit to ground
wheel speed
• WSS signal circuit: short For right hand front WSS tests, GO
C003401 sensor (WSS) -
circuit to power to Pinpoint Test G531322p5.
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of range resistance
Check the condition and fitment of

• WSS faulty/incorrectly
installed the WSS.
Right hand front • WSS or ring Front Wheel Speed Sensor
wheel speed missing/damaged (70.60.03) Check the WSS ring for
C003407
sensor (WSS) - • Excessive gap between damage/contamination. Check the
mechanical fault sensor and ring steering and suspension for
• Incorrect ring (number of
excessive play. Check the WSS ring
teeth)
for correct specification.
• Contamination or debris Check the WSS ring for

Left hand rear
on the WSS ring damage/contamination. Check the
C003607 wheel speed
• WSS ring distorted suspension for excessive play which
sensor (WSS) ring • Excessive vibration could cause vibration.
Left hand rear • WSS signal circuit: short

circuit to ground
wheel speed
• WSS signal circuit: short For left hand rear WSS tests, GO to
C003701 sensor (WSS) - circuit to power Pinpoint Test G531322p6.
of range resistance
• WSS faulty/incorrectly Check the condition and fitment of

Left hand rear installed
C003707 wheel speed the WSS.
• WSS or ring
Rear Wheel Speed Sensor
sensor (WSS) - missing/damaged
• Excessive gap between (70.60.04) Check the WSS ring for
mechanical fault sensor and ring damage/contamination. Check the
• Incorrect ring (number of suspension for excessive play. Check
teeth) the WSS ring for correct
specification.
• Contamination or debris Check the WSS ring for

Right hand rear
on the WSS ring damage/contamination. Check the
C003907 wheel speed
• WSS ring distorted suspension for excessive play which
sensor (WSS) ring • Excessive vibration could cause vibration.
Right hand rear • WSS signal circuit: short

circuit to ground
wheel speed
• WSS signal circuit: short For right hand rear WSS tests, GO to
C003A01 sensor (WSS) -
of range resistance
Check the condition and fitment of

• WSS faulty/incorrectly
installed the WSS.
Right hand rear • WSS or ring Rear Wheel Speed Sensor
wheel speed missing/damaged (70.60.04) Check the WSS ring for
C003A07
sensor (WSS) - • Excessive gap between damage/contamination. Check the
mechanical fault sensor and ring suspension for excessive play. Check
• Incorrect ring (number of
the WSS ring for correct
teeth)
specification.
• Brake pedal switch

circuit: short circuit to
ground
circuit: short circuit to For brake switch circuit tests, GO to
C004064 Brake pedal switch
power Pinpoint Test G531322p2.
circuit: high resistance
failure
• Sensor failure The sensor Refer to the warranty policy and

Brake pressure
C004401 is internal to the control procedures manual if a module is
sensor A module suspect.
• Sensor failure The sensor Refer to the warranty policy and

Brake pressure
C004428 is internal to the control procedures manual if a module is
sensor module suspect.
C004464 Brake pressure • Sensor failure The sensor

is internal to the control
sensor module procedures manual if a module is
suspect.
Brake pressure Refer to the warranty policy and

• Internal hydraulic
C00447A sensor - cross procedures manual if a module is
leak/seal failure
check failure suspect.
• Booster pressure sensor

ground
Booster pressure circuit: short circuit to For booster pressure sensor tests,
C004701
sensor power GO to Pinpoint Test G531322p8.
failure

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ground
C004728
failure
• Brake hydraulic circuit

Check the brake hydraulic circuits.
Booster pressure failure
C004762 Check the master cylinder, etc.
sensor • Booster pressure sensor
failure Brake System

ground
C004764
failure
• Sensor power circuit fault For steering wheel rotation sensor

Steering wheel
C005101 • Sensor ground circuit tests, GO to Pinpoint Test
rotation sensor fault G531322p9.
• Sensor signal circuit fault
• Steering wheel rotation
sensor fault
• Sensor power circuit fault

• Sensor ground circuit
fault Check the sensor and encoder wheel
• Sensor signal circuit fault for correct fitment/alignment.
Steering wheel • Sensor loose/incorrectly Steering Wheel Rotation Sensor
C005102
rotation sensor installed (86.56.58) For steering wheel
• Encoder wheel rotation sensor tests, GO to Pinpoint
misaligned or faulty
Test G531322p9.
• Steering wheel rotation
sensor fault
Check the sensor and encoder wheel

• Sensor loose/incorrectly for correct fitment/alignment.
Steering wheel
installed Steering Wheel Rotation Sensor
C005128 rotation sensor -
• Vehicle track incorrectly (86.56.58) Check the steering and
offset monitoring adjusted suspension for damage/wear which
would affect the track.
Cycle the ignition off and on, drive

• Center position not the vehicle in a straight line for
learnt/lost three seconds at a speed higher
Steering wheel • Implausible signals from than 50 Kmh (31 Mph) to learn the
C005167
rotation sensor other sensors (yaw rate, center position. Check the sensors
lateral acceleration, listed for correct fitment/damage.
wheel speed sensors)
Check for DTCs indicating a sensor
fault.
Check the sensor and encoder wheel

• Sensor apertures blocked
for correct fitment/alignment and
Steering wheel • Encoder wheel
C005192 condition.
rotation sensor misaligned or faulty
• Sensor fault Steering Wheel Rotation Sensor
(86.56.58)
• Sensor incorrectly For steering wheel rotation sensor

Steering wheel
C005195 assembled Circuit tests, GO to Pinpoint Test
rotation sensor incorrectly connected G531322p9.
• Sensor circuit(s): short For steering wheel rotation sensor

Steering wheel
C005196 circuit to each other tests, GO to Pinpoint Test
rotation sensor • Sensor fault G531322p9.
C006101 Yaw rate sensor • Sensor fault Install a new sensor.

and Yaw Rate Sensor and Accelerometer
accelerometer (86.56.64)
Carry out the yaw rate sensor reset

special application using the Jaguar
Yaw rate sensor • Sensor incorrectly approved diagnostic system. Clear
C006128 and calibrated the DTC and drive the vehicle to a
accelerometer • Sensor fault speed greater than 20 kmh (12.5
mph) for more than 3 seconds to
confirm the fix.
Check the sensor for correct

• Sensor loose/incorrectly installation.
Yaw rate sensor installed
Yaw Rate Sensor and Accelerometer
C006164 and • Sensor ground circuit:
high resistance (86.56.64) For yaw rate sensor and
accelerometer
• Sensor fault accelerometor tests, GO to Pinpoint
Test G531322p10.
Yaw rate sensor Install a new sensor.

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C006301 and • Sensor fault Yaw Rate Sensor and Accelerometer


Yaw rate sensor • Sensor incorrectly approved diagnostic system. Clear
C006328 and calibrated the DTC and drive the vehicle to a
accelerometer • Sensor fault speed greater than 20 kmh (12.5
mph) for more than 3 seconds to
confirm the fix.
Check the sensor for correct

• Sensor loose/incorrectly installation.
Yaw rate sensor installed
C006364 and • Sensor ground circuit:
high resistance (86.56.64) For yaw rate sensor and
accelerometer
• Sensor fault accelerometor tests, GO to Pinpoint
Test G531322p10.
Yaw rate sensor • Sensor supply circuit: For yaw rate sensor and
C006A01 and high resistance accelerometor tests, GO to Pinpoint
accelerometer • Sensor fault Test G531322p10.
• Sensor supply circuit:

Yaw rate sensor short circuit to power For yaw rate sensor and
C006A04 and • Sensor supply circuit: accelerometor tests, GO to Pinpoint
accelerometer short circuit to ground Test G531322p10.
high resistance
• Sensor failure

Yaw rate sensor short circuit to power
and • Sensor supply circuit: For yaw rate sensor and
C006A16 accelerometer - short circuit to ground accelerometor tests, GO to Pinpoint
low voltage • Sensor supply circuit: Test G531322p10.
detected high resistance
• Sensor failure
Yaw rate sensor

and • Sensor supply circuit: For yaw rate sensor and
C006A17 accelerometer - short circuit to power accelerometor tests, GO to Pinpoint
high voltage • Sensor failure Test G531322p10.
detected

C006A47 and • Watchdog/Safety failure Yaw Rate Sensor and Accelerometer

C006A95 and • Incorrect part fitted Yaw Rate Sensor and Accelerometer

C006B00 and • Sensor failure Yaw Rate Sensor and Accelerometer

Hydraulic control
C008247 • Internal HCU failure procedures manual if a module is
module fault
suspect.

Hydraulic control
module fault
suspect.

Hydraulic control
module fault
suspect.

Yaw rate sensor
C008254 and • Calibration failure
approved diagnostic system. Clear
accelerometer
the DTC and retest.
Internal pressure
sensor fault
suspect.
Traction control Check for transmission DTCs.

C110964 • J-Gate module error
switch (TCS) error

Internal pressure
sensor fault
suspect.
Left hand front Refer to the warranty policy and

C113328 brake pressure • Internal HCU failure procedures manual if a module is
sensor suspect.
Left hand front Refer to the warranty policy and

sensor suspect.
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Right hand front Refer to the warranty policy and

sensor suspect.

sensor suspect.

sensor suspect.
The valve values cannot be

Master cylinder • Valve not calibrated calibrated in service. Refer to the
B10DF46 Internal HCU fault
isolation valve warranty policy and procedures
manual if a module is suspect.
• Isolated CAN
CAN Clear the DTCs, retest. If CAN fault
communication error
U000100 communication codes reset,
• CAN circuit fault
bus • Internal HCU failure
CAN • Isolated CAN Clear the DTCs, retest. If CAN fault

U000168 communication communication error codes reset,
software error • Internal HCU failure
Lost • Isolated CAN Clear the DTCs, retest. If CAN fault
U010000 communication communication error codes reset,
with ECM • CAN circuit fault
Lost
• Isolated CAN Clear the DTCs, retest. If CAN fault
communication
U010400 communication error codes reset,
with speed control • CAN circuit fault
module
Lost
communication
communication error
U012500 with yaw rate codes reset,
• Local CAN circuit fault
sensor and • Sensor failure
accelerometer
Lost
• Isolated CAN
communication Clear the DTCs, retest. If CAN fault
communication error
U012588 with yaw rate codes reset,
• Local CAN circuit fault
sensor and • Sensor failure
accelerometer
Lost
communication
with instrument • CAN circuit fault
pack module
• Configuration data not

received from EMS
Control module Confirm that the configuration data
• Configuration data
U030000 software received is not
for the EMS is correct. Confirm that
incompatibility compatible with the DSC the correct DSC module is installed.
module

Control module • Internal HCU software
U030005 procedures manual if a module is
software error error
suspect.
Stored vehicle received is different from Confirm the vehicle configuration.
U030055 configuration data the previous key cycle Reconfigure the module using the
does not match • Control module swapped Jaguar approved diagnostic system
from another vehicle
U030087 Received vehicle Confirm the vehicle configuration.
received is different from
configuration data Reconfigure the module using the
the modules seen on the
does not match network Jaguar approved diagnostic system
• Control module swapped
from another vehicle
Check for engine management

DTCs.
Invalid data
Electronic Engine Controls - VIN
U040164 received from the • Invalid data
Range: G45704->G99999 or
ECM
Range: G45704->G99999
Check for engine management

DTCs.
Torque request
• Engine management Electronic Engine Controls - VIN
U040192 denied by the
fault detected Range: G45704->G99999 or
ECM
Range: G45704->G99999
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TCM messages not • Isolated CAN Clear the DTCs, retest. If CAN fault
U040200 received in the communication error codes reset,
specified time • CAN circuit fault
Invalid data
• Invalid data received Check for transmission DTCs.
U040264 received from the
from the TCM
TCM
Fault declared by Check for speed control DTCs.

• ACC fault detected by the
U040592 the speed control Speed Control - VIN Range: G45704-
speed control module
module >G99999

Missing reverse
gear signal • CAN circuit fault
Speed control
• Braking requested by Check for speed control DTCs.
vehicle
U210868 speed control exceeds Speed Control - VIN Range: G45704-
deceleration allowed threshold >G99999
implausible
• HCU supply circuit

Battery voltage For module supply and ground tests,
U300316 fault(s)
low • Internal HCU failure GO to Pinpoint Test G531322p3.
U300317 Battery voltage • HCU supply circuit

For module supply and ground tests,
fault(s)
high • Charging system fault(s) GO to Pinpoint Test G531322p3.
Pinpoint tests

VACUUM ASSIST FUNCTION
G531322t1 : CHECK THE BRAKE PEDAL TRAVEL WITH THE ENGINE OFF
1. Key off. 2. Pump the brake pedal six times and hold firm pressure on the pedal.
• Did the pedal travel decrease and the pedal go hard as it was pumped?
-> Yes
-> No
CHECK the vacuum circuit to the brake booster. Start the engine and idle for three minutes, switch
off then repeat the test. If the pedal travel does not decrease, suspect the brake booster.
G531322t2 : CHECK THE BRAKE PEDAL TRAVEL WITH THE ENGINE

RUNNING
1. With firm pressure still held on the brake pedal, start the engine.
• Did the pedal travel increase as the engine started?
-> Yes
The vacuum function of the brake booster is operating normally. Check for DTCs indicating a fault
elsewhere in the system.
-> No
CHECK the vacuum circuit to the brake booster.

SWITCH
G531322t3 : CHECK THE OPERATION OF THE BRAKE SWITCH (PEDAL
RELEASED)
1.
Circuit Pin
Brake light switch 41
2.
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Circuit Pin
Power supply 01
Signal 02
3. Key off. 4. Disconnect the brake switch electrical connector, CR078. 5. Make sure the brake pedal
is not pressed. 6. Measure the resistance between:
Brake switch connector CR078, component side Brake switch connector CR078, component side
Pin 01 Pin 02
-> Yes
-> No
INSTALL a new brake switch. CLEAR the DTC, test the system for normal operation.

PRESSED)
1. Press the brake pedal. 2. Measure the resistance between:
Pin 01 Pin 02
-> Yes
-> No
G531322t5 : CHECK THE POWER SUPPLY TO THE BRAKE PEDAL SWITCH

1. Key on, engine off. 2. Measure the voltage between:
Brake switch connector CR078, harness side Battery
Pin 01 Negative terminal
-> Yes
REPAIR the circuit between the brake switch and battery. This circuit includes fuse 35 of the primary
junction box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the
-> No
G531322t6 : CHECK THE BRAKE SWITCH SIGNAL CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Key off. 2. Measure the resistance between:
• Is the resistance less than 100 Kohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test
-> No
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CIRCUIT TO POWER
Pin 02 Positive terminal
• Is the resistance less than 100 Kohms?
-> Yes
-> No
G531322t8 : CHECK THE BRAKE SWITCH SIGNAL CIRCUIT FOR HIGH

RESISTANCE
1. Disconnect the ECM electrical connector, EC300. 2. Measure the resistance between:
Brake switch connector CR078, harness side ECM connector EC300, harness side
Pin 02 Pin 41
-> Yes
CHECK for CAN DTCs indicating a network fault.
-> No
PINPOINT TEST G531322p3 : MODULE

SUPPLIES AND GROUNDS
G531322t9 : CHECK THE MODULE PUMP SUPPLY
1.
Circuit Pin
Pump supply 01
Valves supply 32
Batt supply 02
Ignition supply 08
Pump ground 47
Valve ground 16
2. Key off. 3. Disconnect the ABS module connector, EC030. 4. Measure the voltage between:
Pump supply, pin 01 Negative terminal
• Is the voltage between 9 and 15 volts?
-> Yes
-> No
REPAIR the supply circuit as necessary. This circuit includes fuse 20 of the front power distribution
box. For additional information, refer to the wiring diagrams. Clear the DTC, test the system for
normal operation.
G531322t10 : CHECK THE MODULE VALVES SUPPLY

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1. Measure the voltage between:
Valves supply, pin 32 Negative terminal
-> Yes
-> No
normal operation.
G531322t11 : CHECK THE MODULE BATT SUPPLY

Batt supply, pin 02 Negative terminal

-> Yes
-> No
normal operation.
G531322t12 : CHECK THE MODULE IGNITION SUPPLY

Ignition supply, pin 08 Negative terminal
-> Yes
-> No
REPAIR the supply circuit as necessary. This circuit includes fuse 03 of the primary junction box. For
additional information, refer to the wiring diagrams. Clear the DTC, test the system for normal
operation.
G531322t13 : CHECK THE PUMP GROUND

Pump ground, pin 47 Negative terminal
-> Yes
-> No
REPAIR the ground circuit as necessary. For additional information, refer to the wiring diagrams.
Clear the DTC, test the system for normal operation.
G531322t14 : CHECK THE VALVE GROUND

Valve ground, pin 16 Negative terminal
-> Yes
Refer to the warranty policy and procedures manual if a module is suspect.
-> No
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REPAIR the ground circuit as necessary. For additional information, refer to the wiring diagrams.
Clear the DTC, test the system for normal operation.

HAND FRONT WHEEL SPEED SENSOR
(WSS)
G531322t15 : CHECK THE WSS RETURN CIRCUIT FOR SHORT CIRCUIT TO
GROUND
1.
Circuit Pin
WSS signal 01
WSS return 02
2.
Circuit Pin
Left hand front WSS signal 46
Left hand front WSS return 45
3. Key off. 4. Disconnect the WSS connector, EC044. 5. Disconnect the ABS module connector, EC030.
6. Key on, engine off. 7. Measure the resistance between:
-> Yes
-> No
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test
the system for normal operation by driving the vehicle at more than 20 kph (12.5 mph) for more than
3 minutes.

POWER

-> Yes
-> No
3 minutes.
G531322t17 : CHECK THE WSS RETURN CIRCUIT FOR HIGH RESISTANCE

EC044, harness side EC030, harness side
Pin 02 Pin 45
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-> Yes
-> No
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Clear the
DTC, test the system for normal operation by driving the vehicle at more than 20 kph (12.5 mph) for
more than 3 minutes.
G531322t18 : CHECK THE WSS SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

POWER
-> Yes
-> No
3 minutes.

GROUND
-> Yes
-> No
3 minutes.
G531322t20 : CHECK THE WSS SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin 46
-> Yes
-> No
G531322t21 : CHECK THE WSS SIGNAL AND RETURN CIRCUITS FOR SHORT
CIRCUIT TO EACH OTHER
Pin 01 Pin 02
-> Yes
physical damage to the harness. If no fault is found in the harness, suspect the following
components: - WSS connector - WSS - ABS module connector - ABS module
-> No
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3 minutes.

HAND FRONT WHEEL SPEED SENSOR
(WSS)
GROUND
1.
Circuit Pin
WSS signal 01
WSS return 02
2.
Circuit Pin
Right hand front WSS signal 33
Right hand front WSS return 34
3. Key off. 4. Disconnect the WSS connector, EC015. 5. Disconnect the ABS module connector, EC030.
-> Yes
-> No
3 minutes.

POWER

-> Yes
-> No
3 minutes.

Pin 02 Pin 34
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-> Yes
-> No

POWER
-> Yes
-> No
3 minutes.

GROUND
-> Yes
-> No
3 minutes.

Pin 01 Pin 33
-> Yes
-> No
Pin 01 Pin 02
-> Yes
-> No
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3 minutes.

HAND REAR WHEEL SPEED SENSOR
(WSS)
GROUND
1.
Circuit Pin
WSS return 01
WSS signal 02
2.
Circuit Pin
Left hand rear WSS signal 36
Left hand rear WSS return 37
3. Key off. 4. Disconnect the WSS connector, CV006. 5. Disconnect the ABS module connector, EC030.
CV006, harness side Battery
-> Yes
-> No
3 minutes.

POWER

-> Yes
-> No
3 minutes.

CV006, harness side EC030, harness side
Pin 01 Pin 37
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-> Yes
-> No

POWER
-> Yes
-> No
3 minutes.

GROUND
-> Yes
-> No
3 minutes.

Pin 02 Pin 36
-> Yes
-> No
CV006, harness side CV006, harness side
Pin 01 Pin 02
-> Yes
-> No
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3 minutes.

HAND REAR WHEEL SPEED SENSOR
(WSS)
GROUND
1.
Circuit Pin
WSS return 01
WSS signal 02
2.
Circuit Pin
Right hand rear WSS return 42
Right hand rear WSS signal 43
3. Key off. 4. Disconnect the WSS connector, CV008. 5. Disconnect the ABS module connector, EC030.
6. Key on engine off. 7. Measure the resistance between:
-> Yes
-> No
3 minutes.

POWER

-> Yes
-> No
3 minutes.

Pin 01 Pin 42
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-> Yes
-> No

POWER
-> Yes
-> No
3 minutes.

GROUND
-> Yes
-> No
3 minutes.

Pin 02 Pin 43
-> Yes
-> No
CV008, harness side CV008, harness side
Pin 01 Pin 02
-> Yes
-> No
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3 minutes.
PINPOINT TEST G531322p8 : BOOSTER

PRESSURE SENSOR
G531322t25 : CHECK THE POWER SUPPLY TO THE BOOSTER PRESSURE
SENSOR
1.
Circuit Pin
Power supply 03
Signal A 04
Signal B 01
Ground 02
2.
Circuit Pin
Power supply 26
Signal A 38
Signal B 30
Ground 27
3. Key off. 4. Disconnect the booster pressure sensor connector, EC095. 5. Key on, engine off. 6.
Measure the voltage between:
-> Yes
-> No
G531322t26 : CHECK THE BOOSTER PRESSURE SENSOR POWER SUPPLY
CIRCUIT FOR SHORT CIRCUIT TO GROUND
-> Yes
-> No
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the system for normal operation by applying and releasing the brake pedal firmly three times with
the engine running.
G531322t27 : CHECK THE BOOSTER PRESSURE SENSOR POWER SUPPLY

1. Key off. 2. Disconnect the ABS module connector, EC030. 3. Measure the resistance between:
Pin 03 Pin 26
-> Yes
physical damage to the harness.
-> No
DTC, test the system for normal operation by applying and releasing the brake pedal firmly three
times with the engine running.
G531322t28 : CHECK THE GROUND CIRCUIT TO THE BOOSTER PRESSURE

SENSOR
-> Yes
-> No
G531322t29 : CHECK THE BOOSTER PRESSURE SENSOR GROUND CIRCUIT

-> Yes
-> No
G531322t30 : CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS

OR THE MODULE
1. Key off. 2. Disconnect the ABS module connector, EC030. 3. Key on, engine off. 4. Measure the
resistance between:

-> Yes
-> No
the engine running.
G531322t31 : CHECK THE BOOSTER PRESSURE SENSOR GROUND CIRCUIT

FOR HIGH RESISTANCE
resistance between:
Pin 02 Pin 27
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-> Yes
components: - Booster pressure sensor connector - ABS module connector - ABS module
-> No
G531322t32 : CHECK THE BOOSTER PRESSURE SENSOR SIGNAL A CIRCUIT

FOR SHORT CIRCUIT TO GROUND

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No
the engine running.

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
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-> No
the engine running.
G531322t36 : CHECK THE BOOSTER PRESSURE SENSOR SIGNAL B CIRCUIT

-> Yes
-> No
OR THE MODULE
resistance between:
-> Yes
-> No
the engine running.

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No
the engine running.

FOR HIGH RESISTANCE
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resistance between:
Pin 04 Pin 38
-> Yes
-> No

FOR HIGH RESISTANCE
Pin 01 Pin 30
-> Yes
-> No
G531322t42 : CHECK THE BOOSTER PRESSURE SENSOR SIGNAL A AND B

CIRCUITS FOR SHORT CIRCUIT TO EACH OTHER
Pin 01 Pin 04
-> Yes
-> No
the engine running.

STEERING WHEEL ROTATION
SENSOR
G531322t43 : CHECK THE POWER SUPPLY TO THE STEERING WHEEL
ROTATION SENSOR
1.
Circuit Pin
Sensor power 01
Signal B 02
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Signal A 03
Sensor return 04
2.
Circuit Pin
Sensor power 05
Signal B 09
Signal A 41
Sensor return 40
3. Key off. 4. Disconnect the steering wheel rotation sensor connector, IP037. 5. Key on, engine off. 6.
IP037, harness side Battery
01 Negative terminal
-> Yes
-> No
G531322t44 : CHECK THE STEERING WHEEL ROTATION SENSOR POWER

SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
01 Positive terminal
-> Yes
-> No
the system for normal operation by turning the steering from the center position to full right hand
lock, to full left hand lock and back to the center position before road testing the vehicle on roads
requiring steering input.
G531322t45 : CHECK THE STEERING WHEEL ROTATION SENSOR POWER

SUPPLY CIRCUIT FOR HIGH RESISTANCE
FH110, harness side EC030, harness side
Pin 01 Pin 05
-> Yes
-> No
DTC, test the system for normal operation by turning the steering from the center position to full
right hand lock, to full left hand lock and back to the center position before road testing the vehicle
on roads requiring steering input.
G531322t46 : CHECK THE GROUND CIRCUIT TO THE STEERING WHEEL

ROTATION SENSOR
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FH110, harness side Battery
-> Yes
-> No
G531322t47 : CHECK THE STEERING WHEEL ROTATION SENSOR GROUND

CIRCUIT FOR SHORT CIRCUIT TO POWER

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No
G531322t49 : CHECK THE STEERING WHEEL ROTATION SENSOR GROUND

Pin 04 Pin 40
-> Yes
-> No
G531322t50 : CHECK THE STEERING WHEEL ROTATION SENSOR SIGNAL A


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-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No
G531322t54 : CHECK THE STEERING WHEEL ROTATION SENSOR SIGNAL B
-> Yes
-> No
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OR THE MODULE
resistance between:
-> Yes
-> No

-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No

resistance between:

Pin 03 Pin 41
-> Yes
-> No

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Pin 02 Pin 41
-> Yes
-> No

AND B CIRCUITS FOR SHORT CIRCUIT TO EACH OTHER
FH110, harness side FH110, harness side
Pin 02 Pin 03
-> Yes
-> No
PINPOINT TEST G531322p10 : YAW

RATE SENSOR AND ACCELEROMETER
G531322t61 : CHECK THE POWER SUPPLY TO THE YAW RATE SENSOR AND
ACCELEROMETER
1.
Circuit Pin
CAN negative 01
CAN positive 02
Sensor power 03
Sensor ground 05
2.
Circuit Pin
CAN negative 19
CAN positive 18
Sensor power 22
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Sensor ground 29
3. Key off. 4. Disconnect the yaw rate sensor and accelerometer connector, IP023 5. Key on, engine
off. 6. Measure the resistance between:
-> Yes
-> No
G531322t62 : CHECK THE YAW RATE SENSOR AND ACCELEROMETER

POWER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND

-> Yes
-> No
the system for normal operation by driving the vehicle to a speed greater than 20 Kph (12.5 mph) for
more than 3 seconds.

POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
IP023, harness side EC030, harness side
Pin 03 Pin 22
-> Yes
-> No
DTC, test the system for normal operation by driving the vehicle to a speed greater than 20 Kph (12.5
mph) for more than 3 seconds.
G531322t64 : CHECK THE GROUND CIRCUIT TO THE YAW RATE SENSOR

AND ACCELEROMETER

-> Yes
-> No

GROUND CIRCUIT FOR SHORT CIRCUIT TO POWER

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-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No

GROUND CIRCUIT FOR HIGH RESISTANCE
resistance between:
Pin 05 Pin 29
-> Yes
-> No
G531322t68 : CHECK THE YAW RATE SENSOR AND ACCELEROMETER CAN -

-> Yes
-> No
OR THE MODULE
resistance between:
-> Yes
-> No
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-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No
G531322t72 : CHECK THE YAW RATE SENSOR AND ACCELEROMETER CAN +

-> Yes
-> No

OR THE MODULE
resistance between:

-> Yes
-> No


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-> Yes
-> No

OR THE MODULE
resistance between:
-> Yes
-> No

resistance between:
Pin 01 Pin 19
-> Yes
-> No

Pin 02 Pin 18
-> Yes
-> No

AND - CIRCUITS FOR SHORT CIRCUIT TO EACH OTHER
IP023, harness side IP023, harness side
Pin 02 Pin 01
-> Yes
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-> No
Anti-Lock Brake System (ABS) Module

(70.60.02)
Removal
2 . Disconnect the hydraulic control unit electrical connector.
3 . Detach the engine compartment battery junction box.
4 . Remove the ABS module.
Installation
Brake Master Cylinder Pressure
Transducer
Removal
1
personal injury.
Disconnect the battery ground cable. <<414-01>>

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2 . Disconnect the brake master cylinder primary pressure transducer electrical connector.
3
. CAUTION: If brake fluid is spilt on the paintwork, the effected area must be
immediately washed down with cold water.
Remove the brake master cylinder primary pressure transducer.

Installation
Tighten 30 Nm.
2 . Bleed the ABS brake system. <<206-00>>

Brake Pedal Travel Sensor - VIN Range:
G00442->G49700
Removal
WARNING: Failure to carry out procedure may result in damage to the vehicle.
1 . Depress brake pedal 20 times to remove vacuum from brake booster.
2 . Remove the brake pedal travel sensor.
Disconnect the brake pedal travel sensor electrical connector.

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Using a suitable pick, remove the spring clip.
Installation
1 . Fit new spring clip to sensor housing, ensuring correct alignment.
2 . Lubricate new seal with water and fit seal to the sensor.
3 . Fit and fully seat new brake pedal travel sensor.
Connect the brake pedal travel sensor electrical connector.

Front Wheel Speed Sensor (70.60.03)
Removal
2
. CAUTION: Make sure the ignition is in the ‘OFF’ position before disconnecting the
front wheel speed sensor electrical connector.
Detach the front wheel speed sensor.
1) Remove the front wheel speed sensor retaining clip.
2) Detach the front wheel speed sensor.
3 . Detach the front wheel speed sensor harness.
4 . Remove the front wheel speed sensor.
Disconnect the electrical connector.

Installation
1
. CAUTION: Make sure the wheel speed sensor locating tang is correctly seated in the
hub assembly.
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CAUTION: Make sure the front wheel speed sensor harness is correctly routed
around the front suspension components.

Hydraulic Control Unit (HCU) - VIN
Range: G00442->G45703 (70.60.18)

JDS 9013
Removal
1
personal injury.
NOTE:
Disconnect the battery ground cable.<<414-01>>
3 . Connect a bleed pipe bottle to the caliper bleed nipple and loosen the caliper bleed nipple.
4 Install pedal hold-down tool.

.
Install the tool between the pedal and the seat frame.
Turn the tool hand-wheel to depress and hold the pedal 60 mm (2.4 in)
from the 'Off' position
This will prevent loss of fluid from the reservoir through disconnected
brake pipes.
5 . Remove the bleed pipe and bottle.
Tighten the caliper bleed nipple.
Disconnect and remove the bleed pipe and bottle.
Install the bleed nipple dust cap.

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6
Disconnect the hydraulic control unit brake tubes.
7 . Disconnect the hydraulic control unit electrical connector.

8 . Remove the hydraulic control unit.
Installation
Tighten to 9 Nm.
3 . Bleed the ABS brake system. <<206-00>>

Hydraulic Control Unit (HCU) - VIN
Range: G45704->G99999 (70.60.18)

JDS 9013
Removal
All vehicles
1
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personal injury.
NOTE:
hold the brake pedal down 60 mm (2.4 inch).


3 Connect brake bleed pipes and bottles to the left-hand front and the left-hand rear brake
. caliper bleed nipples and loosen the brake caliper bleed nipples.
4 Install pedal hold-down tool.
.
Install the tool between the brake pedal and the seat frame.
Turn the tool hand-wheel to press and hold the brake pedal 60 mm (2.4
inch) from the 'Off' position
This will prevent loss of fluid from the reservoir through disconnected
brake tubes.
Vehicles with standard brakes

5 . Remove the bleed pipes and bottles.
Tighten the left-hand front caliper bleed nipple.
Tighten to 8 Nm.
Tighten the left-hand rear brake caliper bleed nipple.
Tighten to 14 Nm.
Disconnect and remove the brake bleed pipes and bottles.
Install the bleed nipple dust caps.

6 . Remove the bleed pipes and bottles.
Tighten the left-hand front caliper bleed nipple.
Tighten to 14 Nm.
Tighten the left-hand rear brake caliper bleed nipple.
Tighten to 14 Nm.
Disconnect and remove the brake bleed pipes and bottles.
Install the bleed nipple dust caps.

All vehicles
7 . Disconnect the hydraulic control unit (HCU) electrical connector.
Right-hand drive vehicles

8
immediately washed down with cold water. Failure to follow this instruction may result in
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CAUTION: To minimise brake fluid loss the brake tubes must be disconnected in the
order shown. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Cap the exposed brake tubes and ports to prevent loss of fluid and dirt
ingress. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Using a suitable tool mark the position of the brake tubes to the HCU.
Disconnect the HCU brake tubes.
1) Disconnect the HCU primary and secondary circuit brake tubes.
2) Disconnect the HCU outlet brake tubes.

Left-hand drive vehicles
9
immediately washed down with cold water. Failure to follow this instruction may result in
CAUTION: To minimise brake fluid loss the brake tubes must be disconnected in the
order shown. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Cap the exposed brake tubes and ports to prevent loss of fluid and dirt
ingress. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Using a suitable tool mark the position of the brake tubes to the HCU.
Disconnect the HCU brake tubes.
1) Disconnect the HCU primary and secondary circuit brake tubes.
2) Disconnect the HCU outlet brake tubes.

All vehicles
10 . Remove the HCU.
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Installation
1 NOTE:
.
A new HCU does not come supplied with the HCU base bracket. The HCU base bracket
should be removed and installed to the new HCU. The HCU base bracket securing bolts
must be torqued if a new HCU is being installed to the vehicle.
• Tighten the three HCU base bracket securing bolts to 9 Nm.
3
. CAUTION: Make sure the brake tubes are installed to the correct ports. Failure to
Tighten to 17 Nm.
4 Bleed the anti-lock brake system (ABS).

(70.25.03)
Rear Wheel Speed Sensor (70.60.04)
Removal
2
. CAUTION: Make sure the ignition is in the ‘OFF’ position before disconnecting the
rear wheel speed sensor electrical connector.
Disconnect the rear wheel speed sensor electrical connector.

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3 . Remove the rear wheel speed sensor.
Remove the securing bolt.
Installation
Tighten to 9 Nm.
Steering Wheel Rotation Sensor (86.56.58)
Removal
2 . Remove the steering wheel. <<211-04>>
3 . Disconnect the steering wheel rotation sensor electrical connector.

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4 . Disconnect the steering wheel rotation sensor electrical wiring harness from steering column.
5 . Remove the steering wheel rotation sensor.

Installation
1 . NOTE:
Note the correct routing of the steering wheel rotation sensor electrical wiring harness.

(86.56.64)
Removal
2 . Remove the floor console. <<501-12>>
3 . Remove the air duct.

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4 . Disconnect the lateral/yaw rate sensor electrical connector.
5 . Remove the lateral/yaw rate sensor.

Installation
1 . NOTE:
If sensor appears damaged or is dropped during installation do not fit to vehicle.
NOTE:
Make sure the lateral/yaw rate sensor is fitted the correct way around.
Tighten to 7 Nm.
211 : Steering System
211-00 : Steering System – General Information
Specifications
Specifications
Steering Linkage Specifications
Steering Linkage Free Play Measurement (mm) Measurement (in)

Free play (measured at the steering wheel rim) 0-6 0-0.24
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Power Steering Pump Specifications
Item Specification
Power steering pump relief pressure 106-114 bar
Item Specification
Power steering fluid Dextron 3
General procedures

1. NOTE:
When filling the reservoir, make sure that the fluid is clean and not agitated prior to use.
The fluid should be poured slowly into the reservoir to minimize the possibility of
aeration.
Fill the reservoir to the MAX mark.
2. NOTE:
Do not start the engine.
Turn the steering from lock to lock.
3. Check the fluid level. Fill the reservoir to the MAX mark if necessary.
4. Start the engine and turn the steering from lock to lock.
5. Switch the engine off.
6. Check the fluid level. Fill the reservoir to the MAX mark if necessary.
7. Start the engine, turn the steering wheel from lock to lock. If excessive noise is apparent or
shudder is evident through the steering wheel, repeat the bleed procedure.
Steering Column Lower Shaft Setting
1. Centralize the steering wheel.
2. Loosen the steering column lower shaft pinch bolt.
3. Fully extend the steering column lower shaft swinging link.

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4. Mark the position of the steering column lower shaft relative to the universal joint.
5. Fully retract the steering column lower shaft swinging link.

6. Move the steering column lower shaft until the measurment between the mark on the
steering column lower shaft and the top of the universal joint is 7mm.
7. Tighten to 35 Nm.
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.
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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.
WARNING: Do not work on or under a vehicle supported only by a jack. Always

support the vehicle on safety stands.
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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.
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13. Install a new power steering fluid reservoir.

Steering System
The power steering system is a rack and pinion design, with an engine-driven pump providing
the steering assistance. The system features variable steering assistance with vehicle speed
and a variable ratio steering rack.
Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of
the system. New fluid from a sealed container must be used.
NOTE:
If the steering gear, pump or cooler are being replaced for leakage or noise related issues
and there is no evidence of fluid contamination, there is no need to replace the reservoir.
In some cases where the fluid clearly contains particulate matter, and the system continues to
function, flush the system with fresh fluid and replace the reservoir, as there is the possibility
that the reservoir internal filter may be damaged or faulty.
Steering System
1 . Verify the customer concern by driving the vehicle.
Mechanical Checks
• Incorrect tire pressure, loose wheel nuts, incorrect wheel alignment
• Loose tie-rods
• Loose damper and spring assemblies or ball joint

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• Loose steering column shaft universal joints
• Loose pinch bolts on steering column shaft
• Loose steering gear assembly
• Check for external damage to the steering gear. Damaged tie-rods
CAUTION: If a steering gear assembly is returned under warranty with leaking 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 seals being damaged due to foreign materials entering the steering
gear boot and damaging the steering gear seals thereafter.
•
Damaged steering gear boot
• Damaged accessory drive belt
• Binding or misaligned steering column, pump or steering gear
• Incorrect fluid level
• Hose leaks or line restrictions
• Hose fouling bodywork

Electrical Checks/Tests
• Make sure all connectors are in place (steering gear Servotronic solenoid and steering control
module (SCM) - if applicable)
• Make sure all the fuses are in place and not blown
• DISCONNECT the steering gear transducer and the steering should become heavy
• TEST electrical values: Power Supply to the SCM = 12 Volts Steering gear transducer
resistance 7.0 to 7.5 Ohms is normal Steering gear transducer voltage = 6 Volts Steering gear
transducer current = 840 mA at 0 mph reducing to 0 mA at maximum speed
• RECONNECT all electrical items disturbed during testing
4 . Check the power steering fluid condition. For additional information, REFER to Power Steering
Fluid Condition Check in this section.
5 . If the concern is not visually evident, verify the symptom and REFER to Steering Fault Diagnosis by
Symptom Charts in this section.
Steering Relay Harness Connector

Item Description
1 Steering transducer ground
2 Ignition feed
3 Steering transducer feed
4 Ground
5 Speed sensor signal
6 Serial interface
Steering Linkage Inspection and Backlash (Freeplay) Check
CAUTION: Steering gear boots must be handled carefully to avoid damage. Use new clamps
when installing steering gear boots.
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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 result in the steering gear warranty to become invalid.
3 . The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional
information, <<211-02>>
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. For additional
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 . Allow the fluid to drip onto a facial tissue and examine the stain.
5 . If evidence of solid material is found, the power steering fluid system should be drained for
further inspection.
6 . 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
Item Special Tool Number Description
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).
•
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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.
With the control valve (7) OPEN and the engine idling, the following system pressures may be
checked:
• During turning.
• When the steering is held on full lock.
• With the steering at rest.
CAUTION: To avoid excessive heating of the power steering pump, do not close the valve for
longer than 5 seconds maximum.
CAUTION: 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. For additional information,
Steering Fault Diagnosis by Symptom Charts
Leakage
Condition Possible Sources Action
• CLEAN the area of the leak.

• Inspect the area and confirm the exact
Confirm the position of the
position of leak.
fluid leak. • Make sure the fluid is not from another
system on the vehicle.
• Overfilled system. • CORRECT the fluid level as necessary.
NOTE:
Record the position of the leak and some

indication of the rate of the leak on the
Warranty Return Record Sheet.
• Fluid • Component leak.
leakage
• LOCATE the suspect component or

CHECK hose connections and repair as
necessary.
• Damaged fluid cap. • INSTALL a new fluid cap.
• Loose or damaged • TIGHTEN or INSTALL a new hose as

hose fittings. necessary.
• INSTALL a new power steering pump as

• Leakage at power
necessary. For additional information,
steering pump.
<<211-02>>
• Leakage at steering • CHECK steering hose to steering gear

• Fluid
hose to steering gear connection for leakage. CHECK and
leakage
connection. TIGHTEN the steering hose to steering
gear connection retaining bolts/bolts as
necessary.
• CHECK the power steering system for

signs of steering fluid loss from O-ring
• Power steering fluid seals.
leakage at O-ring seals. • INSTALL new O-ring seals as necessary.
• BLEED the power steering system. For
additional information, <<211-00>>
• CHECK the power steering system for

signs of steering fluid loss from the
transfer pipes.
• Power steering fluid
• CHECK and TIGHTEN the transfer pipes if
leakage from transfer
required, INSTALL new transfer pipes as
pipes.
necessary.
• BLEED the power steering system. For
additional information, <<211-00>>
• CHECK the power steering gear for signs

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• Power steering fluid of fluid loss.

leakage from the • INSTALL a new steering gear as
steering gear. necessary. For additional information,
<<211-02>>
• CHECK the power steering gear for signs

• Power steering fluid of fluid loss.
leakage from steering • INSTALL a new steering gear as
gear boot. necessary. For additional information,
<<211-02>>
Functional
• CHECK the steering linkage for

excess play. For additional
• Excess play in the information, REFER to the
steering linkage. Steering Linkage Inspection
and Backlash (Freeplay) Check
• Free play at steering in this section.
wheel
• CHECK and TIGHTEN the
steering wheel retaining
• Steering wheel loose. bolt/bolts as necessary. For
additional information, <<211-
04>>
• CHECK and TIGHTEN the lower
• Lower steering
steering column pinch bolts as
column pinch bolt
necessary. For additional
loose.
• CHECK for lower steering

• Excessive wear in column for wear in the
lower steering universal joints. If wear is
column. present, INSTALL a new lower
steering column as necessary.
CAUTION: DO NOT attempt to

adjust the steering gear yoke. Failure
to follow this instruction will result
in the steering gear warranty to
• Wear in suspension become invalid.
joints.
• CHECK for excess wear in the

front suspension joints. For
00>>
• CHECK and ADJUST the tire

pressure. For additional
• Incorrect tire information, <<204-04>>
pressure or tire size. • INSTALL a new tire as
• Vehicle is unevenly or
• Vehicle wanders from • ADJUST the load evenly.
excessively loaded.
side to side on the
road, when the
vehicle is driven • INSTALL a new tie-rod end. For
straight ahead and • Loose/worn tie-rods. additional information, <<211-
the steering wheel is 03>>
held in a firm position
• Steering gear bolts • TIGHTEN or INSTALL new
loose or damaged. bolts.
• Loose or worn • INSTALL a new suspension ball

suspension ball joint assembly. For additional
joint(s). information, <<204-01>>
• Steering column • TIGHTEN the steering column

universal joint pinch universal joint pinch bolt. For
bolt loose. additional information, <<211-
04>>
• ADJUST as necessary. For

• Incorrect toe
adjustment.
00>>
• TIGHTEN loose, or INSTALL

• Loose or worn rear new rear suspension
suspension. components. For additional
• Incorrect tire • CHECK and ADJUST the tire

pressure. pressure. For additional
• Incorrect tire size or information, <<204-04>>
different tire/tread • INSTALL a new tire as
type. necessary. For additional
• Uneven tire wear information, <<204-04>>
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• Vehicle is unevenly
loaded or • Adjust the load.
overloaded.

• Incorrect toe
adjustment.
00>>
• Vehicle tends to pull • INSTALL new front suspension

to one side when • Damaged front
components as necessary. For
driven on a level suspension
surface components.
01>>
• INSTALL new rear suspension

• Damaged rear
suspension
components.
02>>
• SHIFT the transmission into

NEUTRAL while driving at no
more than 30 miles/hour (50
km/h) and turn the ignition to
• Steering gear valve
position I (engine OFF-
effort out of balance.
coasting). If the vehicle does
not pull with the engine off,
INSTALL a new steering gear.
For additional information,
<<211-02>>
• If the vehicle does drift with
the engine off, CROSS SWITCH
front wheel assemblies.
• If the vehicle pulls to the
opposite side, SWITCH wheels
that were on the rear to the
same side on the front.
• If the vehicle pull direction is
not changed, CHECK the front
suspension components and
toe adjustments. For
01>>
• Check the front and • ADJUST as necessary. For

rear brakes for additional information, <<206-
correct operation. 00>>
• INSTALL new rear suspension

• Check for bent rear components as necessary. For
suspension additional information, <<204-
components and for 02>>
damaged coil springs • INSTALL new front suspension
in the front components as necessary. For
suspension. additional information, <<204-
01>>
• Check the rear • TIGHTEN or INSTALL new

suspension for loose components as necessary. For
or worn suspension additional information, <<204-
components. 02>>
• CHECK underbody alignment.

• Incorrect underbody
alignment.
<<502-00>>
• CHECK the steering column is

• Lower steering free from interference from
column interference. the engine harness, sound
proofing or the floor covering.
• Poor returnability of • CHECK and ADJUST the tire

• Incorrect tire
the steering pressure. For additional
pressure.
• INSTALL a new tire as

• Incorrect tire size or
type.
• Steering column
• CHECK steering column upper
upper shroud fouling
shroud for fouling. ADJUST as
on the steering
necessary.
wheel.
• Steering column • INSTALL a new steering

universal joints column. For additional
binding. information, <<211-04>>
• CHECK the steering column

• Steering column shaft shaft floor seal for correct
floor seal binding. fitment and REFIT as
necessary.
• Steering column shaft • INSTALL a new steering

floor seal may be column shaft floor seal as
torn. necessary.
•
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CHECK tie-rod end for

excessive wear or tightness in
• Binding or damaged
ball joint. INSTALL a new tie-
tie-rods.
rod end. For additional
• INSTALL new front suspension

• Damaged or worn
front suspension
components.
01>>

• Incorrect toe
adjustment.
00>>
• CHECK steering system for

signs of steering fluid loss.
• Low power steering
• BLEED the power steering
fluid.
system. For additional
• Excessive steering information, <<211-00>>
efforts required
during low speed
• Damaged accessory • INSTALL a new accessory drive
manoeuvring and/or
drive belt tensioner. belt tensioner.
during parking
manoeuvres
• CHECK hose or cooler lines for
• Hose or cooler line correct routing.
restriction. • INSTALL a new hose as
necessary.
• BLEED the system. For
• Fluid aeration. additional information,
• CHECK the steering transducer

circuit. For additional
information, REFER to the
• Steering transducer wiring diagrams.
not closed - no feed • Carry out the electrical checks
voltage. and tests. For additional
Electrical Checks and Tests in
this section.
• CHECK the steering transducer

• Steering transducer wiring diagrams.
not closed - cable • Carry out the electrical checks
fault. and tests. For additional
this section.
• Steering control
• CHECK the SCM and INSTALL a
module (SCM)
new SCM as necessary.
defective.
• CHECK the power steering

• Power steering fluid Power Steering Pressure Test
delivery pressure or in this section.
flow too low. • INSTALL a new power steering
pump as necessary. For
02>>

• Internal steering gear Power Steering Pressure Test
leakage. in this section.
• INSTALL a new steering gear as
• Steering operation is • CHECK steering transducer

• Steering transducer
very heavy when and INSTALL a new steering
driving, but when open early. transducer as necessary.
stationary • Carry out the electrical checks
manoeuvring is good and tests. For additional
this section.
open early, steering • CHECK SCM and INSTALL a
control module (SCM) new SCM as necessary.
fault.
• Steering transducer • CHECK speedo circuit. For

open early, speedo additional information, REFER
signal error. to the wiring diagrams.

• Steering transducer fluid condition. For additional
not open, (no power information, REFER to the
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steering fluid flow). Power Steering Fluid condition

check in this section.
• CHECK the SCM and INSTALL a

new SCM as necessary.
• Carry out the electrical checks
• Steering operation is not open, steering
and tests. For additional
very light when control module (SCM)
driving, but when fault.
stationary this section.
manoeuvring is good
• Steering transducer • CHECK the speedo circuit. For

not open, speedo additional information, REFER
signal error. to the wiring diagrams.
• CHECK the power

steering fluid low • INSTALL a new power steering
pressure pipe for fluid low pressure pipe.
restricted flow.
• CHECK for an air leak into the

power steering system and
repair as necessary.
• Steering heavy
• Air in power steering • BLEED the power steering
operation during
system. system. For additional
rapid manoeuvring
information,
Power Steering System
Bleeding (57.15.02 )
pump for signs of steering
• Fluid loss at the fluid loss.
power steering pump • INSTALL a new power steering
shaft seal. pump as necessary. For
02>>

fluid loss.
delivery pressure or
flow too low.
in this section.
• INSTALL a new power steering
02>>

• CHECK the front wheel

• Incorrect steering
alignment. For additional
geometry.

• Steering heavy pressure. For additional
operation in one information, REFER to the
direction • Faulty rotary Power Steering Pressure Test
valve/seal. in this section.
• INSTALL a new steering gear as
• CHECK for clearance between

the tire and the wheel arch
• Tire fouling on the liner.
wheel arch liner. • Remove and refit the wheel
arch liner or INSTALL a new
wheel arch liner as necessary.
• Low power steering • CHECK steering system for

• Steering heavy
fluid. signs of steering fluid loss.
operation in both
directions system. For additional

fluid loss.
• Air in power steering
system.
02>>

• Fluid loss at the fluid loss.
power steering pump • INSTALL a new power steering
shaft seal. pump as necessary. For
02>>
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fluid loss.
delivery pressure or
flow too low.
in this section.
02>>

• CHECK the speedo circuit. For

• Incorrect
• Steering operation additional information, refer
speedometer signal.
varies from heavy to to the wiring diagrams.
light when driving at
constant speed • CHECK the steering transducer
• Steering transducer information, refer to the
cable/connection wiring diagrams.
faulty or grounded. • Carry out the electrical checks
and tests. For additional
this section.

• Steering wheel varies

• Steering column • INSTALL a new steering
from light to heavy
universal joints column. For additional
two times per
binding. information, <<211-04>>
revolution
• CHECK for wear or failure of

• Seized or damaged suspension bushes and ball
steering components. joints. For additional
Noise
• CHECK accessory drive belt

• Incorrect accessory
condition and INSTALL a new
• Accessory drive drive belt tension or
accessory drive belt as
belt squeal accessory drive belt
glazed.
• CHECK accessory drive belt

condition and INSTALL a new
• Chirp noise in the • Loose or worn
accessory drive belt as
steering pump accessory drive belt.

fluid.
• Power steering • CHECK for leaks. REPAIR as

pump noisy necessary.
• Power steering pump
worn or otherwise
defective.
Power Steering Pressure Test in
this section.
02>>

• Aerated fluid. information,
Power Steering System
Bleeding (57.15.02 )
• Whine type noise

• CHECK for leaks. REPAIR as
necessary.
• Power steering pump.
02>>

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fluid.
• DRAIN the power steering

• Noise during
• Water contamination system.
steering gear
to the power steering • BLEED the power steering
movement
fluid. system. For additional
• CHECK and reposition power

• Cavitation due to
steering feed hoses and
restricted power
INSTALL new hoses as
steering feed hose.
necessary.

fluid.
• CHECK power steering coupling

• Continuous noise
and power steering pump.
coupling or power steering
drive loose.
02>>
• Incorrect accessory • CHECK accessory drive belt

drive belt tension or condition and INSTALL a new
accessory drive belt accessory drive belt as
glazed. necessary. For additional
• CHECK and TIGHTEN the power

steering pump drive pulley
retaining bolts as necessary.
drive pulley loose.
<<303-03>>

pump retaining bolts and
retaining bolts loose.
TIGHTEN as necessary.
• Power steering • CHECK and reposition power

hose/pipe in contact steering hoses/pipes, INSTALL
with the vehicles body. new hoses/pipes as necessary.
• CHECK and reposition power

• Power steering hose
steering hose, replace hose as
restricted/twisted.
necessary.
Vibration
• INSTALL a new tie-rod end.

• Loose/worn tie-
rods.
<<211-03>>
• Feedback (knocking noises CAUTION: DO NOT attempt

in the steering gear) - to adjust the steering gear yoke.
condition where Failure to follow this instruction
roughness is felt in the will result in the steering gear
steering wheel by the
• Steering gear warranty to become invalid.
driver when the vehicle is
driven over rough retaining bolts
surfaces loose or damaged.

steering gear retaining bolts.
• INSTALL new retaining bolts
as necessary. For additional
• TIGHTEN or INSTALL new
• Loose suspension
components as necessary.
bushing, bolts or
ball joints.
<<204-01>>
CAUTION: DO NOT attempt

to adjust the steering gear yoke.
Failure to follow this instruction
will result in the steering gear
• Steering column warranty to become invalid.
retaining bolts
loose.

steering column retaining
bolts/nuts and pinch bolts if
required. For additional
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• CHECK for steering column

for wear in the universal
• Excessive wear in joints and bearings. If wear is
steering column present, INSTALL a new
assembly. steering column as
• CHECK for road wheel

imbalance.
• CHECK for relevant SERVICE
• Road wheel
BULLETINS/SERVICE ACTIONS
imbalance.
for the vehicle on Jaguar
Communications Online
(JCOL) or in hard copy form.
• Nibble (Shimmy)
Oscillation of the steering • CHECK for relevant SERVICE
wheel (not vertical which BULLETINS/SERVICE ACTIONS
• Steering wheel
is SHAKE). This is driven by for the vehicle on Jaguar
replacement.
road wheel imbalance. Communications Online
• CHECK for relevant SERVICE

BULLETINS/SERVICE ACTIONS
• Rack replacement. for the vehicle on Jaguar
Communications Online
Description of 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 rubbing 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.
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Tap
Light, hammering sound like tapping pencil on edge of table. May be rhythmic or intermittent.
Weep
Continuous mid-range sound (lower frequency than squeal, higher frequency than groan).
Whir/Whine
High-pitched buzzing sound, like an electric motor or drill.
Whistle
Sharp, shrill sound, like wind passing a small opening.
Description of 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 the end of 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 test 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. Is generally
caused by interference between moving components such as the steering wheel to steering column
shroud.
Grunt (Squawk)
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 load 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.
Rack Knock (Rack Slap)
Rack 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. Rack 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 with 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 parts, movable and flexible parts, 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 parts.
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
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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 for slow steering inputs. 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 Ripple
Torque ripple is a concern with Electric Power Steering (EPS) systems. Torque ripple is most evident
at static-park steering the wheel very slowly from lock to lock. Torque ripple is primarily caused by
motor commutation.
Torque/Velocity Variation (Phasing/Effort Cycling)

Steering wheel torque variation occurring twice in one revolution is normally as a result of problems
with the lower steering column (intermediate shaft), but foul conditions generally result in either
constant stiffness or single point stiffness. Depending upon the orientation of the joints, the steering
can feel asymmetric (torque falling off in one direction and rising in the other) or else it can simply
have pronounced peaks and troughs as the steering moves from lock to lock.
Wheel Fight (Kick Back)

Wheel fight is excess feedback of sudden road forces through the steering system and back to the
driver. It is evaluated at all vehicle speeds over cobblestones, rough roads, and potholes. The tires,
wheels, and suspension generate forces into the steering systems. Steering friction, hydraulic
damping, hydraulic compliance, mechanical compliance, steering ratio, and assist gain all affect how
much is transmitted to the driver.
Steering Linkage
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.
3.
The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional
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. For additional
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211-02 : Power Steering
Specifications
Specifications

Power steering fluid cooler retaining bolts 7 - 62
Power steering pump retaining bolts 25 18 -
Lower steering column slider pinch bolt 30 22 -
Lower steering column to steering gear pinch bolt 30 22 -
Steering gear retaining bolts 100 74 -
Power steering pump supply line - vehicles with petrol engines 15 11 -
Power steering pump supply line - vehicles with 2.7L diesel engine 22 16 -
Power steering control valve actuator retaining bolt 2 - 18
Steering gear supply and return lines retaining bolt 10 7 -
Power steering fluid reservoir retaining bolts 10 7 -
Power Steering
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1 — Lower steering column
2 — Power steering fluid reservoir
3 — Power steering pump
4 — Power steering fluid cooler
5 — Power steering lines
6 — Steering gear
The vehicle uses a rack and pinion type, variable ratio steering gear with speed proportional
servotronic. The power steering pump is belt driven on all model variants and the power
steering oil cooler is of a tube and fin type and is mounted to the front of the cooling pack.
A variable steering rack ratio reduces the amount of turns from lock to lock to improve
parking maneuvers without loosing any steering feel at higher speeds.
The steering assistance decreases smoothly at a calibrated rate to increase the steering efforts
required as vehicle speed increases. The steering efforts are controlled by the actuator
position, which in turn is controlled electronically by the speed proportional servotronic curve
which is incorporated within the Generic Electronic Module (GEM).
Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of
the system. New fluid from a sealed container must be used.
NOTE:
If the steering gear, pump or cooler are being replaced for leakage or noise related issues
and there is no evidence of fluid contamination, there is no need to replace the reservoir.
Power Steering Pump to Steering Gear Pressure Line – Armoured XJ
Due to the installation of the uprated power steering pump the power steering pump to steering
gear pressure line has to be modified to enable it to be connect to the power steering pump.
Power Steering
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Power Steering Control Valve Actuator

(57.10.32)
Removal
2 . Disconnect the actuator electrical connector.
3 . Remove the actuator.
Drain the fluid into a suitable container.
Remove and discard the O-ring seals and filter.
Installation
Install new O-ring seals and filter.
2
. CAUTION: Make sure both the retaining bolts are tightened an even number of
turns.
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Tighten to 3 Nm.
4 . Bleed the power steering system. <<211-00>>

Power Steering Fluid Cooler (57.15.11)
Removal
All vehicles
1 Remove the Front Bumper Cover.
. For additional information, refer to Front Bumper Cover - VIN Range: G00442->H18679
(76.22.78)
2 . Remove the lower cowl.
3
. CAUTION: If power steering fluid comes into contact with the paintwork, the
affected area must be immediately washed down with cold water.
CAUTION: Cap the power steering line to prevent loss of fluid and prevent dirt
ingress.
Disconnect the power steering fluid cooler lines.

4 . Remove the power steering fluid cooler.

5 . NOTE:

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Remove the power steering fluid cooler.
Installation
Tighten to 7 Nm.
2 NOTE:
.
If the cooler is being replaced for leakage or noise related issues and there is no
evidence of fluid contamination, there is no need to replace the reservoir.
Power Steering Fluid Reservoir -
3.0L/3.5L/4.2L (57.15.08)
Removal
1
CAUTION: Cap the power steering lines to prevent loss of fluid and dirt ingress.

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2
CAUTION: Cap the power steering lines to prevent loss of fluid and prevent dirt
ingress.
NOTE:
Drain fluid into a suitable container.
Remove the power steering fluid reservoir.

Detach the power steering fluid reservoir lines.
Installation
2 . Bleed the power steering system. <<211-00>>

Power Steering Fluid Reservoir - 2.7L
Diesel (57.15.08)
Removal
1 . Remove the air cleaner.
For additional information, refer to Air Cleaner (19.10.05)
2
NOTE:
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Clamp the power steering lines to prevent loss of fluid and dirt ingress.
NOTE:
Detach the power steering fluid reservoir lines.
3 . Detach the air pipe from the reservoir.
4 . Remove the power steering fluid reservoir.
Remove the power steering fluid reservoir retaining bolt.

Installation
1
Tighten to 10 Nm.
2 . Bleed the power steering system.

For additional information, refer to Power Steering System Bleeding (57.15.02 )
Power Steering Pump - 3.0L (57.20.14)
Removal
1 Remove the accessory drive belt.
. For additional information, refer to Accessory Drive Belt - 3.0L, VIN Range: G00442->G45703
(12.10.40)
For additional information, refer to Accessory Drive Belt - 3.0L, VIN Range: G45704->G99999
(12.10.40)

3 . Remove the left-hand front wheel and tire.

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For additional information, refer to Air Deflector (76.11.41)
5 . Remove the power steering pump lower retaining bolts.
7
. CAUTION: Cap the power steering line to prevent loses of fluid and prevent dirt
ingress.
CAUTION: If power steering fluid comes into contact with the paintwork, the
NOTE:
Disconnect the power steering reservoir to power steering pump supply line.
8
. CAUTION: Cap the power steering lines to prevent loses of fluid and prevent dirt
ingress.
NOTE:
Disconnect the power steering pump to steering gear supply line.

9 . Remove the power steering pump.
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Installation
Tighten to 25 Nm.
2 . NOTE:
Tighten to 15 Nm.
4 NOTE:
.
If the pump is being replaced for leakage or noise related issues and there is no evidence
of fluid contamination, there is no need to replace the reservoir.
Published: Feb 19, 2008
Power Steering Pump - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8

(57.20.14)
Engine support beam.

303-021
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Engine lifting brackets

303-749
Removal
All vehicles
1 . Remove the air cleaner assembly.

2 Detach the accessory drive belt.

. For additional information, refer to Accessory Drive Belt - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8
(12.10.40)
3 . Remove the left-hand front wheel and tire.


5 . Remove the left-hand engine mount nut.

6
.
CAUTION: Cap the power steering line to prevent loss of fluid and prevent dirt ingress.
CAUTION: If power steering fluid comes into contact with the paintwork, the affected area must be
NOTE:
7 . Remove the air conditioning (A/C) compressor upper bolt.

. For additional information, refer to Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703
(19.70.04)
For additional information, refer to Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999
(19.70.04)
All vehicles
10 . Install the left-hand engine lifting eye.
11 . Using the special tools, raise the engine to a suitable height.

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12 . Raise the vehicle.
13 . Detach the A/C compressor.

Remove the 2 A/C compressor lower bolts.
14 . Remove the 2 power steering pump lower bolts.
16
.
CAUTION: Cap the power steering lines to prevent loss of fluid and prevent dirt ingress.
CAUTION: If power steering fluid comes into contact with the paintwork, the affected area must be
NOTE:
Disconnect the power steering pump to steering gear pressure line.

17
.
CAUTION: Care must be taken to make sure that the coolant hoses and A/C pipes are not damaged
during the removal of the power steering pump.
NOTE:
The power steering pump rear upper bolt cannot be removed with the power steering pump located on the dowels.
The power steering pump must be detached and rotated to allow the bolt to be removed.
Remove the power steering pump.

Installation
1
.
CAUTION: Care must be taken to make sure that the coolant hoses and A/C pipes are not damaged during
the installation of the power steering pump.
NOTE:
The power steering pump rear upper bolt must be installed before the power steering pump is located on the
dowels.
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3 . Install a new O-ring seal.

Tighten to 15 Nm.
8 NOTE:
. If the pump is being replaced for leakage or noise related issues and there is no evidence of fluid contamination,
there is no need to replace the reservoir.
In some cases where the fluid clearly contains particulate matter, and the system continues to function, flush the system
with fresh fluid and replace the reservoir, as there is the possibility that the reservoir internal filter may be damaged or
faulty.
9 . Bleed the power steering system.

Power Steering Pump - 2.7L Diesel
(57.20.14)
Accessory Belt Detensioner

303-703
Removal
1 . Remove the air cleaner assembly.
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.
Using the special tool, rotate the accessory drive belt tensioner counter
1)
clockwise.
2) Detach the accessory drive belt.

5 . Detach the accessory drive belt from the power steering pump pulley.
6
. CAUTION: Cap the power steering lines to prevent loss of fluid and dirt ingress.
Disconnect the power steering pump to steering gear pressure line.
7 . Remove the power steering pump retaining bolts.

8 . Reposition the power steering pump forwards.
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9
. CAUTION: Cap the power steering lines to prevent loss of fluid and dirt ingress.
Remove the power steering pump.
Detach the hose.

Installation
Tighten to 22 Nm.
Install new O-ring seal.
Lubricate the new O-ring seal with power steering fluid.
3 NOTE:
.
If the pump is being replaced for leakage or noise related issues and there is no evidence
of fluid contamination, there is no need to replace the reservoir.
Steering Gear Bushing (57.10.30)
Steering gear lower bush remover and installer.

204-273
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Steering gear upper bush remover and installer.

211-271
Steering gear bush remover and installer (Nut)

204-274
Bearings
JAG-061
Steering gear bush remover and installer (Bolt)

204-275
Removal
1 . Center the steering wheel.
Lock in position and remove the ignition key.
3 . Disconnect the power steering control valve actuator electrical connector.
4 . Detach the lower steering column.
Remove the steering gear shaft pinch bolt.

6 . Using the special tools, remove the steering gear lower bushes.
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7 . Using the special tools, remove the steering gear upper bush.
Installation
1 . NOTE:
Apply a thin film of lubricant to the steering gear bushes.
Using the special tools, install the steering gear lower bushes.
2 . NOTE:
Apply a thin film of lubricant to the steering gear bush.
Using the special tools, install the steering gear upper bush.
Tighten to 100 Nm.
4 . Attach the lower steering column.

Install the steering gear shaft pinch bolt.
Tighten to 35 Nm.
5 . Connect the power steering control valve actuator electrical connector.

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211-03 : Steering linkage
Specifications
Specifications

Tie-rod end retaining nut 75 55 -
Tie-rod end lock nut 55 41 -
Steering Linkage
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1 — Tie-rod end retaining nut
2 — Tie-rod end
3 — Tie-rod end lock nut
4 — Tie-rod
5 — Tie-rod end boot
The left and right-hand tie-rod assemblies:
• Transmit steering forces from the steering gear to the wheel knuckles.
• Provide front road wheel toe setting by adjustment of the threaded outer tie-rod ends.
NOTE:
Steering geometry adjustments must only be carried out with the vehicle on turn plates to
allow the wheels to move during adjustment.
The left and right-hand steering rack boots:
• Are installed between the steering rack and the tie-rod ends.
• Are of the concertina type.
• Are to prevent the ingress of foreign matter.
Steering Linkage
For additional information, refer to<<211-00>>
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Steering Gear Boot (57.10.29)

Removal
1 . Remove the tie rod end.
2 . Remove and discard the tie-rod boot outer retaining clamp.
3 . Remove and discard the tie-rod boot inner retaining clamp.
4
. CAUTION: Make sure the area is washed down thoroughly before removing the
steering gear boot.
Remove the tie-rod boot.

Installation
1.
CAUTION: Make sure the tie-rod is clean before installing the steering gear boot.
NOTE:
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Install new retaining clamps.

Tie Rod End (57.55.02)
Removal
1 . Remove the front wheel and tire. <<204-04>>
2 . Loosen the tie-rod end lock nut.
3
. CAUTION: Prevent the tie-rod end ball joint ball pin from rotating. Failure to do so
may result in damage to the tie-rod end ball joint boot.
Remove the tie-rod end retaining nut.
4 . NOTE:
Make a note of the number of turns required to remove the tie-rod end.
Remove the tie-rod end.

Installation
1 NOTE:
.
Make sure the tie-rod end is installed on the tie-rod by the same amount of turns used
to remove it.
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Install the tie-rod end.
2
. CAUTION: Prevent the tie-rod end ball joint ball pin from rotating. Failure to do so
may result in damage to the tie-rod end ball joint boot.
CAUTION: Make sure the mating surfaces are free from dirt and lubricant.
Install the tie-rod end retaining nut.
Tighten to 75 Nm.
3 . Tighten the tie-rod end lock nut.
Tighten to 55 Nm.
4 . Check the front toe adjustment. <<204-00>>

211-04 : Steering Column
Specifications
Specifications

Steering wheel retaining bolt 65 48 -
Upper steering column pinch bolt 35 26 -
Lower steering column pinch bolt 35 26 -
Upper steering column retaining nuts 30* 22 -
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Lower steering column retaining nuts 9 - 80

Tilt solenoid retaining bolts 1 - 9
Telescopic solenoid retaining bolts 1 - 9
Telescopic housing retaining bolts 8 - 71
Steering column lower shroud retaining screws 3 - 27
*If you are re-using this fixing on a vehicle built prior to VIN H16709, then tighten to 25 Nm.
If you are replacing a fixing, then you must tighten to 30 Nm.
Steering Column
Upper column
1 — Steering column lock actuator
2 — Steering column
3 — Telescope solenoid
4 — Tilt solenoid
5 — Tilt/Telescopic motor
Lower column
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The steering lock actuator is secured to the lower part of the adjustable steering column and consists
of a locking pin and an electric motor. The electric motor has a hall effect sensor which detects lock
and unlock states, this makes the lock actuator more sensitive for the time taken to lock and unlock.
A bus controller chip has also been added to cope with the high integrity bus traffic. The column is
locked and unlocked by inserting and removing the ignition key respectively. The instrument cluster
provides control for the column adjustment by means of a power tilt/telescope switch on the side of
the steering column lower shroud, memory recall and easy entry or exit.
The upper column is a tilt and telescopic type consisting of one electric motor to tilt and telescope
the steering column. The steering column has 50 mm of telescopic movement and 5 degrees of tilt
adjust. The power tilt and telescope function allows the driver to manually set the steering column
position by using the power tilt/telescope switch, regardless of the ignition switch position. When
moving the column, the switch will only allow one directional movement at a time.
Crash load absorption is provided by a unique peeling tube mechanism. If an accident occurs and the
driver is not wearing a safety belt the steering column must be replaced. The steering column must
also be replaced if the air bag is deployed.
The upper steering column will need to be calibrated if the column or the instrument cluster is
renewed. Calibration is carried out using the Jaguar approved diagnostic system. No routine
maintenance of the steering wheel and driver airbag is required. Any setting of steering wheel for
misalignment must be achieved by adjusting the tie rods.
The lower steering column has the advantage of having a swing link mechanism, this is fitted to
provide movement to occur in the steering system when travelling over bumps and obstacles. This
system improves the driver feel of the steering system as vibrations through the suspension
assembly are greatly decreased.
The lower steering column swing link will need to be calibrated if the lower slider pinch bolt has been
released or removed and if the lower column is replaced. No routine maintenance of the swing link
or lower universal joint is required as these components are sealed with a special lubricant and high
temperature resistant seals.
Steering Column
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Ignition Switch Lock Cylinder (57.40.29)

Removal
Vehicles with ignition switch lock cylinder interlock cable
1
. CAUTION: When disconnecting the 'J' gate make sure that no damage occures to
the interlock cable.
Remove the transmission selector lever. <<307-05>>
All vehicles
2 . Remove the instrument panel lower trim.
3 . Remove the steering column lower shroud.
4
. CAUTION: If excessive force is used to remove the ignition switch lock cylinder
shroud damage may occur to the instrument panel.
Remove the ignition switch lock cylinder shroud.
5
. CAUTION: If excessive force is used to remove the ignition switch lock cylinder
housing damage may occur to the instrument panel.
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Using a suitable tool, detach the ignition switch lock cylinder housing.

Vehicles with ignition switch lock cylinder interlock cable
7.
CAUTION: Make sure the ignition switch lock cylinder interlock cable is not
crimped.
Remove the ignition switch lock cylinder housing.
All vehicles
8 . Remove the ignition switch lock cylinder housing.
9 . Remove the ignition switch lock cylinder.
1) Turn ignition key to position one.
2) Release the retaining plunger.
3) Remove the ignition switch lock cylinder.

Installation
Tighten to 3 Nm.
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Steering Column (57.40.01)
Removal
1 . If possible make sure that the steering column is fully lowered and fully extended.
2 . Remove the clockspring.

For additional information, refer to Clockspring (86.65.92)
3 . Disconnect the steering wheel rotation sensor electrical connector.
4 . Remove the steering wheel rotation sensor.
5 . Detach the left-hand multifunction switch wiring harness.

6 . Detach the left-hand multifunction switch wiring harness.
7 . Detach the right-hand multifunction switch wiring harness.

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8 . Detach the right-hand multifunction switch wiring harness.
9 . Disconnect the steering column electrical connector.

10 . Remove the steering column pinch bolt.
11 . Detach the steering column.
Support the weight of the steering column.
12 . Remove the steering column.
Disconnect the steering column lock actuator electrical connector.

Installation
1 . Install the steering column.
Connect the steering column lock actuator electrical connector.

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2 . NOTE:
Tighten the retaining nuts in the sequence shown.
Attach the steering column.
Tighten to 30 Nm.
NOTE:
If you are re-using this fixing on a vehicle built prior to VIN H16708, then tighten to 25 Nm. If you
are replacing a fixing, then you must tighten to 30 Nm.
3.
CAUTION: Make sure the pinch bolt is correctly installed.
Tighten to 35 Nm.
4 . Connect the steering column electrical connector.
5 . Attach the left-hand multifunction switch wiring harness.

6 . Attach the left-hand multifunction switch wiring harness.
7 . Attach the right-hand multifunction switch wiring harness.

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8 . Attach the right-hand multifunction switch wiring harness.
9 . Install the steering wheel rotation sensor.

10 . Connect the steering wheel rotation sensor electrical connector.
11 . Install the clockspring.

For additional information, refer to Clockspring (86.65.92)
12 . Reposition the steering column back to its original position.

Steering Column Lower Shaft (57.40.05)
Removal
1 . Centralize the steering wheel.
Lock in position and remove the ignition key.

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3 . Detach the lower steering column universal joint from the steering gear.
4 . Remove the upper steering column pinch bolt.

5 . Detach the lower steering column shaft from the upper steering column.
6 . Remove the lower steering column support bearing retaining nuts.
7 . Remove the lower steering column.

Installation
Tighten to 9 Nm.
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4 . Carry out the lower steering column setting procedure. <<211-00>>

Steering Wheel (57.60.01)
Locking Tool
211-326
Removal
1 . Remove the driver air bag module.
For additional information, refer to Driver Air Bag Module (76.73.39)
3
. CAUTION: Position the front wheels in a straight ahead position and centralize
steering wheel. Failure to follow this instruction may result in damage to the clockspring.
CAUTION: Make sure no damage is occured to the electrical connectors. Failure to

Remove the steering wheel.

4
. CAUTION: Failing to install the special tool to the clockspring may result in damage
to the vehicle.
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CAUTION: Do not allow the clockspring to unwind.
Install the special tool to the clockspring.
Installation
2
. 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.
Install the steering wheel.
3
. 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.
Tighten to 65 Nm.
Steering Column
Disassembly
1 . Remove the Steering Column Lock Actuator. <<211-05>>
2 . Detach the wiring harness .

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3 . Detach the steering column electrical connector housing.
4 . Remove the steering column electrical connector housing.

• Disconnect the electrical connectors.
5 . NOTE:
Remove and discard the tilt solenoid retaining bolts.
Remove the tilt solenoid.
• Detach the tilt solenoid wiring harness.
6 . NOTE:
Remove and discard the telescopic solenoid retaining bolts.
Remove the telescopic solenoid.

• Remove and discard the retaining strap.
7 . Remove the tilt/telescopic motor retaining pin.

• Remove and discard the retaining pin and washers.
8 . Remove and discard the telescopic housing retaining bolts.

9
. CAUTION: Make sure the potentiometer sliders are fully disconnected.
Failure to follow this instruction may result in component damage.
Reposition the tilt/telescopic motor.

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10 . NOTE:
The tilt/telescopic motor will only need to be rotated if the motor is inoperative.
Rotate the tilt/telescopic motor as shown.

• Press the telescopic solenoid engagement pin.
11 . Remove the tilt/telescopic motor.

Assembly
1
. CAUTION: Make sure the potentiometer sliders are correctly located.
Failure to follow this instruction may result in component damage.
Install the tilt/telescopic motor.

• Reposition the tilt/telescopic motor to the steering column.
2 . Install new telescopic housing retaining bolts.

3 . Install the supplied spacer between the tilt/telescopic motor and steering column.
4 . Install a new tilt/telescopic motor retaining pin and washers.
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5 . NOTE:
Install new tilt solenoid retaining bolts.
Install the tilt solenoid.

• Attach the tilt solenoid wiring harness.
6 . NOTE:
Install new telescopic solenoid retaining bolts.
Install the telescopic solenoid.

• Install a new retaining strap.
7 . Install the steering column electrical connector housing.
• Connect the electrical connectors.
8 . Attach the steering column electrical connector housing.
9 . Attach the wiring harness.
10 . Install the Steering Column Lock Actuator. <<211-05>>

211-05 :Steering Column Switches

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1 Trip Button
2 Side Lamps/Head Lamps/Auto Lamps and Exit Delay Collar
3 Direction Indicator/Main Beam Switch
4 Wiper Switch
5 Intermittent Wipe Time Delay Collar
6 Wash/Wipe Button
The multifunction switch is situated on the steering column and consists of the wiper switch and the
direction indicator/main beam switch.
Multifunction switch left-hand
The Multifunction switch left-hand is on the left-hand side of the steering column and controls the
following functions.
Direction Indicators
The direction indicators:
• operate when the ignition switch is in position II.

• are operated by moving the multifunction switch up or down until it latches in position, to
indicate a right or left turn respectively.
• can be operated while the multifunction switch is held against spring pressure before
reaching the latch position.
• cancel automatically upon completion of a turn. The multifunction switch then returns to the
center position.
An audible ticking and a flashing green warning lamp on the instrument cluster indicate that the
direction indicators are operating. If an indicator bulb fails, the warning lamp and ticking operate at
twice the normal rate and a message will appear on the instrument cluster message center.
Side Lamps
The Side Lamp function is operated by rotating the multifunction switch collar one position counter
clockwise this will then activate the side lamps.
Head Lamps
The Head Lamp function is operated by rotating the multifunction switch collar two positions counter
clockwise this will then activate the head lamps.
Main Beam
The Main Beam multifunction switch has one pull and one push position. Pulling the main beam
multifunction switch toward the driver will cause the main beam lamps to flash. The main beam
lamps can be flashed with the ignition on or off and will remain activated as long as the multifunction
switch is held.
Pushing the multifunction switch away from the driver to the latch position will operate main beam
lamps continuously if the head lamps are on.
Auto Lamps
The Auto Lamp function is operated by rotating the multifunction switch collar to the auto position.
The head lamps will then operate automatically when the sunload sensor detects low light levels.
Exit Delay
The Exit Delay time can be varied by rotating the multifunction switch collar. Turning the collar
clockwise will decrease the exit delay time and turning the collar counter clockwise will increase the
exit delay time. The head lamps will stay for a set period of time ranging from 10 seconds to 2
minutes.
Trip Function
If the Trip Function switch is pressed once, a menu in the instrument cluster message center will be
displayed and cycle though an option menu. Pushing and holding the switch resets the mileage
calculated in a trip cycle. The trip mileage is displayed in the instrument cluster message center.
Multifunction switch right-hand

The Multifunction switch right-hand is on the right-hand side of the steering column and controls the
following functions.
Flick Wipe
Flick wipe operation:
• is obtained by pulling the multifunction switch towards the driver.

• features a single wipe at normal speed if the multifunction switch is released immediately.
• features continuous wipe action at fast speed while the multifunction switch position is held.
Intermittent Wipe
In the intermittent wipe position:
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• the wiper operates intermittently, with a variable time delay between wipes.
• the time delay can be varied by rotating the multifunction switch collar, turning the collar
clockwise will increase the wiper time delay and turning the collar counter clockwise will
decrease the wiper time delay. The switch has 7 positions and wiper delay varies between 2-
20 seconds wiper delay.
Slow Speed Wiper

In the slow speed position:
• the wiper operates continuously at slow speed.
High Speed Wiper

In the high speed position:
• the wiper operates continuously at high speed.
Windscreen Wash/Wipe
The wash/wipe function:
• is operated by the button at the end of the multifunction switch.

• operates the washers and wiper, while the button is pressed, for up to 20 seconds.
• provides an additional three sweeps of the wiper after the button is released.
• wash function is disabled if the Washer Fluid Low message is displayed, but wipe operation is
still available.
Head lamp Power Wash (if equipped)

The headlamp power wash function:
• operates only when the head lamps are on and the windscreen wash/wipe button is pressed.
• provides two short bursts of approximately 3 seconds apart to the head lamps.
• the powerwash cycle will continue for up to 20 seconds if the wash/wipe button is held.
The headlamp powerwash will operate the first time the wash/wipe button is pressed and thereafter
every sixth succeeding wash/wipe operation.
Moisture Sensitive Wiping

The moisture sensitive wiping function:
• operates if the collar on the multifunction is set to the auto position.

• operates if moisture on the windscreen is detected.
• operates the wipers at varied speeds depending on the amount of moisture detected on the
windscreen.
• operates the wipers at varied speeds depending on the speed of the vehcle.

For a detailed description of the Steering Column Switches, refer to the relevant Description and
Operation sections in the workshop manual.

2 . Visually inspect for obvious signs of electrical damage.

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Electrical
• Fuses/Relays
• Damaged, Loose or Corroded Connector(s)
• Damage to Wiring Loom/Incorrect Location, Stretched or Taught
2 . If the cause is not visually evident, verify the symptom and refer to the Jaguar approved diagnostic
system.
DTC Index
Steering Column Lock Module
NOTE:
If the control module/component is suspect and the vehicle remains under manufacturer
warranty, refer to the Warranty Policy and Procedures manual (section B1.2), or determine if
any prior approval program is in operation, prior to the installation of a new
module/component.
NOTE:
three decimal places and with a current calibration certificate. When testing resistance, always
NOTE:
Check and rectify basic faults before beginning diagnostic routines that involve pinpoint tests.
NOTE:
NOTE:
If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an
terminals.
DTC Description Possible Causes Action
Steering column lock module electronic

failure. Suspect faulty module, check
• Steering column lock
B1342 ECU is defective and install as required, refer to the new
module - failure
module installation note at the top of
the DTC Index
Steering column lock module electronic

failure. Configure steering column lock
Instrument • Stored vehicle
module (Must enable SCLM and
B2162 Cluster ID does identification details
incorrect instrument cluster to transfer ID) i.e.
not match
Configure as for replacement new
module
Steering column lock module

Unable to • Steering column lock
mechanical failure. Suspect faulty
confirm module - failure (cannot
B2168 module, check and install as required,
unlocked complete unlock
command) refer to the new module installation
condition
note at the top of the DTC Index
Steering column lock module
Unable to • Steering column lock mechanical failure. Suspect faulty
B2169 confirm locked module - failure (cannot module, check and install as required,
condition complete lock command) refer to the new module installation
note at the top of the DTC Index
Steering column lock module failure.

Hall Sensor
• Steering column lock Suspect faulty module, check and install
Failed in
B2375 module - hall sensor as required, refer to the new module
Unlocking failure installation note at the top of the DTC
Direction
Index
• Steering column lock Steering column lock module failure.

module - failure (Lock : Suspect faulty module, check and install
Lock Cycle -
B2376 Time between Unlock as required, refer to the new module
Timing Invalid Edge to Lock edge is too installation note at the top of the DTC
short) Index
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• Steering column lock Steering column lock module failure.

module - failure (Unlock : Suspect faulty module, check and install
Unlock Cycle -
B2377 Time between Lock Edge as required, refer to the new module
Timing Invalid to Unlock edge is too installation note at the top of the DTC
short) Index
Steering column lock module failure.

Hall Sensor
• Steering column lock Suspect faulty module, check and install
Failed in
B2378 module - hall sensor as required, refer to the new module
Locking failure installation note at the top of the DTC
Direction
Index
SCLM not • Steering column lock

Configure steering column lock module
configured module is not configured
B2379 (Must enable SCLM and instrument
(inhibited (set after first unlock
command) cluster to transfer ID)
mode)
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.
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Steering Column Multifunction Switch LH
(86.65.78)
Removal
1 Remove the steering column lower cowl.
.
Remove the 2 screws.
If installed, disconnect the steering column and foot pedal control switch
electrical connector.
2 . Remove the steering column upper cowl.
Remove the 3 screws.

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3 . Remove the steering column multifunction switch.
Depress the 2 clips.
Installation
1.
CAUTION: Make sure the electrical harness is not trapped during the installation.

Steering Column Multifunction Switch RH
(86.65.41)
Removal
1 . Remove the instrument panel lower trim.
2 . Detach the steering column lower shroud.
3 . Remove the steering column upper shroud.
4 . Disconnect the steering column multifunction switch RH electrical connector.

5 . Remove the steering column multifunction switch RH switch.
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Installation
3. POWERTRAIN
303 : Engine
303-00 : Engine System – General Information
Specifications
Specifications
General specifications - Vehicles 3.0L engine.
Item Specification
Displacement in liters 2.967
Number of cylinders 6
Bore and stroke (mm) 89.0 x 79.5
Compression ratio 10.5:1
General specifications - Vehicles 3.5L engine.
Item Specification
General specifications - Vehicles with 4.2L engine without supercharger.
Item Specification
General specifications - Vehicles with 4.2L engine with supercharger.
Item Specification
Cylinder Head and Valve Train - Vehicles with 3.0L engine
Item Specification
Valve guide inner diameter (mm) 5.514 - 5.544
Intake valve effective length (mm) 90.13 - 90.93
Exhaust valve effective length (mm) 89.68 - 89.88
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Valve stem to guide clearance intake - diametrical (mm) 0.022 - 0.067

Valve stem to guide clearance exhaust - diametrical (mm) 0.035 - 0.08
Valve head diameter intake (mm) 34.85 - 35.15
Valve head diameter exhaust (mm) 29.85 - 30.15
Intake valve face angle degree 45.75°
Exhaust valve face angle degree 45.25°
Valve stem diameter intake (mm) 5.477 - 5.492
Valve stem diameter exhaust (mm) 5.464 - 5.479
Valve spring free length (mm) 44.2
Valve spring installed height (mm) 33.41
Camshaft lobe lift intake (mm) 9.367
Camshaft lobe lift exhaust (mm) 9.461
Camshaft end play (mm) 0.07 - 0.15
Camshaft journal to cylinder head bearing surface clearance diametrical (mm) 0.025 - 0.076
Camshaft journal diameter standard runout limit (mm) 0.04
Camshaft journal diameter standard out of round (mm) 0.013
Cylinder Head and Valve Train - Vehicles with 3.5L engine
Item Specification
Valve guide inner diameter (mm) 5.02
Valve stem to guide clearance intake - diametrical
0.012 - 0.067
(mm)
Valve stem to guide clearance exhaust - diametrical
0.02 - 0.075
(mm)
Intake valve face angle degree 45° 15'
Exhaust valve face angle degree 45° 15'
Valve spring free length (mm) 45.45 - 46.2
• Front bearing 0.035 - 0.095
Camshaft journal to cylinder head bearing surface
• Other bearings 0.025 - 0.085
clearance diametrical (mm)
• Center bearing to outer

bearing's 0.07
Camshaft journal diameter standard runout limit (mm) • Other bearing to outer
bearing's 0.05

Maximum permitted cylinder head warp (mm) 0.125
Cylinder Head and Valve Train - Vehicles with 4.2L engine without supercharger
Item Specification
0.012 - 0.067
(mm)
0.02 - 0.075
(mm)
• Center bearing to outer

bearing's 0.07
Camshaft journal diameter standard runout limit (mm) • Other bearing to outer
bearing's 0.05

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Cylinder Head and Valve Train - Vehicles with 4.2L engine with supercharger
Item Specification
0.012 - 0.067
(mm)
0.02 - 0.075
(mm)
Camshaft journal diameter standard runout limit (mm) • Center bearing to outer
bearing's 0.07
• Other bearing to outer
bearing's 0.05

Lubrication system - Vehicles with 3.0L engine
Capacity Liters
Engine oil with filter 6.5
Lubrication system - Vehicles with 3.5L engine
Capacity Liters
Lubrication system - Vehicles with 4.2L engine without supercharger
Capacity Liters
Lubrication system - Vehicles with 4.2L engine with supercharger
Capacity Liters
General procedures
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.
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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.
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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.
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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.
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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.
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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 - 3.0L
1. The main bearing machine codes are displayed on the crankshaft (1) and the cylinder block
(2)
2. NOTE:
Main bearing number 1 relates to the front of the engine.
Read the identification numbers from the crankshaft (1).

• The first two numbers represent the code for main bearing number 1.
The second pair of numbers represents the code for main bearing number 2.
The third pair of numbers represents the code for main bearing number 3.
The last pair of numbers represents the code for main bearing number 4.
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3. NOTE:
Main bearing number 1 relates to the front of the engine.
Read the identification numbers on the cylinder block (2).

• The first two numbers represent the code for main bearing number 1.
The second pair of numbers represents the code for main bearing number 2.
The third pair of numbers represents the code for main bearing number 3.
The last pair of numbers represents the code for main bearing number 4.
4. Using the select fit chart, for each main bearing match the crankshaft code (1) and the
block code (2) with it's corresponding column or row. By reading across the crankshaft code
row (1) and down the block code column (2) select the correct grade bearing for each main.
• 1 Crankshaft code.
• 2 Block code.
5. E.g. if the crankshaft code is *8580*8082* and the Block code is *0609*0711*, main
bearing 1 should be assembled with a grade 1 bearing, as determined by the intersection of the
number 06 block column (2) and the number 85 crankshaft row (1).
• Main bearing 2, 3 and 4 would all be assemble with a grade 2.
Crankshaft Main Bearing Journal
Clearance - 3.5L/4.2L
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:
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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
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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.
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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.
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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.
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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.
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.

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Valve Spring Free Length
1. Using a vernier gauge, measure the free length of each valve spring. Verify the length is
within specification.
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.
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Engine
Vehicles with 3.0L engine
The 3.0L engine consists of:
• a six cylinder 60 degree 'V' configuration liquid cooled aluminium cylinder block with dry cast
liners
• aluminium pistons with cut-outs in the piston crown to clear the valve heads for any
available combination of camshaft profile and valve phasing
• two aluminium cylinder heads with square squish chambers
• two steel overhead camshafts per bank
• four valves per cylinder
• mechanical tappets and top mounted phosphate coated cast iron shims
• continuous variable camshaft timing (VCT) of the inlet camshafts
• two silent timing chains with one hydraulic tensioner per chain
• magnesium alloy valve covers with rubber seals
• a variable intake system containing two electrically controlled intake manifold tuning valves
• plastic lower intake manifold with integral fuel rail and injectors
• engine front cover manufactured from aluminium which accommodates the crankshaft front
oil seal
• an oil pump located at the front of the crankshaft
• an aluminium bed plate
• an aluminium oil pan
• a steel crankshaft
• fracture-split connecting rods in sintered-forged steel
• cast iron exhaust manifolds
• a single, multi-vee belt which drives the front end accessories
• an advanced engine management system incorporating electronic throttle control
• the requirements of the CARB OBDII USA legislation
The engine code and serial number are located on the engine front cover as well as the left-hand side
of the bed plate adjacent to the oil cooler assembly.
Vehicles with 3.5L or 4.2L engine

The 3.5L or 4.2L engine without supercharger consists of:
• an eight cylinder 90 degree 'Enclosed V' configuration liquid cooled aluminium cylinder block
with dry cast liners
• pistons of open-ended skirt design, with two compression rings and a three piece oil control
ring
• two aluminium cylinder heads, each incorporating two hollow camshafts manufactured in
chilled cast iron
• aluminium tappets and top mounted shims
• continuous variable camshaft timing (VCT) of the inlet camshafts
• valve covers manufactured from Thermoplastic
• fuel injectors each with twelve holes
oil seal
• multi row primary and single row secondary chains drive the camshafts of each cylinder bank
• a cast iron crankshaft
• brackets bolted to the front of the cylinder block which are used to mount all accessories
• stainless steel exhaust manifolds
• an advanced engine management system incorporating electronic throttle control
• the requirements of the CARB OBDII USA legislation
The engine number is stamped onto the engine block adjacent to the thermostat housing.
Engines with supercharger

The 4.2L engine with supercharger consists of:
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• an eight cylinder 90 degree 'Enclosed V' configuration liquid cooled aluminium cylinder block
with dry cast liners
• pistons of open-ended skirt design, with two compression rings and a compact two piece oil
control ring
• two aluminium cylinder heads, each incorporating two hollow camshafts manufactured in
chilled cast iron
• aluminium tappets and top mounted shims
• valve covers manufactured from Thermoplastic
• fuel injectors each with twelve holes
oil seal
• multi row primary and single row secondary chains drive the camshafts of each cylinder bank
• oil spray jets in each cylinder bore
• a cast iron crankshaft
• brackets bolted to the front of the cylinder block which are used to mount all accessories
• stainless steel exhaust manifolds
• an advanced engine management system incorporating electronic throttle control.
• the requirements of the CARB OBDII USA legislation.
The engine number is stamped onto the engine block adjacent to the thermostat housing.
Engine - 3.0L/3.5L/4.2L
Since diagnosis and testing actually begins when repairs are taken on, the following procedure is
recommended.
1 . Verify the customer concern by operating the system.
2 . Visually inspect for obvious signs of mechanical damage or electrical damage. If the concern
cannot be reproduced, carry out a road test and/or visual check with the aid of the following table.
Mechanical
• Coolant leaks
• Oil leaks
• Leaks in the fuel system
• Visibly damaged or worn parts
• Loose or missing nuts or bolts
4 . If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Difficult to start during hot or cold start
Possible Source(s):
• Piston ring(s) worn, damaged, sticking or worn piston/cylinder.
Action(s) to take:
• INSTALL a new engine.
Possible Source(s):
• Head gasket damaged.

Action(s) to take:
• INSPECT the head gasket.
Possible Source(s):
• Fuel system damaged or inoperative.
Action(s) to take:
• <<303-04A>> Or <<303-04B>>
Possible Source(s):
• Ignition system inoperative.
Action(s) to take:
•
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<<303-07A>> Or <<303-07B>>
Poor Idling
Possible Source(s):
• Restricted exhaust system.
Action(s) to take:
• INSPECT the exhaust system. <<309-00>>
Possible Source(s):
• Vacuum leak.
Action(s) to take:
• CARRY out the Intake Manifold Vacuum Test in this section. REPAIR and INSTALL new
Possible Source(s):
• Burned valve(s).
Action(s) to take:
• INSPECT the valve(s).

Possible Source(s):
• Incorrect valve to valve seat contact.
Action(s) to take:
• INSPECT the valve and valve seat.
Possible Source(s):
Action(s) to take:
Possible Source(s):
Action(s) to take:
• <<303-04A>> Or <<303-04B>>
Insufficient power
Possible Source(s):
• Compression leakage from valve seat.
Action(s) to take:
• INSPECT the valve or valve seat.
Possible Source(s):
• Valve sticking.
Action(s) to take:
• INSPECT valve stem to valve guide clearance or carbon accumulation.
Possible Source(s):
• Valve spring weak or broken.

Action(s) to take:
• INSPECT the valve spring.
Possible Source(s):
Action(s) to take:
Possible Source(s):
• Cylinder head cracked or distorted.
Action(s) to take:
•
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INSPECT the cylinder head.
Possible Source(s):
• Piston ring(s) worn, damaged or sticking.
Action(s) to take:
Possible Source(s):
Action(s) to take:
• <<303-04A>> Or <<303-04B>>
Possible Source(s):
• Brakes dragging.
Action(s) to take:
• <<206-00>>
Possible Source(s):
• Restricted exhaust system.
Action(s) to take:
• INSPECT the exhaust system. <<309-00>>
Excessive or insufficient compression.
Possible Source(s):
• Valve(s) burnt or sticking.
Action(s) to take:
• INSPECT the valve(s).
Possible Source(s):
• Valve spring(s) weak or broken.
Action(s) to take:
• INSPECT the valve spring(s).
Possible Source(s):
Action(s) to take:
Possible Source(s):
Action(s) to take:
Possible Source(s):
• Carbon accumulation in combustion chamber.
Action(s) to take:
• ELIMINATE carbon build up.
Possible Source(s):
Action(s) to take:
• <<303-04A>> Or <<303-04B>>
Excessive oil consumption
Possible Source(s):
Action(s) to take:
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Possible Source(s):
• Valve stem seal worn or missing.
Action(s) to take:
• INSPECT the valve or valve stem seal.
Possible Source(s):
• Oil leakage.
Action(s) to take:
• REPAIR oil leakage.
Possible Source(s):
• Valve stem or valve guide worn.
Action(s) to take:
• INSPECT the valve stem or valve guide.
Possible Source(s):
• Incorrect oil viscosity.
Action(s) to take:
• DRAIN and FILL with new oil.
Possible Source(s):
• Diluted oil.
Action(s) to take:
• CHECK oil dilution. DRAIN and FILL as necessary.
Possible Source(s):
• Crankcase overfilled.
Action(s) to take:
• CHECK and adjust the oil level.
Possible Source(s):
• Incorrect oil pressure.
Action(s) to take:
• CHECK the oil pressure. REPAIR as necessary.
Engine noise
Possible Source(s):
• Excessive crankshaft main bearing clearance.
Action(s) to take:
Possible Source(s):
• Excessive crankshaft end play.
Action(s) to take:
Possible Source(s):
• Excessive connecting rod bearing oil clearance.
Action(s) to take:
Possible Source(s):
• Piston/cylinder worn.
Action(s) to take:

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Possible Source(s):
• Piston ring damaged.
Action(s) to take:
Possible Source(s):
• Connecting rod bent.
Action(s) to take:
Possible Source(s):
• Valve spring(s) broken.
Action(s) to take:
• INSPECT the valve spring(s).
Possible Source(s):
• Excessive valve guide clearance.

Action(s) to take:
• INSPECT the valve guide or valve.
Possible Source(s):
• Cooling system inoperative (water pump, vibration of radiator),
Action(s) to take:
• Refer to <<303-03>>
Possible Source(s):
• Fuel system inoperative.
Action(s) to take:
• <<303-04A>> Or <<303-04B>>
Possible Source(s):
• Excessive carbon buildup.
Action(s) to take:
• ELIMINATE carbon buildup.
Possible Source(s):
• Exhaust gas leakage.
Action(s) to take:
• REPAIR leakage. <<309-00>>
Possible Source(s):
• Incorrect drive belt tension.
Action(s) to take:
• INSPECT the drive belt tension. <<303-05>>
Possible Source(s):
• Generator front bearing worn.
Action(s) to take:
• <<414-02>>
Tappet noise, engine running
Possible Source(s):
• Incorrect tappet clearance.
Action(s) to take:
• CHECK and ADJUST the tappet clearance as necessary.
Component Tests
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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 UV 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 causes the powertrain control module
(PCM) to log an error message. After the measurements have been carried out this error
message should be cleared from memory by connecting to the Jaguar 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: On manual transmissions shift the transmission into neutral. On automatic

transmission vehicles, select "P". Failure to follow these instructions may result in personal injury.
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 components in reverse order, observing the specified tightening torques.
8 . Reset the PCM fault memory.

Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading cylinder
is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the
measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and
prevent damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some
engine oil into the combustion chamber and repeat the compression measurement.
If the reading greatly improves then the piston rings are damaged.
If the reading stays the same then the cause is either damaged valve seats or valve stem seals.
If the measurements for two cylinders next to each other are both too low then it is very likely that
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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.
Excessive Engine Oil Consumption

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 is a partial list of conditions that can affect oil consumption rates:
• Engine size.
• Operator driving habits.
• Ambient temperatures.
• Quality and viscosity of oil.
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) per liter oil consumption rate is about 2,400 km (1,500 miles) per liter.
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.
Oil Consumption Test

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. Vehicles in normal service should get a least 16,000 km (10,000
miles) per liter. 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's 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.
3 . Verify that the engine has the correct oil level.
4 . Verify that the engine is not 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. In no case should the level
be above the top of the cross-hatched area and the letter "F" in FULL. If significantly overfilled, carry
out step 5, sub steps 1 through 4.
5 . Carry out an oil consumption test:
Drain engine oil and fill with one liter less than the recommended amount.
Run the engine for three minutes (10 minutes if cold), and allow oil to drain back for at least five
minutes with vehicle parked on level surface.
Remove the oil level indicator and wipe clean. (Do not wipe with anything contaminated with
silicone compounds.) Install the oil level indicator making sure to seat the oil level indicator
firmly in the oil level indicator tube. Remove the oil level indicator and draw a mark on the back
(unmarked) surface at the indicated oil level. (This level should be about the same as the ADD
mark on the face of the oil level indicator.)
Add one liter of oil. Start the engine and allow to idle for at least two minutes. Shut off the
engine and allow the engine oil to drain back for at least five minutes. Mark the oil level dipstick,
using the procedure above. (This level may range from slightly below the top of the cross-
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hatched area to slightly below the letter "F" in FULL.
Record the vehicles mileage.
Instruct the customer to drive the vehicle as usual and:
Check the oil level regularly at intervals of 160-240 km (100-150 miles).
Return to the service point when the oil level drops below the lower (ADD) mark on the oil level
indicator.
Add only full liters of the same oil in an emergency. Note the mileage at which the oil is added.
Check the oil level under the same conditions and at the same location as in steps 3 and 4.
Measure the distance from the oil level to the UPPER mark on the oil level indicator and record.
Measure the distance between the two scribe marks and record.
Divide the first measurement by the second.
Divide the distance driven during the oil test by the result. This quantity is the approximate oil
consumption rate in kilometers per liter or in mile per quart.
If the oil consumption rate is unacceptable go to Step 6.
6 . Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged.
7 . Check for plugged oil drain-back holes in the cylinder head and cylinder block.
8 . If the condition still exists after carrying out the above tests go to step 9.
9 . Carry out a cylinder compression test. Refer to the procedure in this section : Compression Test.
This can help determine the source of oil consumption such as valves, piston rings or other areas.
10 . Check valve guides for excessive guide clearance. Install new valve stem seals after verifying
valve guide clearance.
11 . 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.
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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
(dotted needle), 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 (dotted needle), 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 (dotted) 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 RETARDING: 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.
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Engine - 2.7L Diesel
No data
303-01A : Engine – 3.0L
Specifications
Specifications
Description Specification
Engine oil (EUROPE), SAE 5W-30 WSS-M2C-913A or B
Engine oil (US), SAE 5W-30 ILSAC GF3, API SJ
Engine assembly lubricant SQM-2C9003 AA EP90
Sealant WSS M4G 320-A3
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Hose assembly surfactant ESE-M99 B144-B
Capacities
Description Liters
Engine oil, initial fill 7.0
Engine oil, service fill with oil filter change 6.5

Accessory drive belt idler pulley retaining bolt 25 18 -
Accessory drive belt tensioner retaining bolt 48 35
Air conditioning (A/C) compressor retaining bolts 25 18 -
A/C compressor mounting bracket retaining bolts 25 18 -
A/C compressor lines retaining bolts 9 - 80
Camshaft bearing caps retaining bolts A - -
Camshaft position sensor retaining bolt 7 - 62
Connecting rod cap retaining bolts A - -
Coolant by-pass tube to cylinder head retaining bolts 10 7 -
Crankshaft position sensor retaining bolt 10 7 -
Crankshaft pulley retaining bolt A - -
Cylinder head retaining bolts A - -
Engine ground strap retaining bolt 10 7 -
Engine front cover retaining bolts A - -
Engine mounting bracket retaining bolts 40 30 -
Engine mount bracket to engine mount retaining nuts 55 40 -
Engine mount retaining bolts to crossmember retaining nuts 63 46 -
Engine mount/oil filter housing retaining bolts A - -
Engine wiring harness retaining bracket 7 - 62
Exhaust manifold heat shield retaining bolts 10 7 -
Exhaust manifold retaining studs 9 - 80
Exhaust manifold retaining nuts A - -
Flywheel retaining bolts 80 59 -
Flexplate retaining bolts 80 59 -
Generator retaining bolts 48 35 -
Ignition coils retaining bolts 7 - 62
Knock sensor retaining bolts 25 18 -
Lower cylinder block retaining bolts A - -
Lower intake manifold retaining bolts A - -
Oil level indicator tube retaining bolt 10 7 -
Oil pan retaining bolts A - -
Oil pan drain plug 24 18 -
Oil pressure sensor 16 12 -
Oil pump to engine block retaining bolts 10 7 -
Oil separator blanking plate 10 7 -
Oil temperature sensor 14 10 -
Spark plugs 15 11 -
Timing chain guide retaining bolts A - -
Timing chain tensioner retaining bolts 25 18 -
Upper intake manifold retaining bolts A - -
Upper intake manifold support retaining bolts 10 7 -
Variable camshaft timing oil control unit retaining bolt 40 + 90° 30 + 90° -
Valve cover studs and retaining bolts A - -
Water pump retaining bolts 25 18 -
Wiring harness to valve cover retaining nuts 10 7 -
A = refer to the procedure for correct torque sequence - - -
General procedures

1. Remove the left-hand valve cover.
2. Remove the right-hand valve cover.

3. Turn the crankshaft pulley clockwise to position the relevent camshaft lobe 180 degrees to
the shim being replaced.
4. Remove the camshaft bearing cap.

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5. Install the special tool.

• Making sure the legs of the tool are in contact with the edge of the valve bucket,
compress the bucket.
6. Use compressed air to remove the shims that require replacing.

• Blow compressed air between the shim edge and bucket to dislodge the shim.
7. Use the following formula to calculate the required shim thickness.

• Original shim thickness + measured clearance - desired clearance = required shim
thickness.
8. Apply a light coat of engine oil to the replacement shim(s) and install.
9. Install the left-hand valve cover.
10. Install the right-hand valve cover.

1. Remove the left-hand valve cover. For additional information, refer to .
2. Remove the right-hand valve cover. For additional information, refer to .
3.
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
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valve clearance will be incorrect.
Rotate the engine clockwise to position the camshaft lobe away from the shim surface.
4. Using the feeler gauge set, measure the clearance between the camshaft and the shim
surface. Record and check the readings. For additional information, refer to <<303-00>>.
Adjust the clearances as necessary. For additional information, refer to.
5. Install the right-hand valve cover. For additional information, refer to .
6. Install the left-hand valve cover. For additional information, refer to .

Engine
The 3.0 litre 24 valve V6 engine has four overhead camshafts and are driven by two timing chains.
The engine incorporates electronic engine management with distributorless ignition system,
sequential electronic fuel injection. It also has two catalytic converters in the exhaust system which
includes two oxygen sensors and two catalytic monitor sensors.
Viewed from the driving position, the right-hand cylinder bank is numbered 1 to 3, from the front of
the vehicle and the left-hand cylinder bank are numbered 4 to 6, from the front of the vehicle.
The engine includes the following:
• Compression ratio of 10.5:1.

• 3 Stage variable geometry intake manifold.
• Lightweight valve gear.
• Unique camshaft lift and duration.
• Twin knock sensor engine management control.
• Fully variable camshaft timing (VCT) system.
Variable Intake System (V.I.S).

The variable intake system consists of a three stage upper intake manifold assembly, two position
electronically driven gate valves and an engine management powertrain control system.
The engine control module (ECM) switches the intake manifold tuning valves between fully open and
fully closed at calibrated engine speeds.
The intake manifold efficiency is therefore increased which will also increase the engine torque and
engine performance.
Variable Camshaft Timing (VCT)

Oil is supplied to the front of each VCT actuator via the spider bracket assembly which contains the
VCT actuator solenoid, supply oil galleries and timing chain guide. Oil pressure advances and retards
the camshaft timing which is controlled by the engine management system via a solenoid valve
mounted on top of the oil feed spider assembly. Camshaft timing, dependant on engine speed, load
and oil temperature can be optimized over the adjustment range of 30 degrees.
Engine Lubrication System

The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to
the:
• crankshaft main bearings.

• crankshaft thrust main bearing.
• connecting rod bearings.
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• valve shims.
• camshaft bearings.
• variable camshaft timing.
All other parts are lubricated by gravity flow or splash of the oil.
Oil Pump
The rotary oil pump develops the oil pressure:
• The oil pump is located at the front of the crankshaft.

• The oil pump is driven by the crankshaft.
• A full flow oil filter is externally mounted on the oil filter housing.
If the filter element should become blocked a spring-loaded bypass valve will open and allow an
uninterrupted flow of oil to the engine.
Engine
Removal
Engine (12.41.01)

303-661
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303-021

418-535
Removal
1 . Remove the automatic transmission assembly. <<307-01>>
3 . Remove the hood assembly. <<501-03>>

4 . Remove the air cleaner assembly. <<303-12A>>
6 . NOTE:
Remove the engine compartment panel retaining bolts.
7 . NOTE:
Remove the engine compartment panel.

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10 . Remove the passenger side front wheel and tire assembly. <<204-04>>
12 . Disconnect the engine harness ground strap.

13 NOTE:
.
The engine control module (ECM) electrical connector retaining bolt remains captive in
the electrical connector
Disconnect the ECM electrical connector.
14 NOTE:
.
The main engine harness electrical connector retaining bolt remains captive in the
electrical connector.
Disconnect the engine wiring harness electrical connectors.
1) Loosen the engine harness main electrical connector retaining bolt.
2) Disconnect the engine wiring harness electrical connectors.

15 . Reposition the engine wiring harness from the vehicle body.
16 . Disconnect the evaporative emission canister purge valve to intake manifold hose.
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17 . Disconnect the fuel supply manifold spring lock coupling. <<310-00>>
18 . Remove the cooling module. <<303-03A>>
19 . Detach the brake booster vacuum hose from the brake booster.
20
. CAUTION: Cap the power steering line to prevent loses of fluid and dirt ingress.
NOTE:
21
. CAUTION: Cap the power steering lines to prevent loses of fluid and dirt ingress.
NOTE:
Disconnect the power steering pump to steering gear supply line.

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22 . NOTE:
Inlet manifold shown removed for clarity.
Detach the right-hand valve cover wiring harness.
23 . Disconnect the left-hand ignition coils electrical connectors.

24 . Detach the left-hand valve cover wiring harness.
25 . Remove the dipstick tube retaining bolt.
Reposition the dipstick tube.
26 . NOTE:

27 . NOTE:

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28 . NOTE:


.
1) Rotate the accessory drive belt tensioner counter-clockwise.
Use a 3/8 inch square drive bar to rotate the accessory drive belt
tensioner.

33 . Detach the generator battery positive cable protective cover.
34 . Remove the generator battery positive cable retaining nut.

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35 . Remove the air conditioning compressor. <<412-03>>
36 . Detach the power steering hose.
37 . Reposition the power steering hose away from the engine.

38 . NOTE:
Remove the engine mounts lower retaining bolts.
39 . Detach the automatic transmission oil cooler tubes bracket.
40 . Reposition the automatic transmission oil cooler tubes away from the engine.
41 . Reposition the automatic transmission wiring harness away from the engine.

44 . Remove the engine assembly.
Using the special tools, install a suitable floor crane.

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Installation
Engine (12.41.01)

303-661

303-021

418-535
Installation
1 NOTE:
.
Make sure all wiring harnesses and oil pipes are suitably positioned for engine
installation.
Install the engine assembly.
Make sure engine mounts are correctly located

Remove the floor Crane.

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4 . Attach the automatic transmission oil cooler tubes bracket.
Tighten to 10 Nm.
5 . NOTE:
Left-hand shown, right hand similar.
Install the engine mounts lower retaining bolts.
Tighten to 63 Nm.
6 . Attach the power steering hose.
Tighten to 10 Nm.
7 . Install the air conditioning compressor. <<412-03>>
8 . Install the generator battery positive cable retaining nut.
Tighten to 12 Nm.
9 . Attach the generator battery positive cable protective cover.
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10 Attach the accessory drive belt.

.
tensioner.
2) Attach the accessory drive belt.


16 . NOTE:
Tighten the exhaust manifold retaining nut.
Tighten to 25 Nm.
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17 . Install the dipstick tube retaining bolt.
Tighten to 10 Nm.
18 . Attach the left-hand valve cover wiring harness.

19 . Connect the left-hand ignition coils electrical connectors.
20 . NOTE:
Intake manifold shown removed for clarity.
Attach the right-hand valve cover wiring harness.
21 . NOTE:
Un-cap the power steering pump exposed ports.
Install new power steering pump supply line O-ring seal.
22
Connect the power steering pump to steering gear supply line.

23
Connect the power steering reservoir to power steering pump supply line.
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24 . Attach the brake booster vacuum hose from the brake booster.
25 . Install the cooling module. <<303-03A>>

26 . NOTE:
Connect the fuel supply manifold spring lock coupling. <<310-00>>
27 . Connect the evaporative emission canister purge valve to intake manifold hose.
28 . Connect the engine wiring harness electrical connectors.
1) Align the engine harness main electrical connector retaining bolt.
2) Connect the engine wiring harness electrical connectors.
29 . Connect the engine control module (ECM) electrical connector.

Tighten to 6 Nm.
30 . Connect the engine harness ground strap.

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32 . Install the passenger side front wheel and tire assembly.
Tighten to 128 Nm.

35 . NOTE:
Install the engine compartment panels.
Tighten to 10 Nm.
36 . NOTE:
Install the engine compartment panels retaining bolts.
Tighten to 10 Nm.
Tighten to 10 Nm.
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38 . Install the air cleaner assembly. <<303-12A>>
39 . Install the hood assembly. <<501-03>>
41 . Install the automatic transmission assembly. <<307-01>>

In vehicle repair
Removal
1 . Remove the timing drive components.
For additional information, refer to Timing Drive Components (12.65.13)
2 . Remove the camshaft bearing caps evenly.
3 . Remove the camshafts.
Installation
1 NOTE:
.
Lubricate the camshafts and the camshaft bearing caps with oil meeting Jaguar
specification prior to installation.
Install the camshafts.

2
. CAUTION: Do not install the cylinder head camshaft journal thrust caps until the
camshaft journal caps are installed or damage to the thrust caps may occur.
Install the camshaft bearing caps in their original position.

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Install the camshaft bearing cap retaining bolts evenly.
Tighten the retaining bolts in the sequence shown to 10 Nm.
3 . Carry out a valve clearance check. For additional information, refer to

For additional information, refer to .
4 . Install the timing drive components.

Crankshaft Front Seal Remover

303-700
Crankshaft Front Seal Installer

303-542
Crankshaft pulley installer

303-102
Removal
1 . Remove the crankshaft pulley.
2 . Using the special tool, remove and discard crankshaft front seal.
Installation
1 . Using the special tools, install the crankshaft front oil seal.
Lubricate the seal lip with clean engine oil.
2 . Install the crankshaft vibration damper.

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Wrench strap-universal
303-D055
Crankshaft Pulley Remover

303-D121
Crankshaft Pulley Installer

303-102
Trust Pad
303-D121-01

303-335/2
Removal
2 . Carry out the cooling system draining procedure. <<303-03A>>
3 . Remove the accessory drivebelt.
1) Rotate the belt tensioner counter-clockwise.
Use a 3/8 inch square drive bar to rotate the belt tensioner.
2) Remove the accessory drivebelt.

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5 . Remove the throttle body. <<303-04A>>
6 . Disconnect the radiator top coolant hose.

7 . Disconnect the coolant hose from the top coolant hose assembly.
8 . Disconnect the hose assembly from the water pump and lower hose.
9 . Remove the hose assembly.

11 . Remove the crankshaft pulley retaining bolt.

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13 . Using the special tools, remove the crankshaft pulley.
Installation
1 Using the special tools, install the crankshaft pulley.
.
Coat the crankshaft pulley keyway with silicone gasket sealant meeting
Jaguar specification.
Coat the sealing surfaces of the crankshaft pulley with silicone gasket
sealant meeting Jaguar specification.
3 . Install the crankshaft pulley bolt.
Torque to 120 Nm.
Loosen the bolt (minimum 1 turn).
Torque to 50 Nm.
Angle Torque to 90°.
4 . Install the hose assembly.

5 . Install the hose assembly to the water pump and lower hose.
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6 . Install the coolant hose to the housing assembly.
7 . Connect the radiator top coolant hose.

8 . Install the throttle body. <<303-04A>>
10 . Install the accessory drivebelt.
2) Install the accessory drivebelt.
13 . Carry out the cooling system filling and bleeding procedure. <<303-03A>>
Crankshaft Rear Seal Remover

303-566
Crankshaft Rear Seal Installer

303-178
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Crankshaft Rear Seal Installer Adapter Bolts

303-384
Crankshaft Rear Seal Installer Draw Bolts

303-102
Removal
Vehicles With Manual Transmission
1 . Remove the flywheel. For additional information, refer to
Vehicles With Automatic Transmission

2 . Remove the flexplate. For additional information, refer to
All Vehicles
3
. CAUTION: Avoid scratching or damaging the oil seal sealing surfaces on the
crankshaft and cylinder block.
Using the special tools, remove the crankshaft rear main oil seal.
Installation
All Vehicles
1 . Clean and inspect the crankshaft rear oil seal sealing surfaces.
2 Lubricate the crankshaft flange, the crankshaft rear oil bore seal, and the oil seal lip.
.
Use engine assembly lubricant or equivalent meeting Jaguar specification
ESR-M99C80-A.
3 NOTE:
.
Alternate bolt tightening to correctly seat the crankshaft rear oil seal until it is flush with
the cylinder block.
Using the special tools, install the crankshaft rear oil seal.
Vehicles With Automatic Transmission
4 . Install the flexplate. For additional information, refer to
Vehicles With Manual Transmission

5 . Install the flywheel. For additional information, refer to
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Removal
RH and LH Cylinder Heads
1 . Remove the right-hand valve cover.
For additional information, refer to Valve Cover RH (12.29.44)
2 . Remove the left-hand valve cover.

3 . Disconnect the coolant temperature (ECT) electrical connector.
4 . Disconnect the fuel pressure regulator electrical connector and vacuum hose.
5 . Remove the fuel supply manifold and lower intake manifold.
Remove and discard the lower intake manifold gaskets.

6 . Remove the coolant crossover tube.
Discard the O-ring seals.

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7 . Remove the catalytic converters. <<309-00>>

For additional information, refer to Camshafts LH (12.13.19)
Cylinder Head-LH
9 . Remove the oil level indicator tube.
1) Remove the retaining nut.
2) Remove the oil level indicator tube.

10 . NOTE:
Remove the retaining bolts in the indicated sequence.
Remove the cylinder head. (Left-hand shown, right-hand similar).
Remove and discard the cylinder head gasket.
11 . Clean and inspect the cylinder head and cylinder block. <<303-00>>
Installation
1 . NOTE:
The head gaskets must be installed over the cylinder head to block dowels.
Install a new cylinder head gasket.

2
. CAUTION: Use care when installing the cylinder head. Damage to the cylinder block
and or the cylinder head may result.
NOTE:
Make sure the cylinder head is installed in its original position.
NOTE:
Tighten the retaining bolts in the indicated sequence in six stages.
Install the cylinder head and install new cylinder head retaining bolts and washers.
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Stage 1: tighten to 30 Nm.
Stage 2: tighten 90 degrees.
Stage 3: loosen 360 degrees.
Stage 4: tighten to 30 Nm.
Stage 5: tighten 90 degrees.
Stage 6: tighten 90 degrees .
Cylinder Head-LH
3 . Install the oil level indicator tube.
Tighten to 10 Nm.

4 . Install the camshafts.
5 . Install the catalytic converters. <<309-00>>
6 . NOTE:
Install the coolant crossover tube.
Tighten to 10 Nm.
7 . NOTE:
Install new lower intake manifold gaskets.
Install the fuel supply manifold and lower intake manifold.
Tighten to 10 Nm.
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8 . Connect the fuel pressure regulator electrical connector and vacuum hose.
9 . Connect the ECT electrical connector.
10 . Install the left-hand valve cover.

11 . Install the right-hand valve cover.

Engine Front Cover (12.65.01)
Wrench strap-universal
303-D055
Crankshaft Pulley Remover

303-D121

303-102
Thrust Pad
303-D121-01

303-335/2
Removal

3 . Remove the oil pan.


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5 . Remove the accessory drivebelt.
2) Remove the accessory drivebelt.

8 . Disconnect the coolant hose from the top coolant hose assembly.
9 . Disconnect the hose assembly from the water pump and lower hose.
10 . Remove the hose assembly.

12 . Remove the crankshaft pulley retaining bolt.

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14 . Using the special tools, remove the crankshaft pulley.

15 . Remove the crankshaft front seal.
For additional information, refer to Crankshaft Front Seal (12.21.14)
16 . Detach the coolant hose.
17 . Remove the coolant hose.
18 . Remove the water pump.
19 . Detach the fuel supply manifold retaining bolt.

20 . Remove the accessory drive belt tensioner.
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21 . Detach the engine harness from the right-hand idler pulley.
Detach the splash shield.
Detach the engine harness from the right-hand idler pulley.
22 . Remove the right-hand idler pulley.

23 . Remove the left-hand idler pulley.
24 . Remove the power steering pump upper retaining bolts.
26 . Detach the power steering pump.

28 . Disconnect the crankshaft position (CKP) sensor electrical connector.

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29 . NOTE:
Disconnect the camshaft position (CPS) sensors.
30 . Remove the engine front cover
Remove and discard the engine front cover gaskets.

Installation
1 . Install new engine front cover gaskets.
2 NOTE:
.
Prior to applying sealer clean the front cover to engine block and cylinder head sealing
surfaces with metal surface cleaner.
Apply a 6 mm diameter dot of silicone sealant meeting Jaguar specification to the indicated
locations.
3 NOTE:
.
The engine front cover retaining bolts numbered 3,4,10 and 11 are longer than the
retaining bolts numbered 1,2,5,6,7,8,9,12,13,15 and 16. The retaining bolt numbered 14
is a retaining bolt with a stud head.
Install the engine front cover, completing the tightening sequence.
Tighten to 25 Nm.
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4 . NOTE:
Connect the camshaft position (CPS) sensors.
5 . Connect the crankshaft position (CKP) sensor electrical connector.

7 . Attach the power steering pump.
Tighten to 25 Nm.
8 . Install the power steering pump upper retaining bolts.
Tighten to 25 Nm.
9 . Install the left-hand idler pulley.
Tighten to 25 Nm.
10 . Install the right-hand idler pulley.
Tighten to 25 Nm.
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11 . Attach the engine splash shield.
Attach the engine harness to the right-hand idler pulley.
Attach the engine splash shield.

12 . Install the accessory drive belt tensioner.
Tighten to 45 Nm.
13 . Attach the fuel supply manifold retaining bolt.
14 . Install the water pump.
Tighten to 25 Nm.
15 . Install the coolant hose.

16 . Attach the coolant hose.
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17 . Install a new crankshaft front seal.


.
Coat the crankshaft pulley keyway with silicone gasket sealant meeting
Coat the sealing surfaces of the crankshaft pulley with silicone gasket
sealant meeting Jaguar specification.
20 . Install the crankshaft pulley bolt.
Torque to 120 Nm.
Loosen the bolt (minimum 1 turn).
Torque to 50 Nm.
Angle Torque to 90°.
21 . Install the hose assembly.
22 . Install the hose assembly to the water pump and lower hose.
23 . Install the coolant hose to the housing assembly.
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24 . Connect the radiator top coolant hose.
25 . Raise vehicle.
26 . Install the accessory drivebelt.
2) Install the accessory drivebelt.

27 . Install the oil pan.


31 . Carry out the cooling system feeling and bleeding procedure. <<303-03A>>
32 . Refill the engine with oil.

Engine Mount (12.45.13)
Engine lifting Bracket

303-661
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303-021
Removal

5 . NOTE:
6 . NOTE:

7 . NOTE:
8 . Disconnect the left-hand ignition coil electrical connectors.

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11 . NOTE:
12 . NOTE:

13 . NOTE:

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16 . Remove the left-hand catalytic converter. <<309-00>>
17 . Remove the steering gear shaft pinch bolt.

19 . Secure the steering gear.
20 . NOTE:
Remove the engine mount lower retaining bolts.


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24
. WARNING: Do not remove the front subframe retaining bolts. Failure to follow this
procedure may result in personal injury.
Loosen the front subframe retaining bolts to enable the engine mount to be removed.
25 . NOTE:
Remove the engine mount.
Installation
1
. CAUTION: Make sure the engine mount locators are correctly aligned on
installation.
NOTE:
Install the engine mount.
Tighten to 63 Nm.
2 . Carry out the front subframe alignment procedure. <<204-01>>

4
. CAUTION: Make sure the engine mounts locate into the correct position when the
engine is repositioned.
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Using the special tools, reposition the engine.
6 . NOTE:
Install the engine mount lower retaining bolts.
Tighten to 63 Nm.
8 . Attach the steering gear.
Tighten to 100 Nm.
9 . Install the steering gear shaft pinch bolt.
Tighten to 35 Nm.
10 . Install the left-hand catalytic converter. <<309-00>>

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14 . NOTE:

Install the exhaust manifold retaining nut.
Tighten to 25 Nm.
Tighten to 10 Nm.
17 . Connect the left-hand ignition coil electrical connectors.

18 . Attach the right-hand valve cover wiring harness.
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19 . NOTE:
Install the engine compartment panel.
Tighten to 10 Nm.
20 . NOTE:

Install the engine compartment panel retaining bolts.
Tighten to 10 Nm.
Tighten to 10 Nm.

Exhaust Manifold LH - VIN Range:
G004442->G45703 (30.15.55)
Removal
1 . Remove the left-hand catalytic converter.
For additional information, refer to Catalytic Converter - 3.0L/3.5L/4.2L (17.50.05)

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6 . Remove the left-hand exhaust manifold heat shield.
8 NOTE:
.
Engine shown removed for clarity.
NOTE:
When an exhaust manifold retaining stud is removed, it must be replaced with a new
retaining stud and nut.
Remove the left-hand exhaust manifold lower retaining nuts.

10 NOTE:
.
NOTE:
Remove the left-hand exhaust manifold.

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Remove and discard the left-hand exhaust manifold gasket.
Installation
1 . NOTE:
NOTE:
When a new exhaust manifold retaining stud is installed, tighten to 9 Nm.

NOTE:
Tighten the exhaust manifold retaining nuts in the sequence shown.
Install a new left-hand exhaust manifold gasket.
Tighten to 20 Nm.
Exhaust Manifold LH - VIN Range:
G45704->G99999 (30.15.55)
Removal
All vehicles
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2 . Remove the left-hand exhaust manifold heat shield.
Vehicles with secondary air injection (AIR)

3 . Disconnect the secondary air injection (AIR) control valve to exhaust manifold tube.
All vehicles
4 NOTE:
.
NOTE:
Remove the left-hand exhaust manifold upper retaining nuts.

6 NOTE:
.
NOTE:
Remove the left-hand exhaust manifold.
Remove and discard the left-hand exhaust manifold gasket.

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Installation
All vehicles
1 . NOTE:
NOTE:
When a new exhaust manifold retaining stud is installed, tighten to 9 Nm.
NOTE:
Tighten the exhaust manifold retaining nuts in the sequence shown.
Install a new left-hand exhaust manifold gasket.
Tighten to 20 Nm.
Vehicles with secondary air injection (AIR)
All vehicles
Removal
1 . Remove the automatic transmission. <<307-01>>
2 . Detach the accessory drivebelt.
2) Detach the accessory drivebelt.

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4 . NOTE:
Prevent the flexplate from rotating.
Remove the flexplate.

Installation
1 . NOTE:
Make sure the crankshaft and flexplate mating faces are clean before installation.
NOTE:
The flexplate will only locate in one position.
NOTE:
Tighten the retaining bolts working diagonally.
Install the flexplate.
Tighten to 80 Nm.

3 . Attach the accessory drivebelt.
2) Attach the accessory drivebelt.

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4 . Install the automatic transmission. <<307-01>>

Intake Manifold (30.15.01)
Removal
1
. WARNING: Never remove the coolant expansion tank pressure cap under any
circumstances while the engine is operating. Failure to follow this instruction may result in
personal injury.
WARNING: To avoid hot coolant or steam blowing out of the cooling system, use
extreme care when removing the coolant expansion tank pressure cap. Wait until the
engine has cooled down, then insulate the coolant pressure cap with a suitable cloth and
slowly loosen the coolant expansion tank pressure cap until the cooling system pressure is
released. Do not remove the coolant expansion tank pressure cap. Step back while the
pressure is released from the system. When all of the pressure has been released slowly
remove the coolant expansion tank pressure cap (still with the suitable cloth in position)
from the coolant expansion tank. Failure to follow this instruction may result in personal
injury.
Release the cooling system pressure.
Remove the coolant expansion tank pressure cap.
2 . Remove the air cleaner outlet pipe.


4 . Disconnect the throttle motor electrical connector.
5 . Disconnect the throttle position sensor (TPS) electrical connector.

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6 . Disconnect the positive crankcase ventilation (PCV) hose.
7 . NOTE:
Cap the coolant hoses to minimize coolant loss.
Detach the coolant hoses from the throttle body.

8 . Detach the engine wiring harness from the intake manifold side retaining bracket.
9 . Detach the intake manifold right-hand side retaining bracket.
10 . Loosen the intake manifold right-hand side retaining bracket.

11 . Detach the intake manifold front retaining bracket.
12 . Loosen the intake manifold front retaining bracket.

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13 . Detach the coolant temperature sensor wiring harness.
14 . Remove the engine cover front retaining bracket.

15 . Detach the evaporative emission canister purge valve transfer pipe.
16 . Remove the engine cover left-hand side retaining bracket.
17 . Remove the fuel pressure sensor bracket retaining bolt.
18 . Detach the fuel pressure sensor bracket.

19 . Detach the intake manifold.
20 NOTE:
.
The evaporative emission canister purge valve transfer pipe is attached to the
induction manifold by a quick release coupling.
Disconnect the evaporative emission canister purge valve transfer pipe.

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21 . Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
22 . Disconnect the fuel pressure sensor vacuum hose.

23 . NOTE:
Left-hand intake manifold tuning (IMT) valve shown, right-hand (IMT) valve similar.
Disconnect the IMT valves electrical connectors.
24 . Disconnect the fuel pressure regulator vacuum hose.
25 . Disconnect the brake booster vacuum hose.

26 . Remove the intake manifold.
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Installation
1 NOTE:
.
Install new intake manifold gaskets.
NOTE:
The intake manifold retaining bolts in position 1, 4 and 5 are longer than the retaining
bolts in position 2, 3 and 6.
NOTE:
Do not fully tighten the retaining bolts.
Install the intake manifold.

2 . Connect the brake booster vacuum hose.
3 . Connect the fuel pressure regulator vacuum hose.
4 . NOTE:
Left-hand intake manifold tuning (IMT) valve shown, right-hand (IMT) valve similar.
Connect the IMT valves electrical connectors.

5 . Connect the fuel pressure sensor vacuum hose
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6 . Connect the manifold absolute pressure (MAP) sensor electrical connector.
7 NOTE:
.
The evaporative emission canister purge valve transfer pipe is attached to the induction
manifold by a quick release coupling.
Connect the evaporative emission canister purge valve transfer pipe.

8 NOTE:
.
The intake manifold retaining bolts in position 1, 4 and 5 are longer than the retaining
bolts in position 2, 3 and 6.
Reposition the intake manifold.
Tighten to 10 Nm.
Complete the tightening sequence.
9 . Install the fuel pressure sensor bracket retaining bolt.

10 . Attach the fuel pressure sensor bracket.
11 . Install the engine cover left-hand side retaining bracket.

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12 . Attach the evaporative emission canister purge valve transfer pipe.
13 . Install the engine cover front retaining bracket.

14 . Attach the coolant temperature sensor wiring harness.
15 . Attach the intake manifold front retaining bracket.
16 . Fully tighten the intake manifold front retaining bracket.
17 . Fully tighten the intake manifold right-hand side retaining bracket.

18 . Fully tighten the intake manifold right-hand side retaining bracket.
19 . Attach the engine wiring harness to the intake manifold side retaining bracket.
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20 . NOTE:
Un-cap the coolant hoses.
Attach the coolant hoses to the throttle body.
21 . Connect the positive crankcase ventilation (PCV) hose.

22 . Connect the throttle position sensor (TPS) electrical connector.
23 . Connect the throttle motor electrical connector.

25 . Install the air cleaner outlet pipe.
26 Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty
. percent mixture of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar
specification WSS M97B44-D and fifty percent water.
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Lower Intake Manifold (30.15.61)
Removal
For additional information, refer to Intake Manifold (30.15.01)
2 . Disconnect the spring lock coupling.

For additional information, refer to Spring Lock Couplings
3 . Disconnect the fuel charging wiring harness.
4 . NOTE:
Fuel may still be present in the fuel injection supply manifold.
NOTE:
Remove and discard the lower intake manifold O-ring seals.
Remove the lower intake manifold.

Installation
1 . NOTE:
NOTE:
Tighten in the sequence shown.
Tighten the retaining bolts in the sequence shown.
Tighten to 10 Nm.
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Oil Cooler (12.60.68)
Removal
2 . Remove the left-hand engine mount.

3 . Drain the engine oil.
4 . Remove and discard the engine oil filter.
5 . Disconnect the coolant hoses.
6 . Remove the oil filter housing.
1) Remove the center oil filter housing retaining bolt.
Discard the 'O' ring seal.

2) Remove the oil filter housing.
7 . Remove the oil cooler.
Remove and discard the oil cooler O-ring seal.

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Installation
1 . Install the oil cooler.
Install a new oil cooler O-ring seal.
Tighten to 58 Nm.
2 . NOTE:
Install a new 'O' ring seal.
Install the oil filter housing.
1) Loosely install the oil filter housing retaining bolts.
2) Loosely install the center oil filter housing retaining bolt.
3) Install the oil filter housing.
3 . NOTE:
Tighten the bolts in the indicated sequence.
Tighten all bolts to 25 Nm.
2) Tighten to 40 Nm + 90 degrees.
4 . Connect the coolant hoses.
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5 . Install a new engine oil filter.
6 . Install the left-hand engine mount.

7 . NOTE:
Install a new sealing washer to oil pan drain plug
Install the oil pan drain plug

Tighten to 24 Nm.
10 . Carry out the coolant fill and bleeding procedure.

Oil Pan (12.60.44)

303-661
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303-021
Removal

5 . NOTE:
6 . NOTE:

7 . NOTE:
8 . Disconnect the left-hand ignition coils electrical connectors.

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11 . NOTE:
12 . NOTE:

13 . NOTE:

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16 . Remove the air conditioning (AC) compressor. <<412-03>>
17 . Remove the air conditioning compressor bracket.

19 . Remove the generator battery positive cable retaining nut.
20 . Disconnect the generator electrical connector.

21 . Remove the generator.
23 . Detach the power steering hose.

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24 . Remove the steering gear shaft pinch bolt.

26 . Secure the steering gear.
27 . NOTE:
Remove the engine mounts lower retaining bolts.
28 . Detach the automatic transmission oil cooler tubes retaining bracket.


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32 . Detach the engine earth strap from the transmission.
33
. WARNING: Do not remove the front subframe retaining bolts. Failure to follow this
procedure may result in personal injury.
Loosen the front subframe retaining bolts to enable the oil pan to be removed.
34 . Remove the oil pan rear retaining bolts.
35 Remove the oil pan.

.
Remove and discard the oil pan gasket.
Clean and inspect the oil pan and cylinder block sealing surfaces using
metal surface cleaner or equivalent meeting Jaguar specification.
Installation
1 NOTE:
.
Apply an 10 mm dot of silicone gasket and sealant meeting Jaguar specification to the
engine block and front cover mating surface.
NOTE:
Loosely install the oil pan to transmission housing bolts.
NOTE:
Tighten all oil pan retaining bolts within six minutes of applying the sealer.
Install the oil pan rear retaining bolts.

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Tighten to 25 Nm.
2 . Install the oil pan rear retaining bolts.
Tighten to 45 Nm.
3 . Carry out the front subframe alignment procedure. <<502-00>>
5
. CAUTION: Make sure the engine mounts locate into the correct position when the
engine is repositioned.
Using the special tools, reposition the engine.

7 . Install the engine earth strap to the transmission.
Tighten to 10 Nm.
8 . Attach the automatic transmission oil cooler tubes retaining bracket.
Tighten to 10 Nm.
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9 . NOTE:
Install the engine mounts lower retaining bolts.
Tighten to 63 Nm.
Tighten to 100 Nm.
Tighten to 35 Nm.
13 . Attach the power steering hose.
Tighten to 10 Nm.
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14 . NOTE:
Install a new sealing washer to the oil pan drain plug
Install the oil pan drain plug
Tighten to 24 Nm.
15 . To install the generator.
Tighten to 48 Nm.
16 . Connect the generator electrical connector.
17 . Install the generator battery positive cable retaining nut.
Tighten to 12 Nm.

19 . Install the air conditioning compressor bracket.
Tighten to 25 Nm.
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20 . Install the air conditioning (AC) compressor. <<412-03>>

23 . NOTE:
Tighten the exhaust manifold retaining nut.
Tighten to 25 Nm.
24 . NOTE:

25 . NOTE:
Remove the special tool from the exhaust manifold.

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Tighten to 10 Nm.
28 . Connect the left-hand ignition coils electrical connectors.

29 . NOTE:
Attach the right-hand valve cover wiring harness.
30 . NOTE:
Install the engine compartment panel.
Tighten to 10 Nm.
31 . NOTE:
Install the engine compartment panel retaining bolts.
Tighten to 10 Nm.
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Tighten to 10 Nm.


Oil Pump (12.60.26)
Removal
1 . Remove the timing drive components.
2 . NOTE:
Engine inverted for clarity.
Remove the oil pump tube.

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3 . Remove the oil pump.
Inspect the oil pump for damage and wear.

Installation
1
. CAUTION: Install the oil pump flush to the cylinder block for correct sealing.
CAUTION: Rotate the inner rotor of the oil pump to align with the flats on the
crankshaft before installation.
Install the oil pump.
Tighten to 10 Nm.
2 . NOTE:
Install the oil pump tube.
Tighten to 10 Nm.
3 . NOTE:
Tighten to 5 Nm + 45°.
4 . Install the timing drive components.

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Timing Drive Components (12.65.13)
Removal
1 . Remove the engine front cover.
3 NOTE:
.
Note the position of the crankshaft position (CKP) sensor pulse wheel during removal. It
must be returned to its original position during installation.
Remove the crankshaft position (CKP) sensor pulse wheel.
4
. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may
bind causing engine damage.
Install the crankshaft pulley retaining bolt and washer.

5
Rotate the crankshaft clockwise until the crankshaft keyway is at the 7 O'clock position, the
alignment mark on the right-hand intake camshaft sprocket is at the 1 O'clock position and the
alignment mark on the right-hand exhaust camshaft sprocket is at the 8 O'clock position.
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6 . Release the timing chain tensioner ratchet.
7 . NOTE:
Keep the timing chain tensioner ratchet released.
Reposition the timing chain tensioner plunger.

8 . Retain the timing chain tensioner plunger.
9 . Remove the right-hand timing chain tensioner.
10 . Remove the right-hand timing chain outer guide.
11 . Remove the right-hand timing chain.

12 .
CAUTION: Inspect and replace the O-ring seal if necessary.
Remove the right-hand timing chain inner guide.
13
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Rotate the crankshaft clockwise until the crankshaft keyway is at the 11 O'clock position, the
alignment mark on the left-hand intake camshaft sprocket is at the 9 O'clock position and the
alignment mark on the left-hand exhaust camshaft sprocket is at the 2 O'clock position.
14 . NOTE:
Right-hand bank shown, left-hand bank similar.
Release the timing chain tensioner ratchet.

15 . NOTE:
NOTE:
Keep the timing chain tensioner ratchet released.
Reposition the timing chain tensioner plunger.
16 . NOTE:
Retain the timing chain tensioner plunger.

17 . Remove the left-hand timing chain tensioner.
18 . Remove the left-hand timing chain inner guide.

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19 . Remove the left-hand timing chain.
20 .
Remove the left-hand timing chain outer guide.

21
. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock position before any
further engine repairs are carried out.
Remove the crankshaft pulley retaining bolt and washer.
22 . Remove the crankshaft sprocket.
Installation
1 . NOTE:
Make sure the crankshaft sprocket timing marks are facing outwards.
Install the crankshaft sprocket.
2
. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock position before the
camshaft positions are aligned.

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3 Rotate the left-hand intake camshaft clockwise until the camshaft sprocket alignment mark is
. at the 9 O'clock position and rotate the left-hand exhaust camshaft sprocket clockwise until
the camshaft sprocket alignment mark is at the 2 O'clock position.
4 Rotate the right-hand intake camshaft clockwise until the camshaft sprocket alignment mark is
. at the 5 O'clock position and rotate the right-hand exhaust camshaft sprocket clockwise until
the camshaft sprocket alignment mark is at the 12 O'clock position.
5 . Rotate the crankshaft clockwise until the keyway is at the 11 O'clock position.
6.
CAUTION: Make sure the O-ring seal is correctly installed.
Install the left-hand timing chain outer guide.
Tighten the retaining bolts in the sequence shown in two stages.
Stage 1: Tighten bolt 1 to 25 Nm.
Stage 2: Tighten bolts 2 to 25 Nm.
7
. CAUTION: Make sure the crankshaft keyway is at the 11 O'clock position, the
alignment mark on the left-hand intake camshaft sprocket is at the 9 O'clock position and
the alignment mark on the left-hand exhaust camshaft sprocket is at the 2 O'clock position.
CAUTION: Make sure the timing chain alignment marks are correctly positioned to
the crankshaft sprocket and camshaft sprocket alignment marks.
CAUTION: Make sure the timing chain slack is on the tensioned side of the timing
chain.
Install the left-hand timing chain.

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8 . Install the left-hand timing chain inner guide.
9.
CAUTION: Do not manually adjust the timing chain tensioner.
Install the left-hand timing chain tensioner.
Tighten to 25 Nm.
10
. CAUTION: Do not manually adjust the timing chain tensioner.
Make sure the left-hand timing chain alignment marks have remained correctly positioned to
the camshaft sprocket and crankshaft sprocket alignment marks.
11 .
Remove the timing chain tensioner retaining pin.

12
Rotate the crankshaft clockwise until the crankshaft keyway is at the 3 O'clock position.
13 .
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CAUTION: Make sure the O-ring seal is correctly installed.
Install the right-hand timing chain inner guide.
Tighten the retaining bolts in the sequence shown in two stages.
Stage 1: Tighten bolt 1 to 25 Nm.
Stage 2: Tighten bolts 2 to 25 Nm.

14
alignment mark on the right-hand intake camshaft sprocket is at the 5 O'clock position
and the alignment mark on the right-hand exhaust camshaft sprocket is at the 12 O'clock
position.
chain.
Install the right-hand timing chain.
15 . Install the right-hand timing chain outer guide.
16 .
Install the right-hand timing chain tensioner.
Tighten to 25 Nm.
17 .
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Remove the timing chain tensioner retaining pin.
18
. CAUTION: Make sure the right-hand timing chain alignment marks have remained
correctly positioned to the camshaft sprocket and crankshaft sprocket alignment marks.
Make sure all the timing chain alignment marks are in the positions shown.
19
NOTE:
Rotate the crankshaft using hand tools only
Rotate the crankshaft two complete turns clockwise to make sure the valves and pistons do
not clash.
20
21
. CAUTION: Make sure the CKP sensor pulse wheel is correctly installed with the
missing tooth aligned to the crankshaft keyway.
CAUTION: Make sure the CKP sensor pulse wheel is correctly installed with the
teeth pointing outwards.
Install the CKP sensor pulse wheel.

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22 . Install the spark plugs.
Tighten to 15 Nm.
23 . Install the engine front cover.

Removal
2 . Remove the left-hand on-plug coils. <<303-07A>>
4 . Detach the engine breather tube.
5 . Detach the engine wiring harness retaining bracket.

6 . Remove the valve cover.
Remove and discard the gaskets.

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Installation
1 NOTE:
.
Apply a 5mm diameter bead of silicone gasket sealant or equivalent meeting Jaguar
specification on the half round gaskets and apply an 8mm diameter on the two places
where the cylinder head and front cover join.
Install new valve cover gaskets.
Tighten to 10 Nm.
Removal
For additional information, refer to Intake Manifold (30.15.01)
2 . Remove the right-hand on-plug coils. <<303-07A>>
3 . Detach the right-hand valve cover wiring harness.

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4 . Remove the intake manifold rear retaining bracket.
5 . Detach the engine wiring harness retaining bracket.

Installation
1 NOTE:
.
Apply a 5mm diameter bead of silicone gasket sealant or equivalent meeting Jaguar
specification on the half round gaskets and apply an 8mm diameter on the two places
where the cylinder head and front cover join.
Tighten to 10 Nm.
Disassembly
Piston (12.17.02)
Disassembly
1 NOTE:
. Mark the pistons to the original connecting rods to make sure correct installation
in the same cylinders from which they were removed.
Remove the top compression ring.

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2 . Remove the second compression ring.
3 . Remove the first oil control ring.

4 . Remove the oil control spacer ring.
5 . Remove the second oil control ring.
6
. WARNING: The retaining rings have a tendency to spring out during
removal. Cover the end of the pin bore with a hand or a rag when removing the
retaining ring. Eye protection should be worn. Failure to follow these instructions
Remove the retaining clips.
7 . Remove the piston pin and the connecting rod from the piston.
8 Clean and inspect the connecting rod and the piston. For additional information, refer
. to <<303-00>>.
Assembly
1 . Install the piston pin.

• Lubricate the piston pin and piston bore.
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2 . Install the retaining clips.
3 . Check the piston ring end gap. For additional information, refer to <<303-00>>.
4 . Lubricate the piston and piston rings.
5 . Install the second oil control ring.

6 . Install the oil control spacer ring.
7 . Install the first oil control ring.
8 Install the second compression ring.

. • The top of the second compression ring has a "0" marked on it. Position this side
of the ring towards the top of the piston.
9 . Install the top compression ring.

• The top compression ring can be installed with either side up.
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Disassembly / assembly of subassemblies

Valve Spring Compressor

303-252
Disassembly
1
. CAUTION: If the cylinder head valve components are to be reused, mark position of
the valve components to make sure they are reassembled in the same position.
Remove the bucket tappet and shim assemblies.
2 . Using the special tool, compress the valve springs.
• Remove the valve collets.

3 . 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.

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4 . Remove the valves from the cylinder heads.
4. Remove the intake valves.
5. Remove the exhaust valves.

5 . Inspect the cylinder heads and the related components. <<303-00>>
6 . 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 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.

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9. Install the valve springs.
10. Install the valve spring retainers.
• Install the valve collets.

6 . Install the bucket tappet and shim assemblies.
Piston (12.17.02)
Disassembly
1 NOTE:
. Mark the pistons to the original connecting rods to make sure correct installation
in the same cylinders from which they were removed.
Remove the top compression ring.

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2 . Remove the second compression ring.
3 . Remove the first oil control ring.
4 . Remove the oil control spacer ring.

5 . Remove the second oil control ring.
6
. WARNING: The retaining rings have a tendency to spring out during
removal. Cover the end of the pin bore with a hand or a rag when removing the
retaining ring. Eye protection should be worn. Failure to follow these instructions
Remove the retaining clips.
7 . Remove the piston pin and the connecting rod from the piston.
8 Clean and inspect the connecting rod and the piston. For additional information, refer
. to <<303-00>>.
Assembly
1 . Install the piston pin.

• Lubricate the piston pin and piston bore.
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2 . Install the retaining clips.
3 . Check the piston ring end gap. For additional information, refer to <<303-00>>.
4 . Lubricate the piston and piston rings.
5 . Install the second oil control ring.
6 . Install the oil control spacer ring.

7 . Install the first oil control ring.
8 Install the second compression ring.

. • The top of the second compression ring has a "0" marked on it. Position this side
of the ring towards the top of the piston.
9 . Install the top compression ring.

• The top compression ring can be installed with either side up.
Assembly
Engine
Wrench Strap-Universal
303-D055
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Crankshaft Rear Seal Installer

303-178
Crankshaft Rear Seal Installer Adapter Bolts

303-384
Piston Ring Compressor

303-372
Cylinder Bore Protector
303-535

303-102

303-335/2
Assembly
1
. CAUTION: Use only 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. For additional information, refer to <<303-
00>>.
Install the upper crankshaft thrust washer.
• Align assembly tab on thrust bearing to machining spot face on cylinder block.
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4 . Install the upper crankshaft main bearings.
• Lubricate the bearings and thrust washer.

5.
CAUTION: Avoid damage to any crankshaft journal bearing surfaces.
Install the crankshaft.
6 NOTE:
.
Push the crankshaft rearward prior to installation of upper thrust bearings.
NOTE:
Visually inspect the bearings to verify that the bearing oiling holes align with cylinder
block oil feed holes.
Install the lower crankshaft bearings into the cylinder block.
1. Install the lower crankshaft thrust main bearing into lower cylinder block.
2. Install the lower crankshaft main bearings into lower cylinder block.
• Lubricate the bearings and thrust washer.

7 NOTE:
.
Sealant application must stop 6 mm from the rear crankshaft bore on each side.
NOTE:
Install lower cylinder block and tighten all bolts to specification within four minutes of
applying sealer.
Apply a bead of sealant to the cylinder block housing.
• Use Silicone gasket and sealant.

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8
. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to
tightening the bolts.
NOTE:
Before installing the bolts lightly seat the crankshaft forward.
NOTE:
Do not lubricate the lower cylinder block bolts.
NOTE:
Loosely install the lower cylinder block bolts.

NOTE:
Do not rotate crankshaft until all bolts are tightened to specification.
NOTE:
Bolts must be tightened within 4 minutes of applying sealant.
Install the lower cylinder block on the cylinder block.
• Push crankshaft rearward to seat the crankshaft thrust washer.
9.
CAUTION: Bolts 1 through 16 are tighten-to-yield and must be replaced.
NOTE:
Tighten the bolts in the indicated sequence in four stages.
• Stage 1: Bolts 1-8, 25 Nm

• Stage 3: Bolts 1-16, 90°
• Verify the crankshaft rotates freely.

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10 . Remove excess sealant which may squeeze out at the front cover sealing surface.
11 NOTE:
.
Alternate bolt tightening to correctly seat the crankshaft rear oil seal until it is flush
with the cylinder block.
Using the special tools, install the crankshaft rear oil seal.
12
. CAUTION: Use appropriate protection to prevent damage to the crankshaft
bearing journals and cylinder bore surfaces.
Install special tools to the connecting rods.
• Position the crankshaft journal at the bottom of the stroke.
13 NOTE:
.
Make sure the piston ring gaps are positioned at different locations opposite the thrust
side of the piston before installation.
NOTE:
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.

14
. 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.
NOTE:
Remove the special tools from the connecting rods.
NOTE:
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Tighten the bolts in the indicated sequence in three stages.
Position the connecting rod cap on the appropriate connecting rod.
• Stage 1: 23 Nm
• Stage 2: 43 Nm
• Stage 3: 105°
15 . Rotate the crankshaft to check correct operation.

16
. CAUTION: Install the oil pump flush to the cylinder block for correct sealing.
CAUTION: Rotate the inner rotor of the oil pump to align with the flats on the
crankshaft before installation.
• Install a new O-ring seal.
17 .
CAUTION: Oil pan baffle nuts are tightened to yield and must not be reused.
NOTE:
NOTE:
Tighten the nuts in the indicated sequence in two stages.
Install the oil pan baffle.
• Stage 1: 5 Nm
• Stage 2: 45°
18 . NOTE:

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Install the oil pump tube.
19 . NOTE:
20 . Install the engine coolant housing.
• Install new O-ring seals.
21 . Position the crankshaft.
• Turn the crankshaft until the key is in the 11 O'clock position.
• Remove the crankshaft pulley bolt and washer.
22 . Install a new cylinder head gasket (left-hand shown - right-hand similar).

3. Make sure the cylinder head dowels are correctly located.
4. Install a new cylinder head gasket.
23 . NOTE:
Install the bolts in the indicated sequence.

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Install the left-hand cylinder head.
• Tighten 90°.
• Loosen 360°.
• Tighten 90°.
• Tighten 90°.
24 . NOTE:
Install the bolts in the indicated sequence.
Install the right-hand cylinder head.
• Tighten 90°.
• Loosen 360°.
• Tighten 90°.
• Tighten 90°.
25 . Install the left-hand inlet camshaft.
26
NOTE:
Lubricate the camshafts and the camshaft bearing caps with oil WSE-M2C908-A or
equivalent meeting Jaguar specification prior to installation.
Install the left-hand inlet camshaft bearing cap bolts evenly.
• Install the inlet camshaft bearing caps.
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27 . Install the left-hand exhaust camshaft.
28
NOTE:
Lubricate the camshafts and the camshaft bearing caps with oil WSE-M2C908-A or
equivalent meeting Jaguar specification prior to installation.
Install the left-hand exhaust camshaft bearing cap bolts evenly.
• Install the exhaust camshaft bearing caps.
29 . Install the right-hand inlet camshaft.
30 . Install the right-hand inlet camshaft bearing cap bolts evenly.
• Install the inlet camshaft bearing caps.
31 . Install the right-hand exhaust camshaft.

32 . Install the right-hand exhaust camshaft bearing cap bolts evenly.
• Install the exhaust camshaft bearing caps.

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33 Rotate the right-hand intake camshaft clockwise until the camshaft sprocket alignment mark
. is at the 5 O'clock position and rotate the right-hand exhaust camshaft sprocket clockwise
until the camshaft sprocket alignment mark is at the 12 O'clock position.
34 . Install the crankshaft inner sprocket.

35 . Install the left-hand timing chain outer guide.
• Tighten the retaining bolts in the sequence shown in two stages.
• Stage 1: Tighten bolt 1 to 25 Nm.
• Stage 2: Tighten bolts 2 to 25 Nm.
36
alignment mark on the left-hand intake camshaft sprocket is at the 9 O'clock position and
the alignment mark on the left-hand exhaust camshaft sprocket is at the 2 O'clock
position.
chain.
Install the left-hand timing chain.
37 . Install the left-hand timing chain inner guide.

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38
. CAUTION: Use suitable protective covers on the vice jaws to protect the timing
chain tensioner.
Secure the left-hand timing chain tensioner in the vice jaws.
39
. CAUTION: During timing chain tensioner compression, do not release the ratchet
stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the
ratchet stem will result.
Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away
from the ratchet stem.
40 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.
41 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.
42 . Install the left-hand timing chain tensioner.
43 . Release the tension in the left-hand timing chain tensioner.
• Remove the retaining tool.

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44 Make sure the left-hand timing chain alignment marks have remained correctly positioned to
. the camshaft sprocket and crankshaft sprocket alignment marks.
45
46
Rotate the crankshaft clockwise until the crankshaft keyway is at the 3 O'clock position.
47
48 . Install the crankshaft outer sprocket.
49 . Install the right-hand timing chain inner guide.
• Tighten the retaining bolts in the sequence shown in two stages.

• Stage 1: Tighten bolt 1 to 25 Nm.
• Stage 2: Tighten bolts 2 to 25 Nm.
50
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alignment mark on the right-hand intake camshaft sprocket is at the 5 O'clock position
and the alignment mark on the right-hand exhaust camshaft sprocket is at the 12 O'clock
position.
chain.
Install the right-hand timing chain.

51 . Install the right-hand timing chain outer guide.
52
chain tensioner.
Secure the right-hand timing chain tensioner in the vice jaws.
53
Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism
away from the ratchet stem.
54 NOTE:
.
Slowly compress the right-hand timing chain tensioner.
55 NOTE:
.
Using a suitable tool, retain the right-hand timing chain tensioner piston.
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56 . Install the right-hand timing chain tensioner.
57 . Release the tension in the right-hand timing chain tensioner.

58
. CAUTION: Make sure the right-hand timing chain alignment marks have remained
correctly positioned to the camshaft sprocket and crankshaft sprocket alignment marks.
Make sure all the timing chain alignment marks are in the positions shown.
59

60
Check the engine valve timing is correctly set.
• Rotate the crankshaft two complete turns clockwise. Make sure the alignment marks
on the camshaft sprockets are in the positions shown when the crankshaft keyway is at
the 11 O'clock position.
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61
62 NOTE:
.
Make sure the CKP sensor pulse wheel is correctly installed with the teeth pointing
outwards.
Install the CKP sensor pulse wheel.

63 . Carry out a valve clearance check.
For additional information, refer to Valve Clearance Check (12.29.47)
64 . Install new front timing cover gaskets.
65 NOTE:
.
Prior to applying sealer clean the front cover to engine block and cylinder head sealing
surfaces with metal surface cleaner.
Apply a 6 mm diameter dot of silicone sealant meeting Jaguar specification to the indicated
locations.
66 NOTE:
.
The engine front cover retaining bolts numbered 3,4,10 and 11 are longer than the
retaining bolts numbered 1,2,5,6,7,8,9,12,13,15 and 16. The retaining bolt numbered
14 is a retaining bolt with a stud head.
Install the engine front cover, completing the tightening sequence.
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67 NOTE:
.
Apply an 10 mm dot of silicone gasket and sealant meeting Jaguar specification to the
engine block and front cover mating surface.
NOTE:
Loosely install the oil pan to transmission housing bolts.
NOTE:
Tighten all oil pan retaining bolts within six minutes of applying the sealer.
Install the oil pan rear retaining bolts.
• Complete the tightening sequence.
68 . NOTE:
Install the valve covers.
• Complete the tightening sequence.
69 . Install the left-hand idler pulley.
.
• Coat the crankshaft pulley keyway with silicone gasket sealant meeting Jaguar
specification.
• Coat the sealing surfaces of the crankshaft pulley with silicone gasket sealant meeting
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71 . Install the special tool, install the crankshaft pulley retaining bolt.
• Torque to 120 Nm.
• Loosen the bolt (minimum 1 turn).
• Torque to 50 Nm.
• Angle Torque to 90°.

• Tighten 45 Nm.
73 . Install the water pump and coolant hose assembly.
5. Attach the hose.
6. Install the water pump and coolant hose assembly.
74 . NOTE:
Install new coolant crossover O-ring seals.
Install the coolant crossover tube.
75 . Install the engine oil pressure and oil temperature sensors.
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76 . NOTE:
Install the oil filter housing assembly.
• Tighten all oil filter housing retaining bolts to 25 Nm.

77 . Tighten the oil filter housing assembly retaining bolts in sequence.
• Tighten to 40 Nm + 90 degrees.
78 . Install the engine rear backing plate.
79 . Install the flexplate.
• Prevent the engine from rotating.
80 . NOTE:
Install the exhaust manifolds.
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81 . NOTE:
Install the exhaust manifold heat shields.
82 . NOTE:
Install the oil level indicator tube.

83 . Install the A/C compressor mounting bracket.
84 . Install the power steering pump.
85 . Install the generator.
86 . Install the right-hand idler pulley.
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87 . Install the accessory drive belt.
• Use a 3/8 inch drive bar to release the accessory drive belt tensioner.
• Install the accessory drive belt.
88 . Install the left-hand knock sensor.

89 . Install new lower intake manifold gaskets.
90 . Install the lower intake manifold and injector supply manifold.
91 . Install the ignition coils.
92 . Install the engine wiring harness.
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93 . Connect the engine wiring harness electrical connectors.
94 . Connect the left-hand ignition coils.

95 . Connect the left-hand camshaft position sensor.
96 . Attach the engine harness.
97 . Connect the right-hand ignition coils.

99 . Attach the engine harness retaining bracket.

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100 . Disconnect the right-hand camshaft position sensor.
101 . Install the rear knock sensor.
7. Attach the knock sensor wiring harness.
8. Install the rear knock sensor.
102 . Attach engine harness.
104 . Connect the electrical connectors.


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107 . Connect the oil cooler coolant hoses.
108 . Install the evaporative emission purge valve hose.

109 . Install new intake manifold gaskets.
110 NOTE:
.
The intake manifold retaining bolts in position 1,2,3 and are longer than the retaining
bolts in position 4,5 and 6.
111 . Connect the evaporative emission canister purge valve transfer pipe.
112 . Attach the intake manifold rear retaining bracket.

113 . Attach the engine wiring harness from the intake manifold rear retaining bracket.
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114 . Attach the intake manifold front retaining bracket.
115 . Install the fuel pressure sensor bracket.
117 . Connect the fuel pressure sensor vacuum hose.

119 . Connect the positive crankcase ventilation (PCV) hose.
120 . Connect the throttle position sensor electrical connector.

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303-01B : Engine – 3.5L/4.2L
Specifications
Specifications
Engine oil, SAE 5W-30 WSS-M2C-912A
Engine assembly lubricant SQM-2C9003 AA EP90
Sealant WSS M4G 320-A3
Hose assembly surfactant ESE-M99 B144-B
Capacities
Description Liters
Engine oil, initial fill 6.8
Engine oil, service fill with oil filter change 6.5
Cylinder Head
Item Specification
lb-
Description Nm lb-ft
in
Accessory drive belt idler pulley retaining bolt 25 18 -
Accessory drivebelt tensioner retaining bolt 40 30 -
Air conditioning compressor retaining bolts 25 18 -
Air conditioning compressor mounting bracket
25 18 -
retaining bolts
A/C manifold retaining bolt 20 15 -
Camshaft bearing caps retaining bolts 10 7 -
Camshaft position sensor retaining bolt 7 - 62
Connecting rod retaining bolts A - -
Crankshaft pulley retaining bolt 377 278 -
Crankshaft position sensor retaining bolt 10 7 -
Cylinder head retaining bolts A - -
Drive plate retaining bolts A - -
Engine front cover retaining bolts 13 10 -
Engine mounting bracket retaining bolts 40 (+/- 15%) 30 (+/- 15%) -
Engine mount retaining nuts to crossmember 55 (+/- 15%) 40 (+/- 15%) -
Engine mount bracket to engine mount retaining nuts 63 (+/- 15%) 46 (+/- 15%) -
Engine wiring harness retaining bracket 10 7 -
Exhaust manifold heat shield retaining bolts 3 - 27
Exhaust manifold heat shield retaining bolt to cylinder
50 37 -
head
Exhaust manifold retaining bolts 20 15 -
Flexiplate retaining bolts A - -
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Front engine cover retaining bolts 12 9 -

Generator lower retaining bolt 40 30 -
Generator upper retaining bolt 21 15 -
Generator lower retaining bolt 40 30 -
Generator mounting bracket retaining bolts 45 33 -
Ignition coil retaining bolts 5 4 -
Intake manifold assembly retaining bolts 22 16 -
Intake camshaft sprocket retaining bolt
Stage 1 20 15 -
Further 90 Further 90
Stage 2 -
degrees degrees
Knock sensor retaining nuts 20 15 -
Lower cylinder block to the upper cylinder block
A - -
retaining bolts
Oil cooler to oil filter housing retaining bolt 20 15 -
Oil filter housing retaining bolts 21 15 -
Oil level indicator tube retaining nut 6 - 51
Oil pan retaining bolts 12 9 -
Oil pump to engine block retaining bolts 12 9 -
Oil pan drain plug 25 18 -
Oil separator retaining bolts 12 9 -
Oil filter 18 13 -
Piston cooling jet retaining bolt 9 - 80
Power steering bracket bracket retaining bolts 25 18 -
Primary timing chain tensioner retaining bolts 12 9 -
Primary timing chain tensioner guide retaining bolts 12 9 -
Secondary timing chain tensioner retaining bolts 12 9 -
Spark plugs 27 20 -
Starter motor retaining bolts 45 33 -
Thermostat housing retaining bolts 10 7 -
Water pump retaining bolts 12 9 -
Water pump pulley retaining bolts A - -
Upper oil pan retaining bolts 21 15 -
Valve cover retaining bolts 10 7 -
Variable camshaft timing (VCT) oil control unit
22 16 -
housing retaining bolts
VCT sprocket centre retaining bolt
Stage 1 20 15 -
Further 90 Further 90
Stage 2 -
degrees degrees
A = refer to the procedure for the correct torque
- - -
sequence
General procedures

Tappet hold down tool

303-540
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Fan nozzle, air gun

303-590
3. Use a cloth to wipe away as much oil as possible from the tappet and shim.
4.
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 the valve
clearance will be incorrect.
5. Install the base plate of the valve clearance adjusting tool to the relevant cylinder head using the
bolts supplied.
• Secure the tool to the valve cover retaining holes.
6.
CAUTION: Do not rotate the crankshaft while the attachment is installed to the base plate.
Install the attachment of the tool to the base plate to remove the relevant shims.
1. Adjust the fingers of the attachment to the highest position.
2. Install the attachment to the base plate.
3. Tighten the retaining screws to secure the attachment to the base plate.
7. NOTE:
Use a mirror to help locating the fingers of the special tool as access is restricted.
Position the fingers on the outer edges of the tappet. Make sure the recessed step on each finger
locates on the edge of the tappet.
8. Tighten the special tool to compress the valve springs.

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9.
WARNING: The following operations require the use of compressed air. Always wear
suitable eye protection.
CAUTION: Do not use a magnet to remove shims. Failure to follow these instructions may
Remove, clean and measure the shim.
1. Surround the immediate working area with a cloth to retain any loose shims displaced by the
compressed air.
2. Use special tool aimed at the edge of the shim to lift it from the tappet. Remove the shim from
each tappet, noting the position of each one.
10. NOTE:
Two shims within each procedure are possible to be replaced using the special tool.
Use the following formula to calculate the required shim thickness.
• Original shim thickness + measured shim clearance - desired clearance = required shim
thickness.
11.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions may
NOTE:
Shims must be fitted with the size markings facing the tappet, not the camshaft.
Apply a light coat of engine oil to the replacement shim(s) and install.
12. Loosen the special tool to allow the valve springs to return to their normal position.
13. Using the feeler gauge set, measure the clearance between the camshaft and the shim surface.
Record and check the readings.
14. When the valve clearance is correct, remove the attachment from the base plate and repeat the
procedure for the following two valves to be adjusted.

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3.
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
the valve clearance will be incorrect.
4. Using the feeler gauge set, measure the clearance between the camshaft and the shim
surface. Record and check the readings. Adjust the clearances as necessary.

Engine
Cylinder Block
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The 3.5L & 4.2L engine consists of an eight cylinder 90 degree 'Enclosed V' configuration liquid cooled
aluminium cylinder block with dry cast liners.
Viewed from the driving position, the right-hand cylinder bank is designated A-bank and the left-
hand cylinder bank as B-bank.
Cylinder Block Drain Plug

The coolant drain plug is located on the rear left side of the cylinder block.
On vehicles supplied with a cold climate package (i.e. vehicles operating in conditions regularly below
-30ºC) a cylinder block heater unit is fitted instead of the drain plug.
Knock Sensors
Two knock sensors are fitted to the cylinder block on the inboard side of each cylinder bank. The
electrical connector of each sensor is secured to the left-hand engine cover bracket.
These piezo-electric sensors provide inputs to the engine control module (ECM) to indicate the
detection and location of detonation during combustion.
Crankshaft
The cast iron crankshaft has undercut and rolled fillets for improved strength and six counter-balance
weights make sure low levels of vibration from the four throw, five bearing configuration.
The main bearing shells are aluminium/tin split plain type. An oil groove in the top half of each
bearing transfers oil into the crankshaft oilway drillings for lubrication of the connecting rod
bearings. A lead/bronze thrust washer is fitted on each side of the top half of the center main
bearing.
The crankshaft rear oil seal is lipped and is a press fit in the interface of the bedplate to cylinder
block.
A torsional vibration crankshaft damper pulley is bolted to the front of the crankshaft.
Connecting Rods and Pistons
The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps.
The opposing sides of each connecting rod being fractured at the bearing horizontal center line.
The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods
and bearing caps. The connecting rod bearing shells are lead/bronze, split plain bearings.
The pistons are open ended skirt design with small recesses for valve clearance and flat upper
surfaces to reduce heat absorption. Three piston rings, two compression and one oil control, are
fitted to each piston. Each piston is fitted on a gudgeon pin which is in a lead/bronze bush fitted in
the connecting rod.
Timing Gear
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1 — Primary chain tensioner
2 — Primary chain
Multi link primary and single link secondary chains drive the camshafts of each cylinder bank. The
primary chains transmit the drive from sprocket on the crankshaft to a sprocket on each intake
camshaft. The secondary chains transmit the drive from a second, smaller sprocket on the intake
camshaft to a sprocket on the exhaust camshaft.
Each chain has a hydraulic tensioner operated by the engine lubricating system. A jet of oil from the
end of each tensioner lubricates the chains. The primary chain tensioners act on pivoting flexible
tensioner blades, the secondary chain tensioners act directly on the chains.
A woodruff key locates the drive sprocket on the crankshaft and these are retained in position by the
crankshaft damper pulley.
1 — Variable valve timing unit
2 — Secondary chain
3 — Secondary chain tensioner
The variable valve timing (VVT) oil control unit and the exhaust camshaft sprockets are non-
interference. They are clamped in place on the camshafts by the retaining bolt and clamping
plate/washer.
Timing Cover
1 — Crankshaft front oil seal
2 — Poly-acrylic seal
The aluminium-alloy timing cover accommodates the crankshaft front oil seal. Poly-acrylic seal in-
groove gaskets seal the joint between the timing cover and the front face of the engine.
Cylinder Heads and Valve Gear

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1 — Cylinder head bolt
2 — Coolant outlet
3 — Valve lifter
4 — Adjustment shim
5 — Camshaft
Cylinder heads are unique to each cylinder bank and are secured, using deep seated bolts, to the
cylinder block. Two hollow dowels align each cylinder head with the cylinder block.
Each cylinder head gasket consists of a silicon beaded composite gasket with metal eyelets for the
cylinder bores.
Each cylinder head incorporates dual overhead camshafts operating four valves per cylinder via solid
aluminium-alloy valve lifters. A steel shim in the top of each lifter allows adjustment of valve
clearances.
Collets, valve collars and spring seats locate the valve springs on the intake and exhaust valves. Valve
stem seals are integrated into the spring seats.
Four 14mm spark plugs are located in a recess on the center-line of each cylinder head. <<303-07B>>
Camshafts
The chilled cast iron camshafts are each retained by five aluminium alloy caps - location numbers 0 to
4 for the intake camshaft and 5 to 9 for the exhaust camshaft from the front.
A machined flat near the front of each camshaft enables the camshafts to be locked during the valve
timing procedure.
Camshaft Sensor
The camshaft sensors are fitted to the rear of each cylinder head and are triggered by four toothed
sensing rings fitted to the rear of the intake camshaft. The camshaft sensors are variable reluctance
sensors that provides an input to the ECM of intake camshaft position.
Camshaft Covers
The valve covers are made from thermoplastic plastic; the right-hand bank cover incorporates an
outlet for the part load engine breather.
The left-hand bank cover incorporates the engine oil filler cap and an outlet for the full load engine
breather. Identical oil separators are incorporated inside the top of each cover. Each oil separator
comprises a wire gauze packing in an open ended enclosure below the breather outlet.
Bedplate
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1 — Bedplate
2 — Sealant track
This is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft and to
further improve overall rigidity.
Main bearing clearance changes due to expansion are minimized by means of iron inserts cast into
the bedplate main bearing supports.
Two hollow dowels align the bedplate with the cylinder block and the joint is sealed by a continuous
bead of sealant.
Engine Mountings
The engine is mounted at two points. At each side of the engine, there is a mounting bracket with a
hydraulic mounting to the subframe.
Engine Lubrication
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil
pump is then filtered and distributed through the internal oil passages.
Where an oil cooler is fitted, the oil is cooled before entering the filter.
All moving parts are lubricated either by pressure or splash oil. Pressurized oil is also provided for
operation of the variable valve timing units and the timing gear chain tensioners.
All of the oil system components are installed on the structural sump.
Oil is returned to the oil pan under gravity through large drain holes in the cylinder heads and the
engine block to make sure quick return of the oil.
Oil Pick-Up
The plastic moulded oil pick-up is attached to the underside of the structural sump. It is immersed in
the oil reservoir to provide a supply to the oil pump during all normal vehicle attitudes. A castellated
inlet allows the supply to be maintained after any deformation of the sump pan (e.g. after
grounding). A mesh screen in the inlet prevents debris from entering the oil system.
Oil Pressure Switch

Installed at the right front of the structural sump, the oil pressure switch connects a ground input to
the instrument cluster when oil pressure is present. This switch operates at a pressure of 0,15 to 0,41
bar (2.2 to 5.9 lbf.in2).
Oil Pump
The oil pump is fitted at the front of the engine and is driven directly by the crankshaft. The inlet and
outlet ports align with oil passages in the bedplate, with a rubber coated metal gasket to seal the
pump to bedplate interface.
An integral pressure relief valve regulates pump outlet pressure at 4,5 bar (65.25lbf.in2).
Oil Pan
The oil pan/sump comprises an aluminium-alloy structural sump bolted to the bedplate and a
pressed steel pan with integral sump plug, bolted to the structural sump.
Oil Filler Cap

The oil filler cap is located on the top of the left-hand bank valve cover.
Windage Tray
A windage tray attached to the top of the structural sump isolates the oil pan from the disturbed air
flow, caused by the rotation of the crankshaft; preventing oil aeration and improving oil drainage.
Crankcase Ventilation
The engine is ventilated through a part-load and a full-load breather; one on each valve cover. These
flexible plastic hoses incorporate O-ring seals and quick release connectors.
The part-load breather ventilates the left-hand valve cover (B-bank) and feeds onto the throttle body
adaptor and the purge valve. This breather is connected between the oil separator in the cover and
the induction elbow.
The full-load breather ventilates the right-hand cover (A-bank) and is connected between the oil
separator in the cover and the air intake duct between the mass air flow (MAF) sensor and the
throttle body.
The MAF sensor unit combines the two sensors: one for air flow and one for air inlet temperature. It
is a hot wire sensor that provides an input which is (approximately) proportional to the mass air flow
into the engine.
Each valve cover oil separator consists of wire gauze packed into an open ended enclosure in the top
of the cover, below the breather outlet.
Variable Valve Timing (VVT)

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1 — Variable valve timing (VCT) oil control unit
2 — Variable valve timing (VCT) oil control solenoid
3 — Bush carrier
The variable valve timing system improves both low speed and high speed engine performance,
engine idle quality and exhaust emissions. It is an infinitely variable system operating on the intake
camshafts only. There is the equivalent of 48º of crankshaft movement between the retarded and
advanced positions. Engine oil pressure operates the system under the control of the ECM.
Engine
Crankshaft Main Bearing Carrier

Crankshaft locking, main tool

303-191
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Adapter
303-191-02

303-588
Crankshaft setting, main tool

303-645
Camshaft setting
303-530
Timing chain tensioning tool

303-532
Crankshaft rear oil seal remover/replacer

303-538
Crankshaft front seal installer

303-538
Remover, crankshaft front seal

303-751
Removal
All vehicles
1 . Remove the engine from the vehicle.
For additional information, refer to Engine (12.41.01)
2 . Mount the engine to a suitable engine stand.

3 . Disconnect the oil cooler hoses.

4 . Detach the supercharger belt.
Use a ½ inch square drive bar to rotate the supercharger belt tensioner.
Detach the supercharger belt.

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5 . Remove the supercharger belt tensioner.
Remove the supercharger belt.

6 . Remove the supercharger belt idler pulley.
7 . Remove the mounting bracket.
All vehicles
8 . Detach the accessory drive belt.
Rotate the accessory drive belt tensioner counter-clockwise.
Detach the accessory drive belt.

Remove the accessory drive belt.

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10 . Remove the accessory drive belt idler pulley.
11 . Detach the battery positive cable.

13 . Remove the battery positive cable.

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16 . Detach the engine wiring harness.
17 . Remove the generator mounting bracket.

18 . Detach the right-hand heated oxygen sensor (HO2S) retaining bracket.
19 . Detach the HO2S wiring harness, from the engine.
20 . Remove the starter motor.
21 . NOTE:
Remove both engine mounts.

Remove the retaining nuts.
22 . Disconnect the air conditioning compressor electrical connector.

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23 . Detach the A/C compressor wiring harness.
24 . Remove the A/C compressor.

25 . Remove the air conditioning compressor mounting bracket.
27 . Remove the power steering pump mounting bracket.

28 . Remove the oil level indicator and tube.

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30 . Remove the CKP sensor.
31 . Detach the left-hand heated oxygen sensor (HO2S) wiring harness.

32 . Detach the engine wiring harness from the cylinder block.
34 Detach the engine wiring harness.

.
Disconnect the variable camshaft timing (VCT) solenoid electrical
connector.
Detach the engine wiring harness.

35 . Disconnect the engine coolant temperature (ECT) sensor electrical connector.
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36 . Remove the thermostat housing.

37 . Disconnect the thermostat housing hoses
38 . Disconnect the ECT sensor electrical connector.
39 . Reposition the thermostat housing hose retaining clip.
40 . Disconnect the hose.

41 . Disconnect the heater supply hose from the thermostat housing.
42 . Disconnect the water pump outlet hose.

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43 . Remove the thermostat housing retaining bolts.
Remove and discard thermostat housing O-ring seals.

45 . Remove the engine cover left-hand retaining bracket.
46 . Remove the engine cover right-hand retaining bracket.
All vehicles
47 . NOTE:
Remove both ignition coil covers.

48 . Disconnect the left-hand ignition coil electrical connectors.
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49 . Detach the left-hand ignition coil wiring harness.
50 . Detach the left-hand ignition coil wiring harness.

51 . Detach the right-hand ignition coil wiring harness.
52 . Disconnect the right-hand ignition coil electrical connectors.
53 . Detach the right-hand ignition coil wiring harness.

.
Detach the ground cable.
Disconnect the variable camshaft timing (VCT) solenoid electrical

connector.

55 . NOTE:
Remove the ignition coils.

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56 . Disconnect the positive crankcase ventilation (PCV) pipe.
All vehicles
Remove and discard the valve cover gaskets.
Remove and discard the valve cover gaskets.
59 . Using the special tool, remove the water pump pulley.
Using the special tool, retain the water pump pulley.

60 . NOTE:
Place a suitable container underneath the oil filter housing to prevent oil spillage.
Remove the oil filter.

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61 . Disconnect the oil pressure switch and oil temperature sensor electrical connectors.

63
. 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.
64 . Remove the special tools.
65 . NOTE:
The crankshaft pulley will be very tight.

Using special tools, remove the crankshaft pulley.
Collect the locking ring.
66 . Using the special tool, remove the crankshaft front seal.

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67
. 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
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead
center (TDC) No. 1 cylinder
69 . Remove the left-hand VCT oil control unit housing.

70 . Install the special tool to the left-hand cylinder head.
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71 . Loosen the left-hand exhaust camshaft sprocket retaining bolt.
72 . Loosen the left-hand inlet camshaft sprocket retaining bolt.

73 . Remove the right-hand VCT oil control unit housing.
74 . Install the special tool to the right-hand cylinder head.
75 . Loosen the right-hand exhaust camshaft sprocket retaining bolt.
76 . Loosen the right-hand exhaust camshaft sprocket retaining bolt.

77 . Remove the right-hand primary timing chain tensioner assembly.
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78 . Remove the right-hand primary timing chain tensioner guide.
79 . Remove the right-hand primary timing chain.

80 . Remove the right-hand primary timing chain guide.
81 . Remove the left-hand primary timing chain tensioner assembly.
82 . Remove the left-hand primary timing chain tensioner guide.
83 . Remove the left-hand primary timing chain.

85 . Remove the left-hand primary timing chain tensioner guide.

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87
. 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 drive plate.
Remove the 8 bolts.

88 . Remove the lower oil pan.
Remove and discard the gasket.
89 . Remove the oil strainer.
90 . Remove the upper oil pan.

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92
. CAUTION: 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.
93 . Discard the crankshaft rear main oil seal.

Installation
All vehicles
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
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2 NOTE:
.
Install the crankshaft main bearing carrier and tighten bolts to specification within
twenty minutes of applying the sealant.
Apply a 2 mm bead of sealant to the cylinder block in the area shown.
Use WSS-M4G323-A4-RTV sealant.
.
3 NOTE:
Install the crankshaft main bearing carrier and tighten bolts to specification within
twenty minutes of applying the sealant.
Apply a 1 mm bead of sealant to the cylinder block in the area shown.
4
. CAUTION: Make sure all dowels are fully seated into the crankshaft main bearing
carrier prior to tightening the bolts.
NOTE:
Do not lubricate the crankshaft main bearing carrier retaining bolts.
NOTE:
Do not rotate the crankshaft until all the retaining bolts are tightened to specification.
NOTE:
The retaining bolts must be tightened within twenty minutes of applying the sealant.
NOTE:
Install the crankshaft main bearing carrier to the cylinder block.

Stage 1: Bolts 21 to 32, tighten to 15 Nm
Stage 5: Bolts 1 to 10, tighten to 35 Nm + 135 degrees
Stage 9: Center punch each of the bolt heads to indicate it has been reused.
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6 . Remove the special tool from the left-hand cylinder head.
7 . Remove the special tool from the right-hand cylinder head.
8
. CAUTION: Make sure that number 1 cylinder intake camshaft lobes are vertical to
the cylinder head face.
Position the right-hand camshafts to the neutral position.

9
. CAUTION: Make sure that number 2 cylinder exhaust camshaft lobes are vertical to
the cylinder head face.
Position the left-hand camshafts to the neutral position.

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10
. CAUTION: Make sure no binding of the crankshaft occurs.
CAUTION: Make sure the spark plugs are removed to enable the engine to rotate
freely.
Carefully rotate the crankshaft two complete turns to check for correct operation.
11
freely.
CAUTION: Do not rotate the crankshaft counterclockwise.
center (TDC) No. 1 cylinder

15 . Remove excess sealant which may squeeze out at the front cover sealing surfaces.
16 . NOTE:
Make sure the transit sleeve is correctly positioned.
Align the rear crankshaft oil seal, to the crankshaft.
Carefully remove the transit sleeve, leaving the seal in place.

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17 . Install the special tool to the crankshaft.
18 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.
19 . NOTE:
Alternate nut tightening to correctly seat the crankshaft rear seal.

Using the special tool, install the crankshaft rear seal.
20 . Remove the special tool from the crankshaft.
Check that the seal is located correctly.
21 . NOTE:
Install a new gasket.
Tighten to 12 Nm.
22 NOTE:
.
It is important that the oil pan extension is bolted to the crankshaft main bearing
carrier within twenty minutes of applying the sealant.
Apply a continuous 3mm bead of sealant around the crankshaft main bearing carrier flange
OR around the oil pan body flange as shown.

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23 NOTE:
.
It is important that the oil pan extension is bolted to the crankshaft main bearing
carrier within twenty minutes of applying the sealant.
Apply a continuous 2mm bead of sealant, around the diverter valve flange as shown.

24 . NOTE:
Install the upper oil pan.
Tighten to 21 Nm.
25 . NOTE:
Install the oil strainer.
Tighten to 12 Nm.
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26 . Install the oil pan gasket to the oil pan body assembly.
27 . Install the lower oil pan.
Install, but do not fully tighten the retaining bolts.

28 . Tighten the retaining bolts in the indicated sequence in two stages.
Stage 1: bolts 1 to 7, tighten to 5 Nm.
29 . Install the drive plate.
Install the drive plate.
Install the drive plate retaining bolts, and tighten in 2 stages.

30 . Position the crankshaft.

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31 . Install the left-hand primary timing chain tensioner guide.
Tighten to 12 Nm.
32 . Install the crankshaft sprocket.
33
. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing
chain.
Install the left-hand primary timing chain.
Install the primary chain over the crankshaft sprocket and the intake
sprocket.
34 . Install the left-hand primary timing chain tensioner guide.
Tighten to 12 Nm.
35
chain tensioner.
Secure the left-hand timing chain tensioner in the vice jaws.

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36
37 NOTE:
.
38 NOTE:
.
39 . Install the left-hand primary timing chain tensioner assembly.
Tighten to 12 Nm.
Remove the retaining tool.

41
. 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 120 Nm.

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42
sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction.
Tighten to 120 Nm.
43 . Install the right-hand primary timing chain guide.

Tighten to 12 Nm.
44
chain.
Install the right-hand primary timing chain.
sprocket.
45 . Install the right-hand primary timing chain tensioner guide.
Tighten to 12 Nm.
46
chain tensioner.
Secure the right-hand timing chain tensioner in the vice jaws.

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47
48 NOTE:
.
49 NOTE:
.
50 . Install the right-hand primary timing chain tensioner assembly.
Tighten to 12 Nm.

52
sprocket bolt.
Tighten to 120 Nm.

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53
sprocket bolt.
Tighten to 120 Nm.

55 . NOTE:
Install the right-hand VCT oil control unit housing.
Tighten to 22 Nm.
57 . NOTE:

Install the left-hand VCT oil control unit housing.
Tighten to 22 Nm.
58 . Install new seals to the timing cover.

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Install the new seal to the inner groove on the face of the timing cover.
Install the new seal to the outer groove on the face of the timing cover.
59 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 (0.12 in) bead. (Install and tighten the
securing bolts within twenty minutes of sealant application).
60 . Install the timing cover.
61 .
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.

62 . Remove the crankshaft seal protector.
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64 . Install the CKP sensor.
Tighten to 12 Nm.
65 . Install a new O-ring seal to the crankshaft pulley.
Lubricate the new O-ring.
66
. 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.
67
Tighten the crankshaft pulley retaining bolt to 375 Nm.

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69 . NOTE:
Tighten to 21 Nm.
70 . Connect the oil pressure switch and oil temperature sensor electrical connectors.
71 . NOTE:
Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal.
Install a new oil filter.
Tighten to 18 Nm.
72 . Install the water pump pulley.
Using the special tool, retain the water pump pulley.
73 NOTE:
.
NOTE:
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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.
Tighten in the sequence shown to 10 Nm.
74 NOTE:
.
NOTE:
Tighten in the sequence shown to 10 Nm.

75 . Connect the PCV pipe.
All vehicles
76 . NOTE:
Left-hand shown, right-hand similar
Install the ignition coils.
Tighten to 5 Nm.
Connect the VCT solenoid electrical connector.
Attach the engine harness.

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78 . Attach the right-hand ignition coil wiring harness
79 . Connect the right-hand ignition coil electrical connectors.

80 . Attach the right-hand ignition coil wiring harness.
81 . Attach the left-hand ignition coil wiring harness.
82 . Attach the left-hand ignition coil wiring harness.

83 . Connect the left-hand ignition coil electrical connectors.
84 . NOTE:
Install both ignition coil covers.

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85 . Install the right-hand engine cover retaining bracket.
86 . Install the left-hand engine cover retaining bracket.

87 . NOTE:
Install new O-ring seals to the thermostat housing.
Install thermostat housing.
Tighten to 10 Nm.
89 . Connect the water pump outlet to thermostat housing hose.

90 . Connect the heater supply hose to the thermostat housing.
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91 . Connect the thermostat outlet hose.

93 . Connect the ECT sensor electrical connector.
94 . Connect the thermostat housing hoses

95 . NOTE:
Install the thermostat housing.
Tighten to 10 Nm.

All vehicles
97 . Attach the engine wiring harness.
Connect the VCT solenoid electrical connector.
Attach the engine wiring harness.

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98 . Attach the engine wiring harness to the cylinder block.
99 . Attach the engine wiring harness to the cylinder block.

100 . Attach the left-hand HO2S wiring harness.
Tighten to 10 Nm.
101 . Connect the CKP sensor electrical connector.
102 . NOTE:
Install the oil level indicator and tube.

Tighten to 6 Nm.
103 . Install the power steering pump mounting bracket.
Tighten to 25 Nm.
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Tighten to 25 Nm.
105 . Install the A/C compressor mounting bracket.

Tighten to 25 Nm.
106 . Install the A/C compressor.
Tighten to 25 Nm.
107 . Attach the A/C compressor harness.
Tighten to 10 Nm.
108 . Connect the A/C compressor electrical connector.
109 . NOTE:
Install both engine mounts.

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Tighten to 43 Nm.
110 . Install the starter motor.
Tighten to 45 Nm.
111 . Attach the right-hand HO2S wiring harness to the cylinder block.
Removal
Engine (12.41.01)

303-536
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303-749

418-535
Removal
All Vehicles
1 Reclaim the air conditioning (A/C) refrigerant.
. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and
Charging (82.30.30)
2 . Remove the automatic transmission.

For additional information, refer to Transmission - 3.5L/4.2L (44.20.01)
3 . NOTE:
Left hand shown, right hand similar.
Remove the engine mount retaining nuts.

4 . NOTE:
Place a suitable container underneath the oil cooler to prevent oil spillage.
Detach the oil cooler lines.
Remove and discard the oil cooler O-ring seals.
5 . Remove the oil cooler inlet line.

6 . Remove the oil cooler outlet line.

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All vehicles
7 . Detach the starter motor positive cable cover.
8 . Detach the starter motor positive cables.

9 . Detach the A/C compressor return line.
Remove and discard the O-ring seals
10 . Detach the power steering line.

12 . Remove the hood.
For additional information, refer to Hood (76.16.01)
13 . Cooling Fan Motor and Shroud

For additional information, refer to Cooling Fan Motor and Shroud (26.25.25)
14 . Detach the lower coolant hose.

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For additional information, refer to Cabin Air Filter (76.10.09)
16 . Remove the cowl vent screen.

For additional information, refer to Cowl Vent Screen (76.10.01)
17 . Remove the engine compartment support.

19 . Remove the engine compartment cover.
21 . Disconnect the engine harness electrical connector.

23 . Detach the engine harness earth.

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24 NOTE:
.
the electrical connector
Disconnect the ECM electrical connector.
25 . Detach the wiring harness retaining clip.

26 Remove the power steering fluid reservoir.
. For additional information, refer to Power Steering Fluid Reservoir - 3.0L/3.5L/4.2L
(57.15.08)
27 NOTE:
.
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.
Remove the clip.
28 . Detach the fuel line retaining bracket.

29 . Install the special tool to the left-hand rear of the engine.
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30 . Install the special tool to the right-hand rear of the engine.
31 . Detach the evaporative emission canister purge valve hose.

Range: G00442->G45703 (19.70.04)
Range: G45704->G99999 (19.70.04)
33 . Detach the brake booster vacuum pipe.

34 . Remove the air intake tube.

36 . Detach the fuel purge line.
All vehicles
37 NOTE:
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.
Install the special tools to the front of the engine.
38 . Remove the engine assembly.
Using the special tools, remove the engine assembly.

Installation
Engine (12.41.01)

303-536
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303-749

418-535
Installation
All Vehicles
1 . Install the engine using suitable hydraulic lift.
2 . Install the rubber blocks supplied with special tool HTJ1200-2.
3 NOTE:
.
Remove the special tools from the front of the engine.

4 . Attach the fuel purge line.

5 . Attach the brake booster vacuum pipe.
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6 . Install the air intake tube.

Range: G00442->G45703 (19.70.04)
Range: G45704->G99999 (19.70.04)
All Vehicles
9 . Attach the evaporative emission canister purge valve hose.
10 . Remove the special tool from the left-hand rear of the engine.
11 . Remove the special tool from the right-hand rear of the engine.
12 . Attach the fuel line retaining bracket.

13 . Connect the fuel line.
Attach the fuel line retaining clip.

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14 Install the power steering fluid reservoir.

. For additional information, refer to Power Steering Fluid Reservoir - 3.0L/3.5L/4.2L
(57.15.08)
15 . Attach the wiring harness retaining clip.

16 . Connect the engine control module (ECM) electrical connector.
Tighten to 6 Nm.
17 . Attach the engine harness earth.
18 . Connect the engine harness electrical connector.

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21 . Install the engine compartment cover.
22 . Install the engine compartment support.

24 . Install the cabin air filter.

25 . Install the cowl vent screen.

26 . Connect the lower coolant hose.
27 . Install the cooling fan motor and shroud.

28 . Install the hood.

For additional information, refer to Hood (76.16.01)

30 . Attach the power steering line.
31 . Connect the A/C compressor return line.

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Tighten to 20 Nm.
34 . Attach the starter motor positive cable cover.



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All vehicles
38 . NOTE:
Left hand shown, right hand similar.
Tighten to 63 Nm.
39 . Install the automatic transmission.

40 Carry out the A/C system evacuation and charging procedure.
. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and
Charging (82.30.30)
41 . Carry out the A/C system flourescent dye leak detection procedure.
For additional information, refer to Fluorescent Dye Leak Detection
In vehicle repair
Camshafts RH - VIN Range: G00442-

>G45703 (12.13.18)
Camshaft setting/locking tool

303-530
www.JagDocs.com

303-532

303-645
Removal
All vehicles
2 . Disconnect the crankshaft position sensor electrical connector.

3 . Remove the crankshaft position sensor.
5 Remove the engine front cover.

. For additional information, refer to Engine Front Cover - VIN Range: G00442->G45703
(12.65.01)

6 . Remove the right-hand variable camshaft timing oil control unit housing.

All vehicles
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9 . Remove the primary timing chain tensioner assembly.

10 . Remove the primary timing chain tensioner guide.
11 . Remove the primary timing chain.
12 . Remove the secondary timing chain tensioner retaining bolts.
13 Remove the camshaft sprockets.

.
Remove the secondary timing chain tensioner and secondary timing chain
from the camshaft sprockets.
14 . Remove the camshaft setting tool.
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15 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).
16 . Remove the right-hand exhaust camshaft.

.
18 . Remove the right-hand intake camshaft.

Installation
All vehicles
1 . 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.

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3.
CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
Tighten to 10 Nm.
4 . NOTE:

6.
Tighten to 10 Nm.
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7 . Install the camshaft setting tool.
8 . Using a suitable tool, retain the right-hand timing chain tensioner piston.
9
. 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.
10 . Install the secondary timing chain tensioner retaining bolts.
Tighten to 12 Nm.
12 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.
13
chain.
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Install the primary timing chain.
sprocket.
14 . Install the primary timing chain tensioner guide.
Tighten to 12 Nm.
15
16 NOTE:
.
17 NOTE:
.
18 . Install the primary timing chain tensioner assembly.
Tighten to 12 Nm.
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20
sprocket bolt.
CAUTION: Make sure that a new bolt is installed.
Tighten to 20 Nm + 90 deg.
21
sprocket bolt.

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24 . Install the right-hand variable camshaft timing oil control unit housing.
Tighten to 22 Nm.
All vehicles
26 . Install the crankshaft position sensor.
Tighten to 10 Nm.
27 . Connect the crankshaft position sensor electrical connector.

29 Install the engine front cover.

(12.65.01)
30 . Carry out the valve clearance check.
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Camshafts RH - VIN Range: G45704-
>G99999 (12.13.18)
Camshaft setting/locking tool

303-530

303-532

303-645
Removal
(12.65.01)

www.JagDocs.com



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.

.

.
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Installation
1 . NOTE:

3.
Tighten to 10 Nm.
4 . NOTE:

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6.
Tighten to 10 Nm.
9
rotate.
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Tighten to 12 Nm.
.
use of the tool.
13
chain.
sprocket.
Tighten to 12 Nm.
15
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16 NOTE:
.
17 NOTE:
.
Tighten to 12 Nm.
20
sprocket bolt.
Using the special tool, apply force to the tool in an anti-clockwise direction to tension the
21
sprocket bolt.
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Using the special tool, apply force to the tool in an anti-clockwise direction.

Tighten to 22 Nm.

Tighten to 10 Nm.
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(12.65.01)
Crankshaft Front Seal - VIN Range:
G00442->G45703 (12.21.14)
Installer, crankshaft front seal

303-750

303-751
Removal
Installation
1.
Using the special tool, install the crankshaft front seal.

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3 . Install the crankshaft pulley.

Crankshaft Front Seal - VIN Range:
G45704->G99999 (12.21.14)
Installer, crankshaft front seal

303-750

303-751
Removal
Installation
1.
Using the special tool, install the crankshaft front seal.

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Locking Tool, Crankshaft Pulley

303-191
Adapter for 303-191/303-588

303-191-02
Remover, Crankshaft Pulley

303-588
Installer/remover, Oil Filter

303-752
Removal
All vehicles
1 . Remove the cooling fan motor and shroud.
2 . Remove the accessory drive belt .
For additional information, refer to Accessory Drive Belt - 3.5L/4.2L (12.10.40)

3 . NOTE:
Place a suitable container underneath the filter to prevent oil spillage.
Using the special tool, remove and discard the oil filter element.
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4 . Detach the oil cooler.
5 . Lower the vehicle
All vehicles
6
NOTE:
8 . NOTE:

10 Remove the crankshaft front seal.

. For additional information, refer to Crankshaft Front Seal - VIN Range: G00442->G45703
(12.21.14)
For additional information, refer to Crankshaft Front Seal - VIN Range: G45704->G99999
(12.21.14)
11 . NOTE:
Check crankshaft pulley and locking ring for damage.
Clean all crankshaft pulley mating faces.

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Installation
All vehicles
1 Install a new crankshaft front seal.
. For additional information, refer to Crankshaft Front Seal - VIN Range: G00442->G45703
(12.21.14)
For additional information, refer to Crankshaft Front Seal - VIN Range: G45704->G99999
(12.21.14)
Lubricate the new O-ring.

3
4


7 . Attach the oil cooler.
Tighten to 55 Nm.
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8 . NOTE:
Using special tool, install a new oil filter.
Tighten to 18 Nm.
All vehicles
9 . Install the accessory drive belt.
For additional information, refer to Accessory Drive Belt - 3.5L/4.2L (12.10.40)

11 . Check and top up the engine oil to the correct level on the oil level indicator.
Crankshaft rear seal remover/replacer

303-538
Removal
1 . Remove the flexplate.
For additional information, refer to Flexplate (12.53.13)
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3 . Reposition the special tool retaining nuts.
4 . Using the special tool pierce the seal face and provide a pilot hole for the self-tapping screws.
5 . Loosen the special tool retaining nuts.
6
. CAUTION: To prevent damage to special tool do not tighten screws more than one
and a half turns.
Install the special tool self-tapping screws.
7 . Using the special tool remove and discard the crankshaft rear seal.
Installation
1 NOTE:
.
Make sure all components are clean and dry.
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Make sure the transit sleeve is correctly in place and install the new seal over the crankshaft.
Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
2 . Carefully remove the transit sleeve, leaving the seal in place.
5.
CAUTION: Alternate nut tightening to correctly seat the crankshaft rear seal.
Check that the seal is located correctly.

Cylinder Head LH - VIN Range: G00442-
>G45703 (12.29.02)
Camshaft setting/locking Tool

303-530

www.JagDocs.com
303-532

303-645
Removal
All vehicles
CAUTION: If a replacement cylinder head is to be installed to a vehicle with variable

camshaft timing (VCT) the cylinder head must have the oil gallery blind rivet removed before
installation.



For additional information, refer to Intake Manifold - VIN Range: G00442->G45703 (30.15.01)

6 . Remove the charge air cooler.
For additional information, refer to Charge Air Cooler
7 . NOTE:
All vehicles
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(12.65.01)

10 . Remove the left-hand variable camshaft timing oil control unit housing.

All vehicles


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16
. CAUTION: Make sure the secondary timing chain and camshaft sprockets are free
to rotate.
Loosen the camshaft sprockets.
17 . Remove the primary timing chain guide.



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.

.
26 . Remove the left-hand exhaust camshaft.

.
28 . Remove the left-hand inlet camshaft.

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29
. 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
follow this instruction may result in damage to the component.
Remove the left-hand cylinder head.
Remove the bolts in the indicated sequence.

30 .
CAUTION: Only use a plastic scrapper to clean off old gasket.
Remove the cylinder head gasket.
Clean the gasket mating faces.
31 .
Clean the cylinder head locating dowels.

32 . Clean and inspect the cylinder head and cylinder block.
Installation
All vehicles
1
. CAUTION: If a replacement cylinder head is to be installed to a vehicle with VCT the
cylinder head must have the oil gallery blind rivet removed before installation.
CAUTION: Make sure that all debris is removed from the cylinder head and cylinder
head oil gallery.
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Vehicles fitted with VCT: Remove the blind rivet from the VCT oil gallary.
Identify the VCT oil supply gallery and the 8 mm (0.31 inch) blind rivet.
Using a suitable 3 mm (0.12 inch) punch release the centre of the blind rivet
until it is released from the outer part of the blind rivet.
Using a suitable extraction tool, remove the remaining part of the blind
rivet.
2 . Clean the component mating faces.

3 . Check cylinder head face for distortion, across the center and from corner to corner.
4 . For cylinder head face distortion data, refer to specifications.

5 NOTE:
.
For cylinder head with distortion above the maximum allowance, the cylinder head
material must be measured.
Measure the cylinder head material.
Check measurement from the centre of the exhaust dowel to the cylinder
head face as shown.
If the measurement is less than 51.88 mm the cylinder head requires

replacement.
6.
CAUTION: The head gasket must be installed over the cylinder block dowels.
Install a new cylinder head gasket

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7
. 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 follow
this instruction may result in damage to the component.
NOTE:
Tighten the bolts 1 to 10 in the sequence shown.
1) Tighten bolts 1 to 10 to 20 Nm.
3) Tighten bolts 1 to 10 to 90°.

8 . NOTE:

10 .
Tighten to 10 Nm.
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12 .
Tighten to 10 Nm.
14
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free
to rotate.
15 . Using a suitable tool, retain the left-hand timing chain tensioner piston.
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Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.
20
chain.
sprocket.
Tighten to 12 Nm.
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22
23 NOTE:
.
24 NOTE:
.
Tighten to 12 Nm.

27
sprocket bolt.
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28
sprocket bolt.
29 . Install the primary timing chain guide.
Tighten to 12 Nm.
30
chain.
sprocket.
Tighten to 12 Nm.
32
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33 NOTE:
.

34 NOTE:
.
Tighten to 12 Nm.
37
sprocket bolt.

38
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sprocket bolt.


41 . Install the left-hand variable camshaft timing oil control unit housing.
Tighten to 22 Nm.

Tighten to 22 Nm.
All vehicles
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Tighten to 10 Nm.


47 Install the intake manifold.
. For additional information, refer to Intake Manifold - VIN Range: G00442->G45703
(30.15.01)

48 . Install the lower intake manifold.
Tighten to 22 Nm.
49 . Install the charge air cooler.

All vehicles
(12.65.01)

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Cylinder Head LH - VIN Range: G45704-
>G99999 (12.29.02)
Camshaft setting/locking Tool

303-530

303-532

303-645
Removal
All vehicles
CAUTION: If a replacement cylinder head is to be installed to a vehicle with variable

camshaft timing (VCT) the cylinder head must have the oil gallery blind rivet removed before
installation.


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6 . Remove the charge air cooler.
7 . NOTE:
All vehicles
(12.65.01)

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16
to rotate.

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.

.
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.
29
Remove the bolts in the indicated sequence.

30 .
Remove the cylinder head gasket.
Clean the gasket mating faces.

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31 .
Clean the cylinder head locating dowels.

Installation
All vehicles
1 . Check cylinder head face for distortion, across the center and from corner to corner.
2 . For cylinder head face distortion data, refer to specifications.

3 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.
4
. CAUTION: If a replacement cylinder head is to be installed to a vehicle with VCT the
cylinder head must have the oil gallery blind rivet removed before installation.
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CAUTION: Make sure that all debris is removed from the cylinder head and cylinder
head oil gallery.
Vehicles fitted with VCT: Remove the blind rivet from the VCT oil gallary.
Identify the VCT oil supply gallery and the 8 mm (0.31 inch) blind rivet.
Using a suitable 3 mm (0.12 inch) punch release the centre of the blind rivet
until it is released from the outer part of the blind rivet.
Using a suitable extraction tool, remove the remaining part of the blind
rivet.
5.
CAUTION: The head gasket must be installed over the cylinder block dowels.
Install a new cylinder head gasket
6 . NOTE:
Tighten the bolts 1 to 10 in the sequence shown.

7 . NOTE:

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9.
Tighten to 10 Nm.
11 .
Tighten to 10 Nm.

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13
to rotate.
Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.
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19
chain.
sprocket.
Tighten to 12 Nm.
21
22 NOTE:
.
23 NOTE:
.
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Tighten to 12 Nm.

26
sprocket bolt.
27
sprocket bolt.
Tighten to 12 Nm.
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29
chain.
sprocket.
Tighten to 12 Nm.
31
32 NOTE:
.

33 NOTE:
.

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Tighten to 12 Nm.
36
sprocket bolt.
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37
sprocket bolt.

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Tighten to 22 Nm.
Tighten to 22 Nm.
Tighten to 10 Nm.

46 Install the intake manifold.
. For additional information, refer to Intake Manifold - VIN Range: G45704->G99999
(30.15.01)

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47 . Install the lower intake manifold.
Tighten to 22 Nm.

All vehicles

For additional information, refer to Engine Front Cover - VIN Range: G45704->G99999
(12.65.01)
Engine Front Cover - VIN Range: G00442-
>G45703 (12.65.01)
Front Pulley Lock

303-191
Front Pulley Lock Adaptor

303-191-02
Remover, Crankshaft Damper

303-588
Removal
All vehicles
1 . Remove the cooling fan motor and shroud. <<303-03A>>



5 . Remove the supercharger drive belt. <<303-05>>
All vehicles
6 . Remove power steering pump. <<211-02>>

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8 . Remove the water pump pulley.

10 . Remove supercharger drive belt tensioner. <<303-05>>
All vehicles
12 . Detach the engine harness.
13

15 . Using special tools, remove the crankshaft pulley.

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Remove and discard all the seals.

Installation
All vehicles
1) Install the new seal to the inner groove on the face of the timing cover.
2) Install the new seal to the outer groove on the face of the timing cover.

.
Tighten to 13 Nm.
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4 . NOTE:
Check crankshaft pulley and locking ring for damage.
Clean all crankshaft pulley mating faces.

5
6


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Tighten to 25 Nm.
10 . Install the accessory drive belt idler pulley.
Tighten to 25 Nm.
11 . Install the supercharger drive belt tensioner. <<303-05>>
All vehicles
13 . Install the air conditioning compressor. <<412-03>>
14 . Install power steering pump. <<211-02>>

15 . Install the supercharger drive belt. <<303-05>>
All vehicles

19 . Install the cooling fan motor and shroud. <<303-03A>>

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Engine Front Cover - VIN Range: G45704-
>G99999 (12.65.01)
Removal
All vehicles
For additional information, refer to Valve Cover LH - VIN Range: G45704->G99999 (12.29.43)

For additional information, refer to Valve Cover RH - VIN Range: G45704->G99999 (12.29.44)

For additional information, refer to Crankshaft Pulley (12.21.09)

For additional information, refer to Oil Cooler - Vehicles Without: Supercharger (12.60.68)

5 . Disconnect the coolant hose.

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11 . Detach the coolant assembly.
12 . Remove the coolant assembly.
Disconnect the coolant hose.

All vehicles
Using a suitable tool, retain the water pump pulley.

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14 Remove the air conditioning (A/C) compressor.

. For additional information, refer to Air Conditioning (A/C) Compressor - 3.5L/4.2L, VIN
Range: G45704->G99999 (82.10.20)
15
. CAUTION: Cap the power steering line to prevent loss of fluid and prevent dirt
ingress.
NOTE:
16 . Remove the power steering pump lower retaining bolts.
19
. CAUTION: Cap the power steering lines to prevent loss of fluid and prevent dirt
ingress.
NOTE:
Disconnect the power steering pump to steering gear high-pressure line.

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22 . Remove the supercharger belt idler pulley and bracket assembly.
All vehicles
24 . NOTE:
Vehicles with supercharger shown, vehicles without supercharger similar.
Disconnect the AIR control valve to exhaust manifold tube.
25 . NOTE:

Reposition the AIR control valve and bracket assembly.

26 . Disconnect the AIR control valve to exhaust manifold tube.
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27 . Remove the AIR control valve to exhaust manifold tube.
All vehicles
Remove and discard all the seals.

Installation
All vehicles
1) Install the new seal to the inner groove on the face of the timing cover.
2) Install the new seal to the outer groove on the face of the timing cover.
www.JagDocs.com

.
Tighten to 12 Nm.
Tighten to 25 Nm.
6 . Install the AIR control valve to exhaust manifold tube.
7 . Connect the AIR control valve to exhaust manifold tube.
Tighten to 35 Nm.
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All vehicles
8 . NOTE:
Reposition the AIR control valve and bracket assembly.
Tighten to 8 Nm.
9 . NOTE:
Connect the AIR control valve to exhaust manifold tube.
Tighten to 35 Nm.

10 . Install the supercharger belt tensioner.
Tighten to 40 Nm.
11 . Install the supercharger belt idler pulley and bracket assembly.
Tighten to 9 Nm.
All vehicles
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Tighten to 61 Nm.
Tighten to 25 Nm.
14 . NOTE:
Remove the blanking caps.
Connect the power steering pump to steering gear high-pressure line.
Tighten to 25 Nm.
Tighten to 35 Nm.
17 . Install the power steering pump lower retaining bolts.
Tighten to 25 Nm.
18 . NOTE:
Connect the power steering reservoir to power steering pump supply line.
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19 Install the A/C compressor.

. For additional information, refer to Air Conditioning (A/C) Compressor - 3.5L/4.2L, VIN
Range: G45704->G99999 (82.10.20)
Using a suitable tool, retain the water pump pulley.
21 . Install the coolant assembly.
Connect the coolant hose.
22 . Attach the coolant assembly.
Tighten to 9 Nm.
23 . Connect the coolant hose.

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For additional information, refer to Oil Cooler - Vehicles Without: Supercharger (12.60.68)
All vehicles
For additional information, refer to Crankshaft Pulley (12.21.09)
31 Install the right-hand valve cover.

. For additional information, refer to Valve Cover RH - VIN Range: G45704->G99999
(12.29.44)

For additional information, refer to Valve Cover LH - VIN Range: G45704->G99999
(12.29.43)
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Engine Support Beam

303-021

303-749
Removal
1 . Remove the throttle body.
For additional information, refer to Throttle Body - VIN Range: G00442->G45703 (19.70.04)

For additional information, refer to Air Cleaner Outlet Pipe (19.10.31)
All vehicles
3 NOTE:
.

4 NOTE:
.

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6 . Remove the left-hand front wheel and tire assembly.

7 . NOTE:
Left-hand drive vehicle shown, right-hand drive vehicle similar.
8 . NOTE:
Detach the steering gear.
9 . NOTE:
Right-hand drive vehicle shown, left-hand drive vehicle similar.
Disconnect the power steering control valve actuator electrical connector.

10 . NOTE:
Secure the steering gear.
11 . NOTE:
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Remove and discard the engine mounting securing nut.
Remove the engine mounting retaining nut.
13 NOTE:
.
Vehicles with 4.2L engine with supercharger shown, vehicles with 3.5L or 4.2L engine
without supercharger similar.
Using the special tools, raise the engine to a suitable height.
1) Adjust the engine support beam (clockwise).

2) Raise the engine to a suitable height.
15 . Remove the engine mount and bracket assembly.
16 . NOTE:

Installation
1
. CAUTION: Make sure the engine mount location peg is correctly located into the
engine bracket. Failure to follow this instruction may result in damage to the vehicle.
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NOTE:
Install a new engine mounting securing nut.
Tighten to 55 Nm (+/- 15%).
2 . Tighten to 40 Nm (+/- 15%).

5 . NOTE:

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Engine Support Beam

303-021

303-749
Removal

All vehicles
3 NOTE:
.

4 NOTE:
.

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6 . Remove the right-hand front wheel and tire assembly.

7 . NOTE:
NOTE:
Remove the engine mounting retaining nut.
9 NOTE:
.
NOTE:
Vehicles with 4.2L engine with supercharger shown, vehicles with 3.5L or 4.2L engine
without supercharger similar.
Using the special tools, raise the engine to a suitable height.
1) Adjust the engine support beam (clockwise).
2) Raise the engine to a suitable height.

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11 . Remove the engine mount and bracket assembly.
12 . NOTE:

Installation
1
. CAUTION: Make sure the engine mount location peg is correctly located into the
engine bracket. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
2 . Tighten to 40 Nm (+/- 15%).

3 . NOTE:

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Exhaust Manifold RH - VIN Range:
G00442->G45703 (30.15.56)
Removal
1 . Remove the exhaust system. <<309-00>>
2 . Remove the right-hand exhaust manifold heat shield
3 . Detach the exhaust gas recirculation (EGR) valve.
Remove and discard the retaining nuts and gasket.
4 . Remove the right-hand exhaust manifold heat shield/gasket retaining bolt.

5 . NOTE:
New exhaust manifold retaining studs must be fitted if the old studs are removed.
Remove the exhaust manifold.
Remove and discard the retaining nuts and heat shield/gasket.

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Installation
1
. CAUTION: When all retaining nuts have been torqued, re-torque all retainig nuts to
25 Nm.
CAUTION: Ensure exhaust manifold and heat shield/gasket is correctly aligned to

cylinder head and studs.
Install the exhaust manifold.
Install new retaining nuts and a new heat shield/gasket.
Tighten to 25 Nm.
2 . Install the right-hand exhaust manifold heat shield/gasket retaining bolt.
Tighten to 50 Nm.
3 . Attach the exhaust gas recirculation (EGR) valve.
Install new retaining nuts and a new gasket.
Tighten to 22 Nm.
4 . Install the right-hand exhaust manifold heat shield

Tighten to 3 Nm.
5 . Install the exhaust system. <<309-00>>

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Exhaust Manifold RH - VIN Range:
G45704->G99999 (30.15.56)
Removal
Lock in position, remove the ignition key.
All vehicles
2 . Remove the right-hand exhaust manifold heat shield upper retaining bolts.


4 . Remove the steering gear coupling upper pinch bolt
5 . Remove the steering gear coupling.

Remove the steering gear coupling lower pinch bolt.
All vehicles
6 . Remove the right-hand exhaust manifold heat shield.
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8 . NOTE:
Detach the exhaust gas recirculation (EGR) valve.

Remove and discard the retaining nuts and gasket.
9 . NOTE:
Remove the right-hand exhaust manifold heat shield/gasket retaining bolt.
10 . Remove the exhaust manifold.
Remove and discard the retaining bolts and heat shield/gasket.

Installation
All vehicles
1
. CAUTION: Make sure that the exhaust manifold and heat shield/gasket is correctly
aligned to cylinder head.
Loosely install new retaining bolts and a new heat shield/gasket.

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2 . Tighten the exhaust manifold retaining bolts to 25 Nm.
3 . NOTE:
Install the right-hand exhaust manifold heat shield/gasket retaining bolt.
Tighten to 50 Nm.
4 . NOTE:
Attach the EGR valve.
Install new retaining nuts and a new gasket.
Tighten to 22 Nm.
Tighten to 35 Nm.
6 . Install the right-hand exhaust manifold heat shield
Tighten to 3 Nm.

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7 . Install the steering gear coupling.
Tighten the steering gear coupling lower pinch bolt to 35 Nm.
8 . Install the steering gear coupling upper pinch bolt
Tighten to 35 Nm.
All vehicles
9 . Install the right-hand catalytic converter.
10 . Install the right-hand exhaust manifold heat shield upper retaining bolts.
Tighten to 3 Nm.
Removal
1 . Remove the automatic transmission. For additional information, refer to
2
. 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:

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Remove the 8 bolts.
Installation
1 . NOTE:
NOTE:

NOTE:
Install, but do not tighten, the flexplate retaining bolts.
2 . NOTE:
Tighten to 15 Nm.
3 . NOTE:
Tighten to 110 Nm.

4 . Install the automatic transmission. For additional information, refer to
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Intake Manifold - VIN Range: G00442-
>G45703 (30.15.01)
Removal
2 . Remove the air cleaner outlet pipe. <<303-12B>>
4 . NOTE:
Remove the on-plug coil covers.
5 . Disconnect the throttle potentiometer (TP) electrical connector.

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7
. WARNING: 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 (STILL WITH A CLOTH)
TURN AND REMOVE THE COOLANT PRESSURE CAP FROM THE COOLANT EXPANSION TANK.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Remove the coolant expansion tank cap.
8 . NOTE:
Cap the coolant hose.
Disconnect the throttle body coolant hose.

9 . Disconnect the knock sensors (KS) electrical connectors.
10 . Remove the left-hand engine cover bracket.
11 . NOTE:

12 . NOTE:
Disconnect the fuel injector electrical connectors.

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13 . Detach the fuel line. <<310-00>>
14 . Detach the left-hand camshaft position sensor electrical connector.
15 . Disconnect the coolant temperature sensor electrical connector.

16 . Remove the right-hand engine cover bracket.
17 . Remove the positive crankcase ventilation (PCV) valve.
18 . Disconnect the fuel pressure regulator electrical connector.

19 . Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
20 . NOTE:
Cap the coolant hose.
Disconnect the exhaust gas recirculation (EGR) valve coolant hose.

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21 . Detach the right-hand engine wiring harness.
22 . Disconnect the right-hand fuel injector electrical connectors.

23 . Disconnect the fuel temperature sensor electrical connector.
24 . Disconnect the right-hand camshaft position (CMP) sensor.
25 . Detach the brake booster vacumn pipe.


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28 . Detach the exhaust gas recirculation (EGR) valve tube.

Installation
1.
CAUTION: Make sure that all gasket mating faces are clean and dry.
Install new gaskets.
Tighten to 22 Nm.
2 . Attach the exhaust gas recirculation (EGR) valve tube.
Tighten to 22 Nm.
Tighten to 10 Nm.
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4 . Connect the manifold absolute pressure (MAP) sensor electrical connector.
5 . Connect the right-hand camshaft position (CMP) sensor.

6 . Connect the fuel temperature sensor electrical connector.
7 . Attach the brake booster vacumn pipe.
8 . Connect the right-hand fuel injector electrical connectors.

10 . NOTE:
Remove the cap from the coolant hose.
Connect the exhaust gas recirculation (EGR) valve coolant hose.

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11 . Connect the exhaust gas recirculation (EGR) valve electrical connector.
12 . Connect the fuel pressure regulator electrical connector.

13 . Install the positive crankcase ventilation (PCV) pipe.
14 . Install the right-hand engine cover bracket.
Tighten to 6 Nm.
15 . Connect the coolant temperature sensor electrical connector.

16 . Attach the left-hand camshaft position sensor electrical connector.
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18 . NOTE:
Connect the fuel injector electrical connectors.

19 . NOTE:
20 . Install the left-hand engine cover bracket.
Tighten to 6 Nm.
21 . Connect the knock sensor (KS) electrical connectors.

22 . NOTE:
Remove the cap from the coolant hose.
Connect the throttle body coolant hose.

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24 . Connect the throttle potentiometer (TP) electrical connector.

25 . NOTE:
Install the on-plug coil covers.
Tighten to 18 Nm.
27 . Install the air cleaner outlet pipe. <<303-12B>>

29 . Check and top up the cooling system.

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Intake Manifold - VIN Range: G45704-
>G99999 (30.15.01)
Removal

4 . Disconnect the supressor electrical connector.
5 . Remove the engine cover right-hand bracket.

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8 . Remove the exhaust gas recirculation (EGR) valve retaining bolts.

9 . Disconnect the brake booster vacumn pipe.
10 . Disconnect the secondary air injection (AIR) vacuum line.
11 . Remove the positive crankcase ventilation (PCV) valve.
12 . Disconnect the throttle body electrical connector.

13 . Disconnect the evaporative emission vent hose.
14
. WARNING: When relieving cooling system pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility of scalding. Failure to follow these instructions
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Remove the coolant expansion tank cap.
15 . NOTE:
Cap the coolant hose to minimize coolant loss.
Disconnect the throttle body coolant hose.
16 . Disconnect the engine cooolant temperature (ECT) sensor electrical connector.

17 . Disconnect the evaporative emission cannister purge valve electrical connector.
18 . Detach the knock sensor (KS) electrical connector.
19 . Reposition the engine cover left-hand bracket.

20 . Disconnect the KS electrical connector.
21 . NOTE:
Remove the on-plug coil covers.

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22 . NOTE:

23 . NOTE:
24 . Disconnect the fuel line.

Release the retaining clip.
25 . Detach the left-hand camshaft position sensor electrical connector.

26 . Disconnect the right-hand camshaft position (CMP) sensor.

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Installation
1.
CAUTION: Make sure that all gasket mating faces are clean and dry.
Install new gaskets.
Tighten to 22 Nm.
Tighten to 10 Nm.
3 . Connect the MAP sensor electrical connector.
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4 . Connect the right-hand CMP sensor.
5 . Attach the left-hand CMP sensor electrical connector.

Secure the retaining clip.
7 . NOTE:
8 . NOTE:

9 . NOTE:
Install the on-plug coil covers.

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10 . Connect the KS electrical connector.
11 . Reposition the engine cover left-hand bracket.
Tighten to 6 Nm.
12 . Attach the KS electrical connector.
13 . Connect the evaporative emission cannister purge valve electrical connector.

15 . NOTE:
Connect the throttle body coolant hose.
16 . Install the coolant expansion tank cap.

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17 . Connect the evaporative emission vent hose.
18 . Connect the throttle body electrical connector.
19 . Install the PCV valve.

20 . Connect the AIR vacuum line.
21 . Connect the brake booster vacumn pipe.
22 . Install the EGR valve retaining bolts.
Tighten to 10 Nm.
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25 . Install the engine cover right-hand bracket.
Tighten to 6 Nm.
26 . Connect the supressor electrical connector.
Tighten to 18 Nm.



Oil Cooler - Vehicles With: Supercharger
(12.60.68)
Removal
2 . Detach the electrical connectors.

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3 . Remove the radiator lower cowl.
4 . NOTE:
Place a suitable container underneath oil cooler to prevent oil spillage.
Detach the oil cooler lines.
Remove and discard the oil cooler O-ring seals.

Installation
Tighten to 7 Nm.
2 . Install the oil cooler lines.
Install new oil cooler O-ring seals.

3 . Install the radiator lower cowl.
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4 . Attach the electrical connectors.
6 . Check and fill the engine oil to the correct level on the oil level indicator.
Oil Cooler - Vehicles Without:
Supercharger (12.60.68)
Installer/remover, Oil Filter

303-752
Removal
1 . Drain the cooling system. <<303-03A>>
3 . Disconnect the oil cooler hose.

6 . NOTE:
Using the special tool remove and discard the oil filter element.
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7 . Disconnect the oil cooler hose.
Remove and discard the O-ring.

Installation
Tighten to 55 Nm.
2 . Connect the oil cooler hose.
3 . NOTE:
Using the special tool, install a new oil filter.
Tighten to 18 Nm.

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6 . Connect the oil cooler hose.
7 . Check and fill the engine oil to the correct level on the oil level indicator.
8 . Carry out cooling system filling and bleeding procedure. <<303-03A>>

Oil Pan (12.60.44)
Removal
Place suitable container under the vehicle.
Remove the drain plug and drain the engine oil.
Installation
1 . NOTE:
Make sure all surfaces are clean.
Install the oil pan gasket to the oil pan extension.

Install, but do not fully tighten the retaining bolts.

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3 NOTE:
.
A new oil pan is supplied with the drain plug installed. Check that the drain plug is
tightened to 25 Nm.
Tighten the retaining bolts in the indicated sequence in two stages.

5 . Check and top-up the engine oil.

Removal
(12.65.01)
(12.65.01)

For additional information, refer to Oil Pan (12.60.44)
3 . Disconnect the engine oil temperature sensor electrical connector.

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4 . Disconnect the engine oil pressure sensor electrical connector.
Using suitable blanking plugs, blank the exposed ports.

7 . Detach the right-hand heated oxygen sensor (HO2S) electrical connector retaining bracket.

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11 . Remove the transmission bell housing to oil pan retaining bolts.
Detach the engine ground cable.

12 . Detach the left-hand HO2S electrical connector retaining bracket.
14 . Detach the transmission fluid cooler pipes.

15 . Remove the oil pan extension.
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Installation
1 . NOTE:
Use only a plastic scraper when removing old gasket material.
2 NOTE:
.
It is important that the oil pan extension is bolted to the bedplate within 20 minutes of
applying the RTV sealant.
Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the flange as
indicated.
3 NOTE:
.
It is important that the oil pan extension is bolted to the bedplate within 20 minutes of
applying the RTV sealant.
Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the diverter
valve flange as indicated.
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4 . NOTE:
Tighten the retaining bolts in the indicated sequence.
Install the oil pan extension to the bedplate.
5 . Attach the transmission fluid cooler pipes.
Tighten to 10 Nm.
7 . Attach the left-hand HO2S electrical connector retaining bracket.
Tighten to 10 Nm.
8 . Install the transmission bell housing to oil pan retaining bolts.
Attach the engine ground cable.
Tighten to 48 Nm.
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Tighten to 10 Nm.

12 . Attach the right-hand HO2S electrical connector retaining bracket.
Tighten to 10 Nm.
13 . Install the oil strainer.
Tighten to 12 Nm.
14 . Install the oil filter housing.
Remove the blanking plugs.
Tighten to 21 Nm.
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15 . Connect the engine oil pressure sensor electrical connector.
16 . Connect the engine oil temperature sensor electrical connector.

(12.65.01)
(12.65.01)
Oil Pump - VIN Range: G00442->G45703
(12.60.26)
Camshaft setting
303-530

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303-532

303-645
Removal
All vehicles


(12.65.01)


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All vehicles

14
to rotate.

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20
to rotate.

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Installation
All vehicles
1 . Install the oil pump.
Tighten to 12 Nm.
2 Install the special tool to the exhaust camshaft sprocket.
.
use of the tool.
Tighten to 12 Nm.
4
chain.
sprocket.
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Tighten to 12 Nm.
6
7 NOTE:
.
8 NOTE:
.
Tighten to 12 Nm.
11
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sprocket bolt.
Tighten to 120 Nm.
12
sprocket bolt.
Tighten to 120 Nm.
Tighten to 12 Nm.
14
chain.
sprocket.
Tighten to 12 Nm.
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16
17 NOTE:
.
18 NOTE:
.
Tighten to 12 Nm.

21
sprocket bolt.
Tighten to 120 Nm.

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22
sprocket bolt.
Tighten to 120 Nm.


Tighten to 22 Nm.

Tighten to 22 Nm.
All vehicles
(12.65.01)
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Tighten to 10 Nm.
Tighten to 12 Nm.

Oil Pump - VIN Range: G45704->G99999
(12.60.26)
Camshaft setting
303-530

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303-532

303-645
Removal


(12.65.01)

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14
to rotate.

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20
to rotate.

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Installation
Tighten to 12 Nm.
2 Install the special tool to the exhaust camshaft sprocket.
.
use of the tool.
Tighten to 12 Nm.
4
chain.
sprocket.
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Tighten to 12 Nm.
6
7 NOTE:
.
8 NOTE:
.
Tighten to 12 Nm.
11
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sprocket bolt.
Tighten to 120 Nm.
12
sprocket bolt.
Tighten to 120 Nm.
Tighten to 12 Nm.
14
chain.
sprocket.
Tighten to 12 Nm.
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16
17 NOTE:
.
18 NOTE:
.
Tighten to 12 Nm.

21
sprocket bolt.
Tighten to 120 Nm.

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22
sprocket bolt.
Tighten to 120 Nm.
23 . Remove the special tool to the right-hand cylinder head.

24 . Remove the special tool to the left-hand cylinder head.
Tighten to 22 Nm.
Tighten to 22 Nm.
(12.65.01)
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Tighten to 10 Nm.

Tighten to 12 Nm.

Secondary Timing Chain Tensioner
12mm Ribe bit socket

303-1077A
Camshaft setting tool

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303-530

303-532

303-645
Removal


6 . NOTE:

Install the special tool to the left-hand cylinder head.
7 . NOTE:

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Using the special tool, remove the exhaust camshaft sprocket retaining bolt.
8 . NOTE:
Remove the secondary timing chain tensioner retaining bolts.

9 . NOTE:
Remove the secondary timing chain tensioner.
1) Reposition the exhaust camshaft sprocket and secondary timing chain.
2) Remove the secondary timing chain tensioner.
Installation
1 . NOTE:
Install the secondary timing chain tensioner.
1) Install the secondary timing chain tensioner.
2) Reposition the exhaust camshaft sprocket and secondary timing chain.

2 . NOTE:
Install the secondary timing chain tensioner retaining bolts.
Tighten to 12 Nm.
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3 . Release the tension in the secondary timing chain tensioner.
4.
NOTE:
Using the special tools, install the exhaust camshaft sprocket retaining bolt.
5 . NOTE:
6 . Install the valve cover.


9 . Connect the crankshaft position (CKP) sensor electrical connector.

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Timing Drive Components - VIN Range:
G00442->G45703 (12.65.13)

303-530

303-532
Crankshaft setting tool

303-645
Removal
All vehicles
(12.65.01)


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6
freely.
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead center
(TDC) No. 1 cylinder
Install the special tool 303-645.

All vehicles
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.
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.
Installation
All vehicles
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2
rotate.
Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.

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8
chain.
sprocket.
Tighten to 12 Nm.
10
11 NOTE:
.
12 NOTE:
.
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Tighten to 12 Nm.

15
sprocket bolt.
16
sprocket bolt.
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18
to rotate.
Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.
22
chain.

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sprocket.
Tighten to 12 Nm.
24
25 NOTE:
.
26 NOTE:
.
Tighten to 12 Nm.
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29
sprocket bolt.
30
sprocket bolt.

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Tighten to 22 Nm.

Tighten to 22 Nm.
All vehicles
Tighten to 10 Nm.


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(12.65.01)
Timing Drive Components - VIN Range:
G45704->G99999 (12.65.13)

303-530

303-532
Crankshaft setting tool

303-645
Removal
(12.65.01)

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6
freely.
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead center
(TDC) No. 1 cylinder



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.
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.
Installation
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2
rotate.
Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.

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8
chain.
sprocket.
Tighten to 12 Nm.
10
11 NOTE:
.
12 NOTE:
.
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Tighten to 12 Nm.

15
sprocket bolt.
16
sprocket bolt.
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18
to rotate.
Tighten to 12 Nm.
.
use of the tool.
Tighten to 12 Nm.
22
chain.

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sprocket.
Tighten to 12 Nm.
24
25 NOTE:
.
26 NOTE:
.
Tighten to 12 Nm.
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29
sprocket bolt.
30
sprocket bolt.

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Tighten to 22 Nm.
Tighten to 22 Nm.
Tighten to 10 Nm.


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(12.65.01)
Valve Cover LH - VIN Range: G00442-
>G45703 (12.29.43)
Removal
All vehicles
1 . Remove the air cleaner. <<303-12B>>
2
3 . Remove the ignition coil-on-plug cover.

5 . Remove the left-hand engine cover bracket.
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.
Disconnect the variable camshaft timing (VCT) oil control solenoid electrical
1)
connector.
2) Detach the engine wiring harness.
7 . NOTE:


All vehicles
9 . Detach the fuel line. <<310-00>>
10 . Disconnect the ignition coil-on-plug electrical connectors.
11 . Remove the ignition coil on-plugs.

12 . Remove the valve cover assembly.
Remove and discard valve cover gaskets.

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13 . NOTE:
On removal of the valve cover retaining bolts note their positions in the valve cover.
Remove the valve cover retaining bolts.
Remove and discard the valve cover retaining bolt O-ring seals.
Installation
All vehicles
1 . NOTE:
Install the valve cover retaining bolts to their positions previously noted.
Install the valve cover retaining bolts.
Install new valve cover retaining bolt O-ring seals.
2 Apply bead of silicone gasket sealant or equivalent meeting Jaguar specification on the two
. places where the cylinder head and front cover join.
The application of sealant must be 3mm diameter by 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.
Tighten to 12 Nm.
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4 . Install the ignition coil-on-plugs.
Tighten to 5 Nm.
5 . Connect the ignition coil-on-plug electrical connectors.

7 . NOTE:

8 Attach the engine wiring harness.
.
Connect the variable camshaft timing (VCT) oil control solenoid electrical
1)
connector.
2) Attach the engine wiring harness.

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9 . Install the left-hand engine cover bracket.
Tighten to 6 Nm.

All vehicles
11 . Install the oil level indicator and tube.
Tighten to 6 Nm.
12 . Install the ignition coil-on-plug cover.
13
Attach the power steering fluid reservoir.
14 . Install the air cleaner. <<303-12B>>

Valve Cover LH - VIN Range: G45704-
>G99999 (12.29.43)
Removal
2

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4 . Remove the ignition coil-on-plug cover.

5 . NOTE:
Detach the engine cover bracket.

.
1)
connector.

7 . NOTE:

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9 . Disconnect the ignition coil-on-plug electrical connectors.
10 . Remove the ignition coil on-plugs.

12 . NOTE:
Installation
1 . NOTE:
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Tighten to 10 Nm.
Tighten to 5 Nm.
5 . Connect the ignition coil-on-plug electrical connectors.

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7 . NOTE:

1) Connect the VCT oil control solenoid electrical connector.
9 . NOTE:
Attach the engine cover bracket.
Tighten to 6 Nm.
10 . Install the ignition coil-on-plug cover.

Tighten to 6 Nm.
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12
Attach the power steering fluid reservoir.
13 . Install the air cleaner.

Valve Cover RH - VIN Range: G00442-
>G45703 (12.29.44)
Removal
All vehicles
1 . NOTE:
Remove the ignition coil-on-plug cover.

2 . Remove the right-hand engine cover bracket.

.
1) Detach the ground harness.
2)
connector.

4 . Detach the right-hand engine wiring harness.
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All vehicles
7 . Disconnect the positive crank ventilation (PCV) pipe.
8 . Disconnect the ignition coil on-plug electrical connectors.
9 . NOTE:
Remove the ignition coil-on-plugs.


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11 . NOTE:
Installation
All vehicles
1 . NOTE:
Tighten to 12 Nm.
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Tighten to 5 Nm.
5 . Connect the ignition coil on-plug electrical connectors.
6 . Connect the positive crank ventilation (PCV) pipe.

7 . Attach the right-hand engine wiring harness.
1) Attach the ground harness.

9 . Install the right-hand engine cover bracket.
Tighten to 6 Nm.
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All vehicles
12 . NOTE:
Install the ignition coil-on-plug cover.

Valve Cover RH - VIN Range: G45704-
>G99999 (12.29.44)
Removal
All vehicles
1 . NOTE:

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2 . Remove the engine cover right-hand bracket.
All vehicles
.
1) Detach the ground harness.
2)
connector.

5 . Disconnect the positive crank ventilation (PCV) pipe.
6 . Disconnect the ignition coil on-plug electrical connectors.

7 . NOTE:
Remove the ignition coil-on-plugs.

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9 . NOTE:
Installation
All vehicles
1 . NOTE:
Tighten to 10 Nm.
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4 . NOTE:
Install the ignition coil-on-plugs.
Tighten to 5 Nm.
5 . Connect the ignition coil on-plug electrical connectors.
6 . Connect the PCV pipe.

1) Attach the ground harness.

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9 . Install the engine cover bracket.
Tighten to 6 Nm.
All vehicles
10 . NOTE:
Install the ignition coil-on-plug cover.

Disassembly
Engine

303-191
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Adapter
303-191-02

303-588

303-645
Camshaft setting
303-530
Crankshaft damper holding tool

303-D055
Cylinder Bore Protectors

303-535
Disassembly
1 . Disconnect the oil cooler hoses.

• Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.
• Detach the supercharger belt.

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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.

8 . Disconnect the generator battery positive cable.

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12 . Remove the generator mounting bracket.
13 . Detach the right-hand oxygen sensor retaining bracket.

• Remove and discard the O-ring seal.
17 . Remove the heat shield.

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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.

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1. Disconnect the variable valve timing (VVT) solenoid electrical connector.
2. Detach the engine wiring harness.

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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.
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40 . Remove and discard the supercharger outlet pipe to charge air coolers ducts.
41 . Disconnect the thermostat housing hoses



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48 . Remove the thermostat housing retaining bolts.
• 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.

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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.

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• 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:
Remove the ignition coil cover.

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66 . Remove the engine cover retaining bracket.
67 . Remove the engine cover retaining bracket.

68 . NOTE:
69 . NOTE:
70 . Disconnect the ignition on-plug coil electrical connectors.

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73 . Disconnect the camshaft position sensor electrical connector.

• Detach the ground cable.
• Disconnect the variable valve timing (VVT) solenoid electrical connector.
3. Detach the engine wiring harness.
• Remove the retaining bolt.

77 . Disconnect the positive crankcase ventilation pipe.

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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.
84 . Disconnect the ignition on-plug coil electrical connectors.

86 . Disconnect the camshaft position sensor electrical connector.

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87 . Detach the engine wiring harness

90 . Remove the lower intake manifold.
91 . NOTE:
Remove the oil filter element.

93 . Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
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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.
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• Using the special tool, retain the water pump pulley.

• Remove and discard the O-ring seals.
104 . NOTE:
Remove the ignition coils.

106 . Remove the right-hand camshaft position (CMP) sensor.
107 . Remove the left-hand camshaft position (CMP) sensor.

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108
NOTE:
• Remove and discard the crankshaft pulley bolt.

110 . NOTE:
• Collect the locking ring.
111 . Remove the crankshaft position (CKP) sensor.

112
freely.
center (TDC) No. 1 cylinder.
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• Discard the valve cover gaskets.

• Discard the valve cover gaskets.

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.
• Remove the secondary timing chain tensioner and secondary timing chain from the
camshaft sprockets.

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.
• Remove the secondary timing chain tensioner and secondary timing chain from the
camshaft sprockets.

.
• 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).

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.

.

.

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143
Remove the right-hand cylinder head.
• Remove the bolts in the indicated sequence.

144
• Remove the bolts in the indicated sequence.
145 . Remove the crankshaft setting peg 303-645 from the crankshaft position sensor location.
6. Remove the flexplate retaining bolts.
7. Remove the flexplate.

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147 . Remove the lower oil pan.

149 . Remove the upper oil pan.

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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.
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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.

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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 may result in damage to the vehicle.
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.

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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.

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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.

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Assembly
Engine

303-191
Adapter
303-191-02

303-645
Camshaft setting
303-530
303-532
Cylinder Bore Protectors

303-535
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Piston Ring Compressor

303-372
Crankshaft rear oil seal remover/replacer

303-538
Crankshaft front seal installer

303-538
Crankshaft damper holding tool
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:
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.

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4.
CAUTION: Avoid damage to any crankshaft bearing surfaces.
Install the crankshaft.
5 NOTE:
.
The main bearings are precision selective fit.
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°

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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.
13 .
CAUTION: Alternate nut tightening to correctly seat the crankshaft rear seal.

• Check that the seal is located correctly.
15
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• 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
12. Tighten to 30 Nm
13. Tighten to 90°

19 . Install the piston cooling jets.
• Tighten to 9 Nm
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• Install a new gasket.
21 . Install the upper oil pan.
• Install, but do not fully tighten the retaining bolts.

24 Tighten to 12 Nm.
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.
• 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.

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
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CAUTION: Tighten the bolts 1 to 10 in the sequence shown.
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.
• Make sure the cylinder head dowels are correctly located.
30
. 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 right-hand cylinder head.

31 . NOTE:
• To the upper face of each bearing surface in the cylinder head.

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• To the upper face of each bearing surface in each bearing cap.
• On the cam lobes ONLY, not on the base circle area.

33 .
34 . NOTE:

36 .
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37 . NOTE:

39 .
40 . NOTE:


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42 .
45
to rotate.

• Install the secondary timing chain tensioner and secondary timing chain to the
camshaft sprockets.
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48 . Install the secondary timing chain tensioner.
.
• Reposition the camshaft sprockets for the most advantageous position for use of the
tool.

52
chain.
• Install the primary chain over the crankshaft sprocket and the intake sprocket.
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54
55 NOTE:
.
56 NOTE:
.
59
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sprocket bolt.
• Tighten to 20 Nm + 90 deg.
60
sprocket bolt.
61
to rotate.
• Install the secondary timing chain tensioner and secondary timing chain to the
camshaft sprockets.
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.
• Reposition the camshaft sprockets for the most advantageous position for use of the
tool.
67
chain.
• Install the primary chain over the crankshaft sprocket and the intake sprocket.
69
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70 NOTE:
.

71 NOTE:
.
74
sprocket bolt.
75
sprocket bolt.
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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.

. • 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).
85 .
Using the special tool, install a new crankshaft front seal.

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• Lubricate the new O-ring.
88

• 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.

92 NOTE:
.
• Install new valve cover gaskets.
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93 NOTE:
.
Install the right-hand valve cover.
• Install new valve cover gaskets.
95 . Install the left-hand camshaft position (CMP) sensor.
96 . Install the right-hand camshaft position (CMP) sensor.
97 . NOTE:
Install the ignition coils.
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98 . Install the thermostat housing.
99 . Install the water pump.
• Install new O-ring seals and gaskets.
• 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.
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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.
107 . Install the oil filter housing.
108 . Connect the oil pressure switch and oil temperature sensor electrical connectors.
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110 . NOTE:
Install a new oil filter.
111 .
112 . Install the intake manifold.
114 . NOTE:
Left-hand shown, right-hand simular.
Install the lower intake manifold.
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116 . Connect the camshaft position 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.

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125 . Connect the positive crankcase ventilation pipe.

30. Connect the earth wire.
31. Connect the variable valve timing (VVT) solenoid electrical connector.
• Attach the engine harness.
129 . Connect the camshaft position sensor electrical connector.

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132 . Connect the ignition on-plug coil electrical connectors.

133 . NOTE:
135 . Install the engine cover retaining bracket.
136 . Install the engine cover retaining bracket.

137 . NOTE:
Install the ignition coil cover.

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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.
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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.

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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.
152 . Connect the IAT sensor electrical connector.

153 . Connect the charge air cooler coolant pipes.
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154 . Install new O-ring seals to the thermostat housing.
155 . Install thermostat housing.

158 . Connect the hose.


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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.
• Reposition the hose retaining clip.

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32. Connect the variable valve timing (VVT) solenoid electrical connector.
33. Attach the engine wiring harness.

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180 . Install the air conditioning compressor mounting bracket.
181 . Install the A/C compressor.
182 . Connect the air conditioning compressor electrical connector.
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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.
187 . Install the heat shield.
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191 . Attach the right hand oxygen sensor retaining bracket.
192 . Install the generator mounting bracket.
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• 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

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• Install the accessory drive belt.
201 . Attach the accessory drive belt.

• Use a 3/8 inch square drive bar to rotate the drive belt tensioner.
• Attach the accessory drive belt.
202 . Install the supercharger belt.
• Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.
203 . Connect the oil cooler hoses.

303-01C : Engine – 2.7L Diesel
Specifications
Specifications
Engine oil, SAE 5W-30 WSS-M2C-913B A1
Sealant WSE M4G323–A4 (Loctite 5910)
Sealant (camshaft caps) ESK M4G269–A (Loctite 518)
Hose assembly surfactant WSE N99C45–A2
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Maximum permissible cylinder head warp

Total flame face 0.1 mm
150 mm x 150 mm square on flame face 0.05 mm
25 mm x 25 mm square on flame face 0.025 mm
Capacities
Description Liters
Engine oil, initial fill 7·7
Engine oil, service fill with oil filter change 6·6

Accessory drive belt idler pulley retaining bolt 47 35 –
Accessory drive belt idler pulley mount bracket retaining bolts 80 59 –
Accessory drivebelt tensioner retaining bolt 47 35 –
Air conditioning compressor retaining bolts 25 18 –
Air conditioning compressor mounting bracket retaining bolts 25 18 –
A/C manifold retaining bolt 20 15 –
Camshaft bearing caps retaining bolts A – –
Camshaft position sensor retaining bolt 10 – 89
Camshaft hub retaining bolts A – –
Camshaft pulley retaining bolts 23 17 –
Crankshaft pulley retaining bolt A – –
Crankshaft position sensor retaining bolt 5 – 44
Coolant inlet housing 10 – 89
Cylinder head retaining bolts A – –
Engine mount retaining nuts to crossmember 63 46 –
Engine mount bracket to engine mount retaining nut 48 35 –
Engine mount bracket to engine block retaining bolts 90 66 –
Engine wiring harness retaining bracket 4 – 35
Exhaust manifold heat shield retaining bolts 10 – 89
Exhaust manifold retaining bolts 23 17 –
Flexplate retaining bolts A – –
Fuel injection pump 23 17 –
Fuel injection pump pulley retaining nut 50 37 –
Fuel injector retaining bolts 10 – 89
Generator retaining bolts 47 35 –
Generator mount bracket retaining bolts 23 17 –
Glow plugs 10 – 89
Knock sensor retaining nuts 20 15 –
Oil cooler to cylinder block retaining bolt 10 – 89
Oil level indicator tube retaining bolt 10 – 89
Oil pan retaining bolts 10 – 89
Oil pump to engine block retaining bolts 10 – 89
Oil pan drain plug 25 18 –
Oil separator pipe retaining bolts 10 – 89
Oil filter 25 18 –
Piston cooling jet retaining bolt 10 – 89
Power steering bracket retaining bolts 23 17 –
Power steering pump retaining bolts 22 16 –
Primary timing chain tensioner retaining bolts 12 9 –
Starter motor retaining bolts 48 35 –
Timing belt tensioner retaining bolt 24 18 –
Timing belt idler pulley retaining bolt 45 33 –
Water pump retaining bolts 10 – 89
Water pump pulley retaining bolts 24 18 –
Water pump outlet pipe retaining bolts 10 – 89
Valve cover retaining bolts 10 – 89
Vacuum pump retaining bolts 23 17 –
Vacuum pump retaining nuts 13 10 –
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Engine
The 2.7 litre engine consists of a six cylinder 60-degree 'Enclosed Vee' configuration liquid cooled
Compacted Graphite Iron (CGI) with the cylinder bores machined directly into the block.
Viewed from the driving position, the right-hand cylinder bank is numbered 1 to 3, from the front of
the vehicle and the left-hand cylinder bank are numbered 4 to 6, from the front of the vehicle.
Knock Sensors
The knock sensor registers increased vibrations which occur due to increased combustion noise. The
ECM uses the signal as a correction factor for calculating the quantity of fuel to be injected during the
injection phase.
Active Engine Mounts
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The function of the engine mounts is to support the engine, whilst also isolating vibrations
transmitted from the engine to the vehicle body.
The active engine mounts are functional only when the engine is at idle, as this is when the engine
high frequency vibrations are the dominant vibrations noticeable to the vehicle's occupants.
The mechanical construction of the active engine mounts is similar to the passive hydraulic engine
mounts, but with the added element of an internal shaker mechanism. The shaker mechanism of the
active engine mounts works on the same concept as a speaker diaphragm to move the top section of
the active engine mounts to oppose the vibrations generated by the engine. The active engine
mounts mechanism estimates the vibration caused by fluctuations in the engine crank rotation and
isolates these vibrations by generating additional vibrations through the internal shaker mechanism.
The result gives vibration isolation and reduction of chassis vibration.
To ensure accurate vibration suppression the active engine mounts have an electronic control
module attached to the body and an accelerometer attached to the base.
Crankshaft
1 — Oil pump drive
2 — Main bearing journal
3 — Big end journal
4 — Rear drive flange
5 Rear oil seal location
6 Trigger wheel location
The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in four
bearings with clamped two layer bearing shells. The upper and lower shells of bearing number four
are flanged, which limits the end float of the crankshaft. The main bearing caps are double bolted
and cross bolted to increase the strength and rigidity of the engine block.
The rear main oil seal and retainer assembly is a one piece unit and is supplied with its own plastic
fitting sleeve. The seal and retainer have two locating dowels and ten fixing bolts. In addition the
retainer has a location for the crankshaft position sensor.
A torsional vibration crankshaft damper pulley is bolted to the front of the crankshaft.
The crankshaft trigger wheel is located on the rear of the crankshaft. It is pressed onto the crank
using a special tool which also precisely aligns the trigger wheel for crankshaft position and timing.
The trigger wheel consists of 60 magnets minus two for ECM crankshaft position reference and
synchronisation. The magnets cannot be seen on the trigger wheel, which therefore can only be
positioned using a special tool.
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1 — Special tool
2 — Trigger wheel
If the trigger is removed for any reason, then a new trigger wheel MUST be fitted.
Connecting Rods and Pistons
1 — Connecting rod bolts
2 — Connecting rod
3 — Piston
4 — Gudgeon pin
5 Circlips
6 Connecting rod identification
In production the connecting rods are fitted in sets of six. The connecting rods are offset fracture
split. Each connecting rod is marked (etched) with the cylinder number on either side of the fracture
split line.
The pistons are made from aluminium alloy and fitted with three rings. The piston crown
incorporates a pronounced bowl. This forms the combustion chamber which promotes swirl and
turbulence, necessary for good combustion and improved emission. In addition, the piston skirt,
which comes into contact with the cylinder bore, has molybdenum-coated surfaces. These
counteract scoring of the cylinder and piston, therefore helping to increase engine life.
The piston also incorporates a double wave gallery within the piston crown to enhance piston
cooling. The piston is supplied with oil by spray jets which are located in the engine block oil gallery.
This ensures optimum piston cooling due to the high temperatures that are generated by the
combustion process.
The arrows on the piston crown point to the front of the engine.
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1 — Ring gap oil control
2 — Ring gap upper compression

3 — Spiral joint oil control
4 — Ring gap lower compression
5 Upper compression ring
6 Lower compression ring
7 Oil control ring
All pistons are common single grade/single part number for all engines.
The piston top ring is a taper type and is fitted with a taper to the top of the piston. All rings marked
'top' are assembled with top to uppermost. All rings must be spaced evenly around the piston before
installing. The circumference gap of the double bevelled oil control ring must be opposite to the
spiral control joint.
Piston bowl volume is 20.025cc and the compression ratio is 17.3:1.
Cylinder Heads and Valve Gear

The cylinder head is of high quality aluminium and cannot be reworked. The cylinder head is secured
to the engine block by eight bolts.
The cylinder head incorporates four valves per cylinder, glow plugs and a knock sensor. A vertically
centrally placed fuel injector guarantees maximum distribution of fuel into the combustion chamber.
The cylinder head gasket is a three layer laminated steel construction that has an excellent service
life and sealing properties. The cylinder head gasket is available in five different thicknesses
depending on the piston protrusion height. The cylinder head gaskets are identified by serrations cut
into the front end of the gasket.
The valves are operated directly by steel roller rockers with hydraulic lash adjusters.
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1 — Steel rocker
2 — Hydraulic adjuster
Inlet Manifold
The induction is designed to optimise torque across the engine speed/load range. The air charge
enters the induction manifold from the EGR throttle valve and passes into the plenum for
distribution to the cylinders.
The purpose of the plenum is to maximise the air charge into the cylinders.
The inlet manifolds are of plastic composite construction and are handed for the left and right hand
bank. The manifolds incorporate a twin plenum intake system and integrated cam covers. The
plenum systems are vacuum operated, these are located at the rear of the manifolds and are ECM
controlled
The inlet manifolds/cam covers are secured to the cylinder head by 13 shouldered bolts and sealed
by means of rubber gasket.
Camshafts
The camshaft's construction is of hollow steel tube with pressed on syntered lobes. There are two
camshafts per cylinder head. The camshafts have pressed on drive sprockets which are marked for
timing purposes. The interconnecting drive chain is also marked for valve timing. The drive chain has
a hydraulic tensioner. Both banks are of similar construction. They are not interchangeable.
1 — Tensioner securing bolts
2 — Camshaft bearing caps
3 — Camshaft
4 — Chain tensioner
5 — Tensioner retaining pin
The drive sprockets also form the thrust faces for the camshaft. In production camshaft endfloat is
set to 0.065mm-0.185mm.
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1 — Drive chain
2 — Tensioner locking pin
3 — Camshaft
4 — Cam lobe
5 — Drive gear
6 — Tensioner
Camshaft Bearings
The camshafts are supported in five line bored bearings. The bearing caps, which are individually
identified, must be fitted in the correct sequence.
The right hand exhaust camshaft drives the vacuum pump which is sealed by an O-ring seal and
secured by three bolts. Both inlet camshafts are sealed at each end by the inlet manifold/cam cover.
The vacuum pump supplies vacuum for the inlet port deactuation system and brake servo assistance.
The pump is located at the rear of the engine and driven by the right hand side exhaust camshaft.
High Pressure Pump

The left hand exhaust camshaft drives the high pressure pump by means of a belt drive sprocket,
which is supported by a boss and a single bolt fixing.
The high pressure pump is not timed to the engine.
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Timing Gear
The camshafts are driven from the crankshaft pulley via a timing belt to the front the of exhaust
camshafts. The camshaft gears are bolted to a drive flange via three elongated adjustment holes and
in turn bolted to the camshafts by a single bolt.
Each pair of camshafts are chain driven and must be timed before assembly.
Sump Pan
The sump pan is made from pressed steel and is secured to the bedplate by 21 M6 x 16 bolts.
1 — Gasket
2 — Draining bolt seal
3 — Draining bolt
4 — Sump pan
5 — Retaining bolts
Engine Lubrication System

Oil is drawn from the oil pan and pressurised by the oil pump. The output from the oil pump is then
filtered and distributed through the internal passage ways. Oil is cooled before entering the filter.
All moving parts are lubricated by pressure or splash oil. Pressurised oil is also provided for operation
of the hydraulic adjusters, turbochargers and timing gear chain tensioners.
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The engine is lubricated by a forced-feed circulation system with full flow oil filter. The oil cooler
forms a unit with the oil filter and fuel cooler which is mounted centrally in the cylinder block
between the two banks of cylinders. The engine oil is cooled using the engine cooling system. This
eliminates the need for an additional engine oil cooler remotely mounted.
1 — Filter housing
2 — 'O' ring seal
3 — Paper element
5 — Cooler assembly
6 — Water inlet connection
Oil Pump
The oil pump is a gear type pump and is bolted and dowelled to the front of the engine block. It is
sealed by means of rubber gasket which is recessed into the oil pump casing. The pump is driven
directly by two flats from the front of the crankshaft. The oil relief valve is an integral part of the
pump.
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1 — Oil pump
2 — Primary tensioner boss

3 — Draining bolt
4 — Sump pan
Oil spray jets are bolted in place under the cylinder bores between the crank bearing journals. The oil
jets help to keep the pistons cool under arduous conditions and also prevent the oil draining back
when the engine is stopped.
Engine Management
The ECM's (Engine Control Module) high capacity processor employs advanced software strategies
that continuously control the engine's operating parameters. It gathers information from an array of
sensors and provides output to the actuators. The ECM also operates a port deactivation system,
which closes or opens flaps in the inlet system to provide the optimum swirl and flow conditions
throughout the operating range of the engine.
In addition, the ECM controls the actuation of the Exhaust Gas Recirculation system, the Variable
Geometry Turbochargers and the throttle, giving faster and more accurate response. A full torque-
based strategy supports multiple injection control and integration with transmission and braking
controllers. Transient torque and boost control enables vehicle performance to be optimised without
compromising engine durability
System Components
All engine functions are controlled by the Siemens common rail ECM
Crank position (CKP) sensor
The CKP signal is used to determine: the quantity of fuel to be injected, the start of fuel delivery and
the quantity of exhaust gases to be recirculated.
The crank position sensor is located at the rear of the crankshaft behind the flywheel.
The crankshaft position sensor (CKP ) is a Hall effect sensor which scans a magnetic disc on the
crankshaft. The air gap between the magnetic disc and the CKP is predetermined by the mounting of
the sensor.
Camshaft position (CMP) sensor

Location: on the cylinder head behind the left hand camshaft timing belt pulley.
The CMP sensor is Hall effect type and is required to identify cylinder No. 1. (This is to synchronise
engine to camshaft). The sensor scans a ring incorporated in the left hand camshaft timing belt
pulley. The air gap between the magnetic ring and the CMP sensor is predetermined by the mounting
of the sensor.
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Engine coolant temperature (ECT) sensor

Location: in the top outlet hose.
The ECT is a NTC type sensor and is fitted into the top water outlet hose. The sensor has a bayonet
type fitting.
Mass Air Flow (MAF) sensor

The MAF sensor is used to calculate the air mass. The MAF sensor is capable of detecting the mass air
flow extremely precisely.
Location: there are two MAF sensors fitted. Each sensor is fitted to separate intake pipes.
On engines with a variable turbocharger, the MAF sensor is used solely to control the exhaust gas
recirculation (EGR) and not the fuel metering. The MAF sensor also incorporates the Intake Air
Temperature (IAT) sensor.
The IAT sensor measures the intake air or, the charge air temperature and supplies the ECM with an
analog voltage signal.
Manifold Absolute Pressure (MAP) sensor

Location: fitted to the top of the throttle valve.
The MAP sensor measures the charging pressure in the intake pipe and sends the ECM an analog
voltage signal.
Air Charge Temperature (ACT) sensor
Location: fitted to the pressure side of the air intake throttle valve.
The ACT sensor measures the intake air or the charge air temperature and supplies the ECM with an
analog signal.
Fuel Rail Pressure sensor

Location: fitted to the diverter rail which in turn is bolted to the high pressure pump at the rear of
the engine.
The fuel pressure sensor measures the instantaneous fuel pressure in the fuel rail very precisely
within a very short time and supplies a voltage signal according to the pressure.
Fuel Temperature sensor

Location: the fuel temperature sensor is located on the low pressure side of the high pressure pump
in the case of the common rail system. The sensor measures the temperature of the fuel in the low
pressure system. Air and excessive heat in the fuel system can have an adverse effect on the
operation of the sensor.
Exhaust Gas Recirculation (EGR) valves

Location: there are two EGR valves fitted, one to each exhaust manifold. These are water cooled and
electronically controlled by the ECM.
Engine
Mechanical
• Coolant level
• Coolant leaks
• Oil level
• Oil leaks
• Visibly damaged or worn parts
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• Loose or missing nuts or bolts
before proceeding to the next step
4 . If the cause is not visually evident, verify the symptom and

Engine - 3.0L/3.5L/4.2L .
Active engine mounts
Overview
The active engine mount system operates at idle speed to help damp out any vibration from the
engine.
The system is triggered by a signal from the engine control module activating the mounts at engine
speeds between 600 and 900 rpm, when the mounts will operate as a pair.
The system determines which side mount is which by sending a ground signal to the right hand
mount (this pin is vacant on the left hand mount).

If the customer concern is of a vibration at other than idle speed, then the fault is not with the
active engine mounts.
2 . Use the Jaguar approved diagnostic system or a scan tool to retrieve any fault codes, as other
causes of vibration or misfire should be eliminated before condemning an active engine mount.
• Active engine mounts, correct fitment/damage • Fuse 9, front power distribution box
• Routing of pipework etc to avoid vibrations • Harnesses/connectors
• Contact anywhere between the driveline and • Active engine mounts
chassis • Engine control module (ECM)
before proceeding.
5 . If any DTCs were present in the steps above, make sure their causes are rectified before beginning
any work on the active engine mounts.
Pinpoint test
PINPOINT TEST G414540p1 : ACTIVE

ENGINE MOUNTS
G414540t1 : CHECK THE ACTIVE ENGINE MOUNT FUNCTION
1.
Circuit Pin
Power ground 01
Power supply 02
Signal 03
Ground 04
2.
Circuit Pin
Power ground 01
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Power supply 02
Signal 03
3.
Circuit Pin
Active engine mount signal H1
4. Key off. 5. Disconnect the right hand active engine mount connector, PI065. 6. Using the Jaguar
approved diagnostic system, activate the mounts. 7. Check for operation of the left hand mount.
Operation can be confirmed by feeling for vibration of the mount. 8. Key off. 9. Reconnect the right
hand active engine mount connector, PI065. 10. Disconnect the left hand active engine mount
connector, PI066. 11. Using the Jaguar approved diagnostic system, activate the mounts. 12. Check
for operation of the right hand mount.
Operation can be confirmed by feeling for vibration of the mount.
• Did both mounts operate when activated?
-> Yes
-> No
G414540t8 : CHECK THE INTERNAL DIAGNOSTIC CIRCUIT FOR SHORT

CIRCUIT
PI065, component side PI065, component side
Pin 04 Pin 01
PI066, component side PI066, component side
Pin 04 Pin 01
• Are both resistances greater than 10 Kohms?
-> Yes
An intermittent fault may be present in the wiring harness. GO to Pinpoint Test G414540t2.
-> No
INSTALL a new active engine mount in place of the suspect unit. Clear any DTCs, test the system for
normal operation.
G414540t2 : CHECK FOR POWER SUPPLY TO THE ACTIVE ENGINE MOUNTS

1. Disconnect the right hand active engine mount connector, PI065. 2. Key on, engine off. 3. Measure
the voltage between:
PI065, harness side Battery

• Is the voltage at both pins greater than 10 volts?
-> Yes
-> No
REPAIR the power supply circuit. This circuit includes harness splice, PIS87. For additional
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information, refer to the wiring diagrams. Clear any DTCs, test the system for normal operation.
G414540t4 : CHECK THE SIGNAL FROM THE ECM

1. Using the Jaguar approved diagnostic system, activate the mounts. 2. Measure the signal voltage
between:
• Is the voltage between 1 and 2.5 volts with the mount active? (the circuit should register 4-
5 volts with the mount inactive).
-> Yes
-> No
G414540t3 : CHECK FOR GROUND TO THE ACTIVE ENGINE MOUNTS
1. Disconnect the battery negative terminal. Link to genproc. 2. Measure the resistance between:
Pin 01 Negative lead
• Are the resistances less than 10 ohms?
-> Yes
INSTALL a new active engine mount in place of the inoperative unit. Clear any DTCs, test the system
-> No
REPAIR the ground circuit. This circuit includes harness splice, PIS88. For additional information, refer
to the wiring diagrams. Clear any DTCs, test the system for normal operation.
G414540t5 : CHECK THE SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND

1. Disconnect the ECM connector, EC066. 2. Measure the resistance between:
-> Yes
-> No
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear any DTCs, test
the system for normal operation. REFER to the warranty policy and procedures manual if an ECM is
suspect.
G414540t6 : CHECK THE SIGNAL CIRCUIT FOR SHORT CIRCUIT TO POWER


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-> Yes
-> No
the system for normal operation. REFER to the warranty policy and procedures manual if an ECM is
suspect.
G414540t7 : CHECK THE SIGNAL CIRCUIT FOR HIGH RESISTANCE

PI065, harness side ECM, harness side
Pin 03 Pin H1
PI066, harness side ECM, harness side
Pin 03 Pin H1
-> Yes
physical damage to the harness or connectors. REFER to the warranty policy and procedures manual
if an ECM is suspect.
-> No
REPAIR the high resistance circuit. This circuit includes harness splice, PIS86. For additional
Removal
Engine (12.41.01)

303-1129
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303-021
Removal
2 . Remove the secondary bulkhead center panel.

For additional information, refer to Secondary Bulkhead Center Panel

4 . Remove the automatic transmission.

For additional information, refer to Transmission - 2.7L Diesel (44.20.01)
5 . Drain the power steering fluid.

7 . Detach the diesel particulate filter high and low-pressure pipes.
8 . Detach the diesel particulate filter differential pressure sensor retaining bracket.
9 . Disconnect the glow plug harness electrical connectors.
10 Disconnect the coolant expansion tank coolant hose from the cylinder head coolant outlet
. assembly.
11 . Detach the coolant expansion tank coolant hose from the intake air shutoff throttle elbow.
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12 . Loosen the charge air cooler outlet tube retaining clip.
13 . Remove the intake air shutoff throttle elbow retaining bolt.

15 . NOTE:
Remove the intake air shutoff throttle elbow and charge air cooler outlet tube assembly.
16 . Disconnect the exhaust gas recirculation (EGR) coolant hose.
17 . Disconnect the radiator top hose from the cylinder head coolant outlet assembly.
18 . Using a suitable tie strap, secure the radiator top hose.
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19 . Disconnect the charge air cooler intake hose.
20 . Disconnect the power assisted steering (PAS) pump supply hose.

21 . Detach the front air spring supply tube.
22 . Detach the PAS fluid reservoir.
23
NOTE:
Cap the power steering lines to prevent loss of fluid and dirt ingress.
NOTE:
Disconnect the PAS pump to steering gear high-pressure line.

24 . NOTE:
PAS pump shown removed for clarity.
NOTE:

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NOTE:
Disconnect the air conditioning (A/C) high-pressure line.
25 . Disconnect the automatic transmission cooler coolant hose.

26 . Disconnect the radiator bottom hose.
27 . Remove the fuel filter.

For additional information, refer to Fuel Filter - 2.7L Diesel (19.25.02)
28 . Remove the fuel filter securing bracket.
29 . Remove the engine compartment brace bar.

30 . NOTE:
Remove the windshield washer reservoir filler neck.

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33 . Remove the engine compartment left-hand panel.
35 . Disconnect the engine control module (ECM) electrical connectors.

37 . Detach the left-hand fender splash shield.
38 . NOTE:

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NOTE:
Disconnect the A/C high-pressure line.
39 . Remove the power steering line retaining bolt.

40 . Disconnect the engine coolant inlet hose.
41 . Reposition the starter motor positive cable insulation cover.
42 . Detach the starter motor positive cable.

43 . NOTE:
Remove the engine mounts lower retaining nuts.

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46 . Remove the engine.

Installation
Engine (12.41.01)

303-1129

303-021
Installation
1 . Install the engine.
2 . Install the special tools.

4 . NOTE:

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Install the engine mounts lower retaining nuts.
Tighten to 63 Nm.
5 . Attach the starter motor positive cable.
Tighten to 12 Nm.
6 . Reposition the starter motor positive cable insulation cover.
7 . Connect the engine coolant inlet hose.
8 . Install the power steering line retaining bolt.
Tighten to 10 Nm.
9 . NOTE:
NOTE:

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Connect the air conditioning (A/C) high-pressure line.
Tighten to 10 Nm.
10 . Attach the left-hand fender splash shield.

12 . Connect the engine control module (ECM) electrical connectors.
Tighten to 10 Nm.
14 . Install the engine compartment left-hand panel.

16 . Attach the cabin air filter.
1) Install the cabin air filter.
2) Attach the cabin air filter.

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17 . NOTE:
Install the windshield washer reservoir fiiler neck.

18 . Install the engine compartment brace bar.
Tighten to 25 Nm.
19 . Install the fuel filter securing bracket.
Tighten 10 mm (0.394 inch's) bolt to 25 Nm.
20 . Install the fuel filter.

For additional information, refer to Fuel Filter - 2.7L Diesel (19.25.02)
21 . Connect the radiator bottom hose.

22 . Connect the automatic transmission cooler coolant hose.
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23 . NOTE:
Power steering pump shown removed for clarity.
NOTE:
NOTE:
Connect the A/C high pressure line.
Tighten to 10 Nm.
24
NOTE:
NOTE:
Connect the power assisted steering (PAS) pump to steering gear high-pressure line.
Tighten to 22 Nm.
25 . Attach the PAS fluid reservoir.

26 . Attach the front air spring supply tube.
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27 . Connect the PAS pump supply hose.
28 . Connect the charge air cooler intake hose.

29 . Remove and discard the tie strap.
30 . Connect the radiator top hose from the cylinder head coolant outlet assembly.
31 . Connect the exhaust gas recirculation (EGR) coolant hose.
32 . NOTE:
Install the intake air shutoff throttle elbow and charge air cooler outlet tube assembly.
33 . Connect the intake air temperature (IAT) sensor electrical connector.
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34 . Install the intake air shutoff throttle elbow retaining bolt.
Tighten to 10 Nm.
35 . Tighten the charge air cooler outlet tube retaining clip.

36 . Attach the coolant expansion tank coolant hose to the intake air shutoff throttle elbow.
37 Connect the coolant expansion tank coolant hose from the cylinder head coolant outlet
. assembly.
38 . Connect the glow plug harness electrical connectors.

39 . Attach the diesel particulate filter differential pressure sensor securing bracket.
Tighten to 25 Nm.
40 . Attach the diesel particulate filter high and low-pressure pipes.
Tighten to 10 Nm.
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42 . Install the automatic transmission.


44 . Install the secondary bulkhead center panel.

45 . Fill the power steering fluid reservoir and bleed the system.

In vehicle repair
Camshaft Front Seal

Holder - camshaft pulleys front

303-1124
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Installer - camshaft oil seal

303-1119
Remover - camshaft oil seal

303-1118
Timing pin - camshaft pulleys

303-1126
Removal
1 . Remove the timing belt.
For additional information, refer to Timing Belt
1) Retain the camshaft pulley.
2) Remove the special tool.
3 . Remove the camshaft pulley.
Remove the camshaft pulley retaining bolts.
4 . NOTE:
Discard the camshaft pulley hub retaining bolt.
Using special tool, remove the camshaft pulley hub.
Remove the camshaft pulley hub retaining bolt.

5 . Install the special tool to the camshaft.
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6
. CAUTION: Make sure the special tool is correctly seated behind the camshaft seal.
Install the special tool into the camshaft front seal.
7 . Install the special tool extracting bolt.

8
. CAUTION: Make sure the special tool is correctly seated behind the camshaft seal.
Install the special tool into the camshaft front seal.
9 . Using the special tool, remove the camshaft front seal.
Installation
1
. CAUTION: Do not use any lubricant on the seal or the camshaft. Failure to follow
CAUTION: Make sure the seal is installed correctly.
NOTE:
Clean the component mating faces.
NOTE:
Use the discarded camshaft pulley hub retaining bolt with the special tool.
Using the special tool, install the camshaft front seal.

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2 . Using special tool, install the camshaft pulley hub.
Tighten the bolts in the sequence shown in two stages.
Stage 2: Tighten to 90 degrees.

3 . Install the camshaft pulley.
Tighten to 22 Nm.
1) Retain the camshaft pulley.
2) Install the special tool.
5 . Install the timing belt.

Camshaft Rear Seal
Camshaft Seal Remover

303-1118
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Camshaft Seal Installer

303-1119
Holder - Camshaft Pulley Rear

303-1125
Removal
1 . Remove the fuel injection pump belt.
2 . Using the special tool, remove the camshaft rear pulley bolt.
3 . Remove the camshaft rear pulley.
4 . Install the special tool to the camshaft.
5
. CAUTION: Make sure the special tool is seated correctly behind the camshaft rear
seal. Failure to follow this instruction will result in damage to the vehicle.
Install the special tool to the camshaft rear seal.

6
. CAUTION: Make sure the special tool is seated correctly behind the camshaft rear
seal. Failure to follow this instruction will result in damage to the vehicle.
Using the special tool, remove the camshaft rear seal.

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Install the reaction arm.
Installation
1 . Using the special tool, install the camshaft rear seal.
2 . Install the camshaft rear pulley.
3.
CAUTION: The camshaft pulley bolt must be tightened in two stages.
Using the special tool, install the camshaft rear pulley bolt.
stage 2: Tighten to 90 degrees.
4 . Install the fuel injection pump belt.

Holder Camshaft Pulleys Front

303-1124
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Installer Camshaft Oil Seal

303-1119
Holder Camshaft Pulleys Rear

303-1125

303-1126
Reaction Arm - Fuel Pump Pulley

310-138
Holder - Fuel Pump Pulley
310-139
Fuel Injector Remover

303-1127
Removal
1
. WARNING: Wait at least 30 seconds after the engine stops before commencing any
repair to the high pressure fuel injection system. Failure to follow this instruction may
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 mixtures are always
present and may ignite. 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 this instruction may
WARNING: Do not carry out any repairs to the fuel injection system with the engine
running. The fuel pressure within the system can be as high as 1650 bar. Failure to follow
this instruction may result in personal injury.
CAUTION: Make sure the workshop area in which the vehicle is being worked on is
as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from
machining or welding operations can contaminate the fuel system and may result in later
malfunction.
CAUTION: Always carry out the cleaning process before carrying out any repairs to
the fuel injection system components. Failure to follow this instruction may result in
foreign matter ingress to the fuel injection system.
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CAUTION: Diesel fuel injection equipment is manufactured to very precise

tolerances and fine clearances. It is therefore essential that absolute cleanliness is
observed when working with these components. Always install blanking plugs to any
exposed ports.
Remove the fuel injection pump belt.

For additional information, refer to Fuel Injection Pump Belt
2 . NOTE:
Discard the camshaft rear pulley retaining bolt.
Remove the camshaft rear pulley retaining bolt.
Using the special tool, retain the camshaft rear pulley.

4 . Remove the fuel injection pump pulley retaining nut.
Using the special tool, retain the fuel injection pump pulley.
Remove the fuel injection pump pulley retaining nut.
5 . Using the special tool, remove the fuel injection pump pulley.
6 . Detach the exhaust gas recirculation (EGR) coolant outlet tube.

7 . Remove the fuel injection pump belt rear cover.
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1) Retain the camshaft sprocket.
2) Remove the special tool.
10 . Remove the camshaft sprocket.

11 . Using special tool, remove the camshaft sprocket hub.
12 . Disconnect the intake air shutoff throttle electrical connector.
13 . Detach the vacuum hoses.

14 . Remove the retaining bolt.
15 . NOTE:
Discard the retaining clips.
Detach the EGR valve outlet tube retaining clips.

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16 . NOTE:
NOTE:
NOTE:
Discard the gaskets.
Remove the right-hand and left-hand EGR valve outlet tubes.

18 . Detach the fuel return line valve from the intake air shutoff throttle.
19
. CAUTION: Make sure the fuel return line valve retaining clip is not damaged.
Reposition the intake air shutoff throttle.

20

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21
NOTE:
Discard the intake air shutoff throttle seals.
Remove the intake air shutoff throttle.

22 . Detach the knock sensor (KS) electrical connector from the left-hand valve cover.
24 . Disconnect the oil pressure sensor electrical connector.

26 . Detach the glow plug electrical connector from the left-hand valve cover.
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27 . Detach the engine breather hose.
28 . Disconnect the vacuum hose.

29
. CAUTION: Make sure that the high-pressure fuel supply line remains in contact
with both the fuel injector and the fuel injection supply manifold until both unions have
been detached and cleaned. Failure to follow this instruction may result in foreign matter
ingress to the fuel injection system.
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel
supply lines, the fuel injectors and the fuel injection supply manifold.
For additional information, refer to Fuel Injection Component Cleaning
31 . Detach the fuel injection wiring harness.
32
33
with both the fuel injector and the fuel rail until both unions have been detached and
cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel
injection system.
CAUTION: Make sure that the fuel injector adaptor union does not move when
loosening the high-pressure fuel supply lines. Failure to follow this instruction may result
in damage to the fuel injector or the fuel injector adaptor union.
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NOTE:
Left-hand rear injector shown, left-hand center and front similar.
Loosen the high-pressure fuel supply lines from the fuel injectors and fuel rail.
34
35 NOTE:
.
Remove and discard the high-pressure fuel supply lines.
Install suitable blanking caps to the open threaded ports on the fuel
injector and the fuel injection supply manifold.
36 Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors and the
. fuel rail.
37 NOTE:
.
Disconnect the fuel return line from the fuel injectors.
Remove and discard the fuel return line retaining clips from the fuel
injectors.

38 . NOTE:
Remove the fuel injectors retaining bolts.

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39 . NOTE:
Install the special tool studs.

40
. CAUTION: Make sure the fuel injector remover legs are correctly engaged to the
fuel injector. Failure to follow this instruction may result in damage to the component.
NOTE:
Left-hand rear injector shown, left-hand centre and front similar.
Install the special tool puller legs to the studs.
41
. CAUTION: Make sure the special tool puller bolts are rotated evenly. Failure to
follow this instruction may result in damage to the special tool or fuel injector.
NOTE:
Left-hand rear injector shown, left-hand centre and front similar.
Using the special tool, remove the fuel injectors.
Install the special tool locking plate to the puller legs.
Rotate the bolts evenly, in a clockwise direction.
Remove the fuel injectors.
Remove and discard the fuel injectors retaining clamps.
Remove and discard the fuel injectors sealing washers.

42 . Remove the high-pressure fuel supply line retaining bolt.
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43
44
. CAUTION: Make sure the tool used to loosen the high-pressure fuel supply line
union is used at the top of the union as this is where there is most material. Failure to
follow this instruction may result in damage to the union.
CAUTION: Make sure that the high pressure fuel supply line remains in contact
with both the fuel pump and the fuel rail until both unions have been detached and
injection system.
CAUTION: While maintaining the pressure on the high-pressure fuel supply line,
clean and vacuum foreign material from the line and unions.
Remove the high-pressure fuel supply line.
45 . Remove the fuel rail.
46 . Remove the fuel rail securing bracket .

47 . Remove the engine cover and wiring harness retainers.
48 . NOTE:
Discard the valve cover gasket.
Remove the left-hand valve cover.

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49 . Retain the secondary timing chain tensioner plunger.
1) Reposition the secondary timing chain tensioner.
2) Retain the secondary timing chain tensioner plunger.

50 . Remove the camshaft bearing caps evenly.
52 . NOTE:
Discard the left-hand exhaust camshaft seals.
Remove the left-hand camshafts and secondary timing chain tensioner assembly.
53 . Remove the secondary timing chain tensioner assembly.

Remove the secondary timing chain from the camshafts.

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Installation
1
times and always observe fuel handling precautions. Failure to follow this instruction may
malfunction.

tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed
when working with these components. Always install blanking plugs to any exposed ports.
CAUTION: Make sure that the colored links on the secondary timing chain align with
the dots and scribed line on the sprocket shoulder. Failure to follow this instruction may
result in damage to the engine.
Install the secondary timing chain onto the camshafts.

2 . Install the secondary timing chain tensioner assembly.
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3
. CAUTION: Make sure that the dots on the camshafts are aligned at the 12 o'clock
position. Failure to follow this instruction may result in damage to the engine.
NOTE:
Lubricate the camshafts and the camshaft bearing caps with oil meeting Jaguar
specification prior to installation.

Tighten to 10 Nm.
5 Apply Loctite 518 sealant to the exhaust camshaft seal bearing caps.
.
Apply Loctite 518 sealant, 2 mm wide, to the left-hand rear and right-hand
front camshaft bearing caps.
Apply Loctite 518 sealant, 7 mm in diameter, to the left-hand front and

right-hand rear camshaft bearing caps.
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6 . NOTE:
Install the camshaft bearing cap retaining bolts evenly.
Install the camshaft bearing caps in their original position.

Stage 1: Bolts 1 to 14, 1 Nm.
7 . Remove the secondary timing chain tensioner retaining pin.
8 . NOTE:
Install a new valve cover gasket.
Tighten to 10 Nm.
9 . Install the engine cover and wiring harness retainers.
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10
. CAUTION: Do not use any lubricant on the seal or the camshaft. Failure to follow
NOTE:
Using the special tool, install the camshaft front seal.
11 . Install the fuel rail securing bracket.

Tighten to 24 Nm.
12 . Install the fuel rail.
Tighten to 24 Nm.
13 NOTE:
.
Install a new high-pressure fuel supply line.
Tighten the high-pressure fuel supply line in the sequence shown:
Tighten the high-pressure fuel supply line union 1 to fuel injector to 15

Nm.
Tighten the high-pressure fuel supply line union 2 to fuel rail to 15 Nm.

Nm.
14 . Install the high-pressure fuel supply line retaining bolt.
Tighten to 10 Nm.
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15
. CAUTION: Do not use tools to install the new fuel return line retaining clip. Failure
to follow this instruction may result in damage to the retaining clip.
NOTE:
Install a new fuel return line retaining clip.
NOTE:
Install a new fuel injector sealing washer.
Install a new fuel injector retaining clamp.

16 . NOTE:
Install the fuel injector.
Tighten to 10 Nm.
17
. CAUTION: Make sure the fuel return line retaining clip is correctly installed to the
fuel injector before installing the fuel return line.
NOTE:
Connect the fuel return line to the fuel injector.
Visually inspect the fuel return line O-ring for damage.
Apply a light coating of petroleum jelly to the fuel line return line O-ring
seals.
18
.
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CAUTION: Do not allow the unions to hit the olive ends of the high-pressure fuel
supply line as this may damage the ends of the line and allow foreign matter enter the
fuel injection system.
Position the high-pressure fuel supply line as near to the final installation position as possible
and then remove and discard the blanking plugs from the high-pressure fuel supply line.
19
. CAUTION: Maintain pressure on the high-pressure fuel supply line to keep the
olives in contact with the fuel injectors and the fuel rail cones while installing the unions.
NOTE:
Install the high-pressure fuel supply lines to the fuel rail end first followed by the fuel
injector end.
NOTE:
Install the new high-pressure fuel supply line.

Nm.

Nm.
20 . Attach the fuel injection wiring harness.

22 . Connect the vacuum hose.
23 . Attach the engine breather hose.

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24 . Attach the glow plug electrical connector onto the left-hand valve cover.

26 . Connect the oil pressure sensor electrical connector.
28 . Attach the KS electrical connector onto the left-hand valve cover.
29
Install the intake air shutoff throttle.

30 . Attach the fuel return line valve onto the intake air shutoff throttle.
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32 . NOTE:
NOTE:

NOTE:
Fit new gaskets.
Install the right-hand and left-hand EGR valve outlet tubes.
Tighten to 10 Nm.
33 . NOTE:
Fit new retaining clips.
Attach the EGR valve outlet tube retaining clips.
34 . Install the retaining bolt.
Tighten to 10 Nm.
35 . Attach the vacuum hoses.
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36 . Connect the intake air shutoff throttle electrical connector.
37 . Using special tool, install the camshaft sprocket hub.
Install the camshaft sprocket hub retaining bolt.

38 . Install the camshaft sprocket.
Install the camshaft sprocket retaining bolts.
1) Retain the camshaft sprocket.
2) Install the special tool.

41 . Install the fuel injection pump belt rear cover.
42 . Attach the EGR coolant inlet tube.
Tighten to 10 Nm.
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43 . Install the fuel injection pump pulley.
44 . Install the retaining nut.
Tighten to 50 Nm.
45
. CAUTION: A new camshaft seal is supplied with an transit sleeve that must not be
removed until the camshaft front seal is fully installed. Failure to follow this instruction
CAUTION: Do not use any lubricant on the seal, the transit sleeve or the camshaft.
NOTE:
Using the special tool, install the camshaft rear seal.
Remove and discard the transit sleeve.

47
. CAUTION: The camshaft pulley bolt must be tightened in two stages. Failure to
Using the special tool, install the camshaft rear pulley retaining bolt.
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48 . Install the fuel injection pump belt.

Locking Tool Flywheel

303-1123
Timing Pin - Automatic Transmission

303-1117
Crankshaft Seal Remover

303-1120
Crankshaft Seal Sleave

303-1122
Crankshaft Seal Installer

303-1121
Removal

For additional information, refer to Starter Motor - 2.7L Diesel (86.60.01)

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5.
CAUTION: The crankshaft pulley retaining bolt must not be re-used.
Remove the crankshaft pulley.

Installation
1
. CAUTION: Do not use any lubricant on the crankshaft front seal, the special tool or
the crankshaft. Failure to follow this instruction may result in damage to the vehicle.
NOTE:

Install a new crankshaft front seal to the special tool.
2 . Reposition the crankshaft front seal along the special tool.

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3 . Using the special tool, install the crankshaft front seal to the crankshaft.

6 . Using the special tool, fully install the crankshaft front seal.
Install the crankshaft pulley retaining bolt.
7.
Remove and discard the crankshaft pulley retaining bolt.

8.
CAUTION: The crankshaft pulley retaining bolt must be tighten in two stages.
Install the new crankshaft pulley retaining bolt.

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For additional information, refer to Starter Motor - 2.7L Diesel (86.60.01)

Removal
1 . Remove the crankshaft position (CKP) sensor ring.
For additional information, refer to Crankshaft Position (CKP) Sensor Ring
2 . Remove the crankshaft rear seal retaining bolts.

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3 . Remove the crankshaft rear seal.
Installation
CAUTION: Make sure the crankshaft rear seal is installed correctly.

1 . NOTE:
Make sure the crankshaft rear seal mating faces are clean and dry.
Apply a 8 mm bead of sealant to the cylinder block in the areas shown.

2 . Tighten to 10 Nm (7 lb.ft).
3 . Tighten to 10 Nm (7 lb.ft).
4 . Install the CKP sensor ring.

For additional information, refer to Crankshaft Position (CKP) Sensor Ring
Crankshaft Vibration Damper (12.21.09)
Accessory belt detensioner

303-703
Removal
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1) Using the special tool, rotate the belt tensioner counter clockwise.
4 . Remove the crankshaft vibration damper.

Installation
Tighten to 14 Nm.
Cylinder Head LH (12.29.02)
Removal
1 . Remove the left-hand camshafts.

For additional information, refer to Exhaust Manifold LH (30.15.55)
3 . Detach the expansion tank hose from the cylinder head coolant outlet assembly.
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4 . Detach the engine coolant hose from the cylinder head coolant outlet assembly.
5 . Detach the radiator top hose from the cylinder head coolant outlet assembly.
6 . NOTE:
Remove the cylinder head coolant outlet assembly.
7 . Remove the left-hand cylinder head glow plugs.

For additional information, refer to Glow Plugs
8 . Disconnect the camshaft position sensor.
9 . Remove the hydraulic adjuster and rocker assemblies.

10 .
CAUTION: Only use a plastic scrapper to clean off the old gasket.
Remove the left-hand cylinder head assembly.
Remove and discard the left-hand cylinder head retaining bolts.

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Remove and discard the left-hand cylinder head gasket.
Installation
1
. CAUTION: Use care when installing the cylinder head. Damage to the cylinder block,
cylinder head or the cylinder head gasket may result.
NOTE:
Install a new cylinder head gasket.

NOTE:
The head gaskets must be installed over the cylinder head to block dowels.
NOTE:
Make sure the cylinder head is installed in its original position.
NOTE:
Tighten the retaining bolts in the indicated sequence in four stages.
Install the cylinder head and install new cylinder head retaining bolts.
2 . Install the hydraulic adjuster and rocker assemblies.

3 . Connect the camshaft position sensor.
4 . Install the left-hand cylinder head glow plugs.

For additional information, refer to Glow Plugs
5 . NOTE:
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Install the cylinder head coolant outlet assembly.
Tighten to 10 Nm.
6 . Attach the radiator top hose onto the cylinder head coolant outlet assembly.
7 . Attach the engine coolant hose onto the cylinder head coolant outlet assembly.
8 . Attach the expansion tank hose onto cylinder head coolant outlet assembly.
9 . Install the exhaust manifold.

For additional information, refer to Exhaust Manifold LH (30.15.55)
10 . Install the left-hand camshafts.

Engine mount retaining nut adaptor

303-1191
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Power train assembly jack

HTJ1200-02
Removal
2 . Remove the power steering return line retaining bolt.
3 . Disconnect the engine mount electrical connector.

4 . Detach the engine mount wiring harness.
5 . Detach the turbocharger intake tube.
6 . NOTE:
Remove the engine mounts lower retaining nuts.

7 . Using the special tool, remove the engine mount upper retaining nut.
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8 . Using the special tool, raise the engine to a suitable height.
9 . Remove the engine mount.

Installation
1
. CAUTION: Make sure that the engine mount location peg is correctly located into
the engine mount bracket. Failure to follow this instruction may result in damage to the
vehicle.
Install the engine mount.
2 . Using the special tool, lower the engine.
3
. CAUTION: Make sure the torque wrench setting procedure is followed correctly.
Calculate the setting for the torque wrench.
Stage 1: Multiply the required torque by the effective length of the torque
wrench (1).
Stage 2: Add the effective length of the special tool (2) to the effective
length of the torque wrench.
Stage 3: Divide the total of stage 1 by the total of stage 2.

Stage 4: Set the torque wrench to the figure arrived at in stage 3.
4 . Using the special tool, install the engine mount upper retaining nut.
Tighten to 48 Nm.
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5 . NOTE:
Install the engine mounts lower retaining nuts.
Tighten to 63 Nm.
6 . Attach the turbocharger intake tube.
7 . Attach the engine mount wiring harness.
8 . NOTE:
Make sure that the engine mount electrical connector is fully seated.
Connect the engine mount electrical connector.

9 . Install the power steering return line retaining bolt.
Tighten to 10 Nm.
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Engine mount retaining nut adaptor

303-1191
Power train assembly jack

HTJ1200-02
Removal
2 . Detach the exhaust gas recirculation (EGR) cooler coolant pipe.
3 . Detach the upper mass air flow (MAF) sensor outlet pipe.
5 . Remove the generator cooling duct.

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6 . Loosen the turbocharger outlet pipe retaining clips.
7 . Remove the turbocharger outlet pipe.

8 . Detach the air cleaner upper outlet tube from the timing cover.
9 . Detach the air cleaner outlet tube.
1) Detach the air cleaner outlet tube to turbocharger retaining clip.
2) Detach the air cleaner outlet tube to breather tube retaining clip.
10 Make sure that the alignment mark on the steering gear pinion seal protection cover is
. central to the steering gear pinion casting.
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14 . Reposition the starter motor positive cable.
15 . Disconnect the engine mount electrical connector.
Detach the engine mount wiring harness.
16 . NOTE:
Remove the engine mounts retaining nuts.

17 . Using the special tool, remove the engine mount upper retaining nut.
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18 . Using the special tool, raise the engine.
19 . Remove the engine mount.

Installation
1 . Install the engine mount.
2 . Using the special tool, lower the engine.
3
wrench (1).

4
Using the special tool, install the engine mount upper retaining nut.
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Tighten to 48 Nm.
5 . NOTE:
Install the engine mountings retaining nuts.
Tighten to 63 Nm.
6 . NOTE:
Make sure that the engine mount electrical connector is fully seated.
Connect the engine mount electrical connector.
Attach the engine mount wiring harness.
Tighten to 10 Nm.
Install the steering gear shaft pinch bolt.
Tighten to 35 Nm.
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11 . Attach the air cleaner outlet tube.
1) Attach the air cleaner outlet tube to turbocharger retaining clip.
2) Attach the air cleaner outlet tube to breather tube retaining clip.
12 . Attach the air cleaner upper outlet tube to the timing cover.
13 . Install the turbocharger outlet pipe.
14 . Tighten the turbocharger outlet pipe retaining clips.

15 . Install the generator cooling duct.

17 . Attach the upper MAF sensor outlet pipe.

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18 . Attach the EGR cooler coolant pipe.

Exhaust Manifold LH (30.15.55)
Removal
1 . Remove the left-hand exhaust gas recirculation (EGR) valve.
For additional information, refer to Exhaust Gas Recirculation (EGR) Valve LH
2 . Remove the left-hand turbocharger.

For additional information, refer to Turbocharger LH
3 . Remove the exhaust manifold heatshield.
5 . NOTE:
Remove and discard the exhaust manifold retaining nuts.

8 . Remove and discard the exhaust manifold gasket.

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Installation
1 . Install a new exhaust manifold gasket.
2
. CAUTION: Make sure that the exhaust manifold and gasket are correctly aligned to
the cylinder head and the exhaust manifold retaining studs.
4 . Install new exhaust manifold retaining nuts.
Tighten to 23 Nm.
6 . Install the exhaust manifold heatshield.
Tighten to 10 Nm.
7 . Install the left-hand turbocharger.
For additional information, refer to Turbocharger LH
8 . Install the left-hand EGR valve.

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Exhaust Manifold RH (30.15.56)
Removal
1 . Remove the right-hand exhaust gas recirculation (EGR) valve.
For additional information, refer to Exhaust Gas Recirculation (EGR) Valve RH
2 . Remove the right-hand turbocharger.

For additional information, refer to Turbocharger RH
3 . Remove the exhaust manifold front heat shield.
4 . Remove the exhaust manifold rear heat shield.
5 . NOTE:
Remove the exhaust manifold.
Remove and discard the retaining nuts.

6 . Remove and discard the exhaust manifold gasket.
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Installation
1
. CAUTION: Ensure the exhaust manifold and gasket are correctly aligned to the
cylinder head and studs.
NOTE:
Install a new exhaust manifold gasket.
Install new exhaust manifold retaining nuts.
Tighten to 23 Nm.
Removal
1 . Remove the transmission.
2 . NOTE:

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Installation
1 . NOTE:
NOTE:
NOTE:
Install, but do not tighten, the flexplate retaining bolts.

2.
CAUTION: Tighten the flexplate securing bolts in three stages.
Tighten the flexplate securing bolts.
3 . Install the transmission.

Oil Filter Element (12.60.02)
Remover - oil filter

303-1128
Removal
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4 NOTE:
.
Remove the oil filter element housing.

Rotate the oil filter element housing five complete turns counter-
clockwise.
Allow the engine oil to drain from the oil filter element housing for two
minutes.
5 . Using the special tool, remove the oil filter element.
Installation
1 . Install the oil filter element.
2 . NOTE:
Install the oil filter element housing.
Tighten to 25 Nm.
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6 . Check and top up the engine oil.
7 . Run the engine.
8 . Check and if necessary top up the engine oil.

Oil Pan (12.60.44)

303-1129
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303-021
Removal
4 . Install the engine lifting bracket.
5 . Install the engine support bracket.

8 Make sure the alignment mark on the steering gear pinion seal protection cover is central to
. the steering gear pinion casting.
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Remove the steering gear retaining bolts.

12 . Using a suitable piece of string secure the steering gear.
13 . Remove the generator cooling duct (if equipped).
14 . Undo the right-hand turbocharger outlet tube securing clips.

15 . Remove the right-hand turbocharger outlet tube.
16 . Remove the left-hand engine mount retaining nut.

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18 . Using special tool raise the left-hand side of the engine.

20 . Disconnect the oil temperature sensor electrical connector.
Detach the oil temperature sensor wiring harness from the oil pan.
21 . Remove the oil pan retaining bolts.
22 . Remove the oil strainer retaining bolt.
23 . Reposition the oil strainer.


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Installation
2 . Loosely install the oil pan.
Install a new oil pan gasket.
3 . Reposition the oil strainer.
4 . Install the oil strainer retaining bolt.
Tighten to 10 Nm.
5 NOTE:
.
A new oil pan is supplied with the drain plug installed. Check that the drain plug is
tightened to 25 Nm.
Install the oil pan.

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Tighten to 10 Nm.
6 . Connect the oil temperature sensor electrical connector.
Attach the oil temperature sensor wiring harness to the oil pan.
8 . Using special tool lower the left-hand side of the engine.
10 . Install the left-hand engine mounting retaining nut.
Tighten to 63 Nm.
11 . Install the right-hand turbocharger outlet tube retaining bolt.
Tighten to 10 Nm.
12 . Install the right-hand turbocharger outlet tube.
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13 . Install the generator cooling duct (if equipped).
14 . Remove the piece of string securing the steering gear.

Tighten to 100 Nm.
Tighten to 35 Nm.

20 . Remove the engine support bracket.
21 . Remove the engine lifting bracket.

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Removal
1 . Remove the transmission.

3 . Remove the left-hand turbocharger outlet pipe retaining bolt.

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4 . Disconnect the left-hand turbocharger outlet pipe.
5 . Remove the left-hand turbocharger outlet pipe from the turbocharger.

7 . Detach the starter motor solenoid harness.

10 . Detach the oil temperature sensor harness from the cylinder block.
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11 . Remove the air conditioning (A/C) compressor lower retaining bolt.
12 . Remove the accessory drive belt tensioner bracket retaining bolt.

13 . Remove the charge air cooler pipe retaining bolt.
Installation
NOTE:
Make sure the oil pan extension mating faces are clean and dry.
NOTE:
Install a new oil pan extension gasket.
1 . Apply a 8 mm bead of sealant to the cylinder block in the areas shown.

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2 . Loosely install all oil pan extension retaining bolts.

3 . NOTE:
The retaining bolts must be tightened within twenty minutes of applying the sealant.
Tighten the oil pan extension retaining bolts in the sequence shown.
1) Tighten bolts A to 10 Nm (7 lb.ft). Tighten bolts B to 4 Nm (2 lb.ft).
2) Tighten bolts A to 24 Nm (18 lb.ft). Tighten bolts B to 10 Nm (7 lb.ft).
4 . Install the charge air cooler pipe retaining bolt.
Tighten to 10 Nm (7 lb.ft).
5 . Install the accessory drive belt tensioner bracket retaining bolt.
6 . Install the A/C compressor lower retaining bolt.

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7 . Attach the oil temperature sensor harness to the cylinder block.

10 . Attach the starter motor solenoid harness.
12 . Install the left-hand turbocharger outlet pipe to the turbocharger.
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13 . Connect the left-hand turbocharger outlet pipe.
14 . Install the left-hand turbocharger outlet pipe retaining bolt.


16 . Install the transmission.

Oil Pump (12.60.26)
Removal
2 . Remove the crankshaft front oil seal.

3
. WARNING: Do not work on or under a vehicle supported only by a jack. Always
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Raise and support the vehicle.

For additional information, refer to Oil Pan Extension (12.60.48)
Remove the bolt.
6 . Release the right hand turbocharger outlet pipe from the turbocharger.
Release the clip.
7 . Remove the right hand turbocharger outlet pipe.
Remove the bolt.
Release the clip.
9 . Disconnect the battery positive cable from the generator.
Reposition the battery positive cable connector cover.

Remove the nut.
10 . Remove the 2 generator lower bolts.

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11 . Release the generator.
Remove the generator upper bolt.
Reposition the generator.
Using a suitable tie strap, secure the generator to the front subframe.
12 NOTE:
.
The generator mounting bracket upper rear bolt cannot be fully removed until the
generator mounting bracket has been detached from the engine.
Remove the generator mounting bracket.
Remove the 4 bolts.
13 . Remove the timing belt idler pulley.
Remove the bolt.
14 . Remove the 2 timing belt cover sealing strips.

Remove the 10 bolts.

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Installation
1 . Prime the oil pump.
Fill the orifice shown with 20 ml of engine oil.

1)
2) Rotate the oil pump drive 2 complete turns.

2.
CAUTION: Make sure that the mating faces are clean and free of foreign material.
CAUTION: Make sure the gasket is installed correctly.
Clean the component mating faces.
Lightly tighten the bolts in the positions shown.
3
. CAUTION: Make sure the base of the oil pump is aligned within 0.2 mm of the base
of the engine block. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
Vehicles fitted with oil pumps without dowels.
Check the oil pump to engine block alignment.

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4 . NOTE:
All vehicles.
Secure the oil pump.
Tighten the 10 bolts to 10 Nm in the sequence shown.

5 . Install the timing belt cover sealing strips.
6 . Install the timing belt idler pulley.
Tighten the bolt to 45 Nm.
7 NOTE:
.
The generator mounting bracket upper rear bolt must be installed to the generator
mounting bracket before the generator bracket is installed to the engine.
Install the generator mounting bracket.
Loosely install the 4 bolts.
Tighten the 4 bolts in the sequence shown to 23 Nm.

Tighten the 3 bolts to 47 Nm.
9 . Connect the generator electrical connections.
Attach the battery positve cable and tighten the nut to 12 Nm.
Reposition the battery positive cable connector cover.
Connect the electrical connection.
10 . Install the RH turbocharger outlet pipe.

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Secure the 2 clips.
Tighten the bolt to 47 Nm.
12 . Install the oil pan extension.

13 . Install the crankshaft front oil seal.


Timing Belt
Check pin - camshaft pulleys

303-1132

303-1126
Timing pin - flexplate automatic transmission

303-1117
Removal
2 . Remove the timing belt cover.

For additional information, refer to Timing Belt Cover
3 . Remove the generator cooling duct (if equipped).

4 . Remove the starter motor retaining bracket.
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8 . NOTE:
Steering shaft shown removed for clarity.
Detach and reposition the starter motor.
9 . NOTE:
Remove the locking pin access grommet.
Align the timing pin hole.
Rotate the crankshaft clockwise.
10 . Using the special tool, lock the flexplate.

12
. CAUTION: If the camshafts are not aligned to the correct position, remove the
special tool (303-1117) and rotate the crankshaft 180 degrees.
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NOTE:
Check that the left-hand camshaft alignment hole is at the 7 o'clock position and that
the right-hand camshaft alignment hole is at the 5 o'clock position.
NOTE:
Using the special tools, lock the camshaft pulleys.
13 . Remove the accessory drive belt pulley and bracket assembly.

14
. CAUTION: The camshaft pulley hub must be counter held while undoing the
camshaft pulley hub retaining bolts. Failure to follow this instruction may result in
damage to the special tools and the engine.
NOTE:
Undo but do not remove the camshaft pulley securing bolts.
1) Counter hold the camshaft pulley hub.
2) Undo but do not remove the camshaft pulley retaining bolts.
15 . Remove and discard the timing belt tensioner.
Release the timing belt tensioner.

16 . NOTE:
Remove and discard the timing belt.

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Installation
1 . Rotate both camshaft pulleys fully clockwise.
2 . Install a new timing belt tensioner.
Do not fully tighten the retaining bolt.

3
. CAUTION: Make sure that the timing belt slack is at the timing belt tensioner.
Failure to follow this instruction may result in damage to the engine.
NOTE:
Install the timing belt in the sequence shown.
1) Install the timing belt to the crankshaft pulley.
2) Attach the timing belt to the idler pulley.
3) Attach the timing belt to the left-hand camshaft pulley.
4) Attach the timing belt to the idler pulley.
5) Attach the timing belt to the right-hand camshaft pulley.
6) Attach the timing belt to the timing belt tensioner.

4
. CAUTION: Make sure the timing belt tensioner window is correctly aligned. Failure
to follow this instruction may result in damage to the engine.
Tension the timing belt.
1) Rotate the tensioner.
2) Make sure the tensioner window is aligned.
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5
. CAUTION: The camshaft pulley hub must be counter held while tightening the
camshaft pulley hub retaining bolts. Failure to follow this instruction may result in damage
to the special tools and the engine.
NOTE:
Fully tighten the camshaft pulley retaining bolts.
1) Counter hold the camshaft pulley hub.
9 . NOTE:

10
. CAUTION: Do not rotate the crankshaft counter clockwise. Failure to follow this
Rotate the crankshaft clockwise two complete turns.
12 . Using the special tool, lock the flexplate.

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14
. CAUTION: If the camshafts are misaligned repeat the timing belt installation
procedure. Failure to follow this instruction may result in damage to the engine.
NOTE:
Using the special tools, make sure the camshafts are aligned.
15 . NOTE:
16 . Install the accessory drive belt pulley and bracket assembly.
Tighten to 80 Nm.

Install the grommet.
19 . NOTE:
Steering shaft shown removed for clarity.

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Install the starter motor.
Tighten to 48 Nm.
20 . Attach the starter motor solenoid harness.
Tighten to 7 Nm.
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21 . Attach the starter motor positive cables.
Tighten to 10 Nm.
22 . Install the starter motor retaining bracket.
Tighten to 23 Nm.
23 . Install the generator cooling duct (if equipped).

24 . Install the timing belt cover.
For additional information, refer to Timing Belt Cover

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Timing Belt Cover

303-703
Removal


.
1)
clockwise.
2) Remove the accessory drive belt.

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10 . Detach the coolant temperature sensor wiring harness.
12 . Detach the oil level indicator tube.

13 . Loosen the power steering pump retaining bolt.
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15 . Remove the left-hand timing cover.

18 . Loosen the charge air cooler retaining clip.

20 . Remove the intake air shutoff throttle elbow.

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21 . Remove the charge air cooler pipe.
22 . Detach the port deactivation valve retaining bracket.

24 . Detach the EGR cooler pipe.
25 . Detach the air temperature sensor wiring harness.

26 . Detach the EGR valve tube.
27 . Remove the right-hand timing cover.
Remove and discard the gaskets

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28 . Remove the crankshaft vibration damper.

For additional information, refer to Crankshaft Vibration Damper (12.21.09)
29 . Detach the charge air cooler hose.
1) Remove the hose clamp.

31 . Remove the charge air cooler pipe.
32 . Detach the turbocharger inlet pipe.
33 . NOTE:
Lock the water pump pulley with suitable 6 mm bar.

NOTE:
Discard the water pump pulley retaining bolts.
Remove the water pump pulley.
34 . Remove the lower timing cover.

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Installation
1 . NOTE:
Install the lower timing cover.
Tighten to 10 Nm.
Install new water pump pulley retaining bolts.
Tighten to 24 Nm.
3 . Attach the turbocharger inlet pipe.
4 . Attach the charge air cooler pipe.

6 . Attach the charge air cooler hose.
1) Tighten to 4 Nm.
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2) Tighten to 8 Nm.
7 . Install the crankshaft vibration damper.

For additional information, refer to Crankshaft Vibration Damper (12.21.09)
8 . NOTE:
Install the right-hand timing cover.
Tighten to 10 Nm.
9 . Attach the EGR valve tube.
Tighten to 3 Nm.
10 . Attach the port deactivation valve retaining bracket.
Tighten to 8 Nm.
11 . Attach the air temperature sensor wiring harness.

12 . Attach the EGR cooler pipe.
Tighten to 10 Nm.
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14 . Install the charge air cooler pipe.
Tighten to 8 Nm.
15 . Install the intake air shutoff throttle elbow.
Tighten to 10 Nm.
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19 . NOTE:
Install the left-hand timing cover.
Tighten to 10 Nm.

21 . Install the power steering pump bolt.
Tighten to 22 Nm.
22 . Attach the oil level indicator tube.
Tighten to 3 Nm.
Tighten to 3 Nm.
24 . Attach the coolant temperature sensor wiring harness.
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.
1)
clockwise.
2) Install the accessory drive belt.


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303-703
Fuel injector remover

303-1127
Removal
WARNING: Wait at least 30 seconds after the engine stops before commencing any repair to
the high-pressure fuel injection system. Failure to follow this instruction 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 mixtures are always present and may
ignite. 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 this instruction may result in
personal injury.
running. The fuel pressure within the system can be as high as 1650 bar. Failure to follow this
CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean
and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or
welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION: Do not disconnect the fuel injector electrical connectors with the engine running.
CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel
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injection system components. Failure to follow this instruction may result in foreign matter ingress
to the fuel injection system.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and
fine clearances. It is therefore essential that absolute cleanliness is observed when working with
these components. Always install blanking plugs to any exposed ports.


.
1)
clockwise.


7 . Detach the ECT sensor wiring harness.

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9 . Detach the oil level indicator tube.
10 . Loosen the power steering pump retaining bolt.

12 . Remove the left-hand timing cover.

14 Remove the exhaust gas recirculation (EGR) valve outlet tubes.

. For additional information, refer to Exhaust Gas Recirculation (EGR) Valve Outlet Tube
(17.45.11)
16 . Remove the engine harness cover.

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17 . Remove the engine harness casing.
18
. CAUTION: Protect the fuel injector electrical connectors with lint-free material to
prevent contamination from the cleaning fluid. Failure to follow this instruction may
result in serious damage to the vehicle.
Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors, high-
pressure fuel supply lines and surrounding areas.
20 . Detach the fuel injection wiring harness.
21 Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors, high-
. pressure fuel supply lines and surrounding areas.
22
injection system.
in damage to the fuel injector or the fuel injector adaptor union.
23
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injection system.
supply lines, the fuel injectors and the fuel rail.
24 NOTE:
.
While maintaining the pressure on the high-pressure fuel supply line, clean and
vacuum foreign material from the line and unions.
injectors and the fuel rail.
. fuel rail.
26 Disconnect the fuel return line from the fuel injectors.

.
Remove and discard the fuel return line retaining clips from the fuel
injectors.
27 . Remove the fuel injectors retaining bolts.

28 . Install the special tool studs.
29
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30
follow this instruction may result in damage to the special tool or fuel injectors.
Using the special tool, remove the fuel injectors.
Remove the fuel injectors.

Remove and discard the fuel injectors retaining clamps.
Remove and discard the fuel injectors sealing washers.

34 . Detach the intake air shutoff throttle elbow.

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39

40

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41
42 . Detach the knock sensor (KS) electrical connector.

44 . Disconnect the engine oil pressure (EOP) sensor electrical connector.

46 . Detach the glow plug harness.
47 . Detach the engine breather pipe.

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48 . Disconnect the vacuum pipe.

50 Using the pneumatic vacuum gun, vacuum foreign material from the fuel injection pump,
. high-pressure fuel supply line and surrounding areas.
51
. CAUTION: Make sure that the tool used to loosen the high-pressure fuel supply line
union is used at the top of the union as this is where there is most material. Failure to
follow this instruction may result in damage to the union.
CAUTION: Make sure that the high-pressure fuel supply line remains in contact
with both the fuel injection pump and the fuel rail until both unions have been detached
and cleaned. Failure to follow this instruction may result in foreign matter ingress to the
NOTE:
While maintaining the pressure on the high-pressure fuel supply line, clean and vacuum
foreign material from the line and unions.
Remove the high-pressure fuel supply line.

53 . Remove the fuel rail securing bracket .
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54 . Remove the engine cover and wiring harness retainers.
Remove and discard the valve cover gasket.

Installation
injury.
personal injury.
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Tighten to 10 Nm.
2 . Install the engine cover and wiring harness retainers.

Tighten to 24 Nm.
Tighten to 24 Nm.
5 Install new a high-pressure fuel supply line.

.
Tighten the high-pressure fuel supply line union 1 to fuel diverter rail to 15
Nm.
Nm.
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Tighten to 10 Nm.
7 . Connect the vacuum pipe.

8 . Attach the engine breather pipe.
9 . Attach the glow plug harness.

11 . Connect the EOP sensor electrical connector.

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13 . Attach the KS electrical connector.
14

Tighten to 10 Nm.
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19 . Attach the inake air shutoff throttle elbow.

Tighten to 10 Nm.
23
. CAUTION: Do not use tools to install the new fuel return line retaining clips. Failure
to follow this instruction may result in damage to the retaining clips.
NOTE:
Install new fuel return line retaining clips.
NOTE:
Install new fuel injector sealing washers.
NOTE:
Install new fuel injector retaining clamps.

Install new fuel injector retaining clamps.
24 . Install the fuel injectors.
Tighten to 10 Nm.
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25
. CAUTION: Make sure the fuel return line retaining clips are correctly installed to
the fuel injectors before installing the fuel return line.
Connect the fuel return line to the fuel injectors.
Visually inspect the fuel return line O-ring seals for damage.
Apply a light coating of petroleum jelly to the fuel line return line O-ring
seals.
Connect the fuel return line to the fuel injectors.

26
. CAUTION: Do not allow the unions to hit the olive ends of the high-pressure fuel
supply lines as this may damage the ends of the lines and allow foreign matter enter the
Position the high-pressure fuel supply lines as near to the final installation position as
possible and then remove and discard the blanking plugs from the high-pressure fuel supply
lines.
27
. CAUTION: Maintain pressure on the high-pressure fuel supply lines to keep the
olives in contact with the fuel injectors and the fuel rail cones while installing the unions.
NOTE:
injector end.
Install new high-pressure fuel supply lines.

Nm.

Nm.
28 . Attach the fuel injection wiring harness.

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30 . Install the engine harness casing.
Tighten to 4 Nm.
31 . Install the engine harness cover.
33 Install the EGR valve outlet tubes.

(17.45.11)

35 . NOTE:
Install the left-hand timing belt cover.
Tighten to 10 Nm.
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37 . Tighten the power steering pump bolt.
Tighten to 22 Nm.
38 . Attach the oil level indicator tube.
Tighten to 3 Nm.
Tighten to 3 Nm.
40 . Attach the ECT sensor wiring harness.

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.
1)
clockwise.
2) Install the accessory drive belt.


48
. WARNING: Do not carry out any repairs to the fuel system with the engine
running. The fuel pressure within the high-pressure system can be as high as 1650 bar.
NOTE:
The fuel return line must be renewed if any leaks are found from the fuel return line O-
ring seals.
Start the engine and check visually for fuel leaks.

Removal
injury.
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personal injury.
1 . Remove the fuel injectors.

3 . Remove the intake air shutoff throttle elbow retaining bolt.
4 . Disconnect the intake air shutoff throttle electrical connectors.


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7 . Remove the intake air shutoff throttle retaining bolt.

10

11

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12
13 . Disconnect the knock sensor (KS) electrical connector.

Detach the KS electrical connector from the valve cover.
14 . Detach the glow plug electrical connector from the valve cover.
15 . Detach the engine breather pipe.
16 . Loosen the right-hand timing cover retaining bolt.

17 . Remove the engine cover mounting bracket.
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18 . Disconnect the port deactivation vacuum pipe.

. fuel rail.
21
with both the fuel injection pump and the fuel injection supply manifold until both unions
have been detached and cleaned. Failure to follow this instruction may result in foreign
matter ingress to the fuel injection system.
CAUTION: While maintaining the pressure on the high-pressure fuel supply line,
clean and vacuum foreign material from the line and unions.
Remove and discard the high-pressure fuel supply line.
23 . Remove the fuel rail securing bracket.

24 . Detach the diesel particulate filter high and low-pressure pipes.
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25 . Detach the exhaust gas recirculation (EGR) coolant rail.
26 . Remove the engine cover locating studs.

Remove and discard the valve cover gasket.
Installation
injury.
personal injury.
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Tighten to 10 Nm.
2 . Install the engine cover locating studs.
3 . Attach the EGR coolant rail.
4 . Attach the diesel particulate filter high and low-pressure pipes.
Tighten to 10 Nm.
Tighten to 24 Nm.
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Tighten to 24 Nm.
7 Install a new high-pressure fuel supply line.

.
Nm.
Nm.
Tighten to 10 Nm.
9 . Connect the port deactivation vacuum pipe.

10 . Install the engine cover mounting bracket.
Tighten to 4 Nm.
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11 . Tighten the right-hand timing cover retaining bolt.
Tighten to 10 Nm.
12 . Attach the engine breather pipe.

13 . Attach the glow plug electrical connector to the valve cover.
Attach the KS electrical connector to the valve cover.
15

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18 . Install the intake air shutoff throttle retaining bolt.
Tighten to 10 Nm.
20 . Attach the inake air shutoff throttle elbow.
21 . Connect the intake air shutoff throttle electrical connectors.

22 . Install the intake air shutoff throttle elbow retaining bolt.
Tighten to 10 Nm.

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24 . Install the fuel injectors.

303-03A : Engine Cooling – 3.0L/3.5L/4.2L
Specifications
Specifications
Jaguar Premium Cooling System Fluid WSS M97B44-D
Jaguar Premium Cooling System Flush EGR-M14P7-A
Cooling System Refill Capacities
Engine Capacity
3.0L 9.4L
3.5L/4.2L 13.3L

Auxiliary water pump retaining bolts 10 - 89
Condenser core retaining stud 7 - 62
Coolant expansion tank bleed screw 3 - 27
Coolant expansion tank retaining bolt 3 - 27
Cooling fan motor and shroud retaining nuts 7 - 62
Cooling module retaining bolts - 4.2L SC 7 - 62
Oil cooler inlet pipe 20 15 -
Oil cooler return pipe 20 15 -
Power steering oil cooler retaining nuts - 3.5L/4.2L 7 - 62
Radiator drain plug 1 - 9
Radiator mounting bracket retaining bolts 6 - 53
Thermostat housing retaining bolts - 3.0L 18 13 -
Thermostat housing retaining bolts - 3.5L/4.2L/4.2L SC 9 - 80
Water pump drive pulley retaining bolts - 3.5L/4.2L/4.2L SC A - -
Water pump retaining bolts - 3.0L 25 18 -
Water pump retaining bolts - 3.5L/4.2L/4.2L SC A - -
Water pump retaining bracket bolts - 4.2L SC 7 - 62
A = refer to the procedure for the correct torque sequence - - -
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General procedures
Cooling System Backflushing

CAUTION: The heater core must be backflushed separately from the engine
cooling system to prevent the engine cooling system particles from clogging the heater
core tubes and reducing (or eliminating) coolant flow through the heater core. All engine
cooling system flushing and backflushing procedures must include a separate
backflushing of the heater core after the flushing or backflushing of the engine cooling
system.
CAUTION: Heater core internal pressure must not exceed 100 kPa (14.5 psi).
Failure to follow this instruction may cause damage to the heater core.
NOTE:
Cooling system backflushing should be carried out before the cooling system components
are installed after the cooling system flushing procedure.
1. Disconnect the heater outlet coolant hose from the engine and connect the heater hose to a
suitable hose pipe.
2. Disconnect the heater inlet coolant hose from the engine and allow the coolant to drain into
a suitable container.
3. Turn the water supply valve to the hose ON and allow water pressure to flow through the
heater core.
4. Allow water pressure to flow through the heater core for approximately five minutes.
5. Turn the water supply valve to the hose OFF and disconnect the hose pipe from the heater
hose.
6. Connect the heater inlet coolant hose to the engine.
7. Connect the heater outlet coolant hose to the engine.
8. Fill the cooling system as described using a 50% mixture of Jaguar Premium Cooling
System Fluid, or equivalent meeting Jaguar specification WSS M97B44-D and 50% distilled
water.
9. Test the system for correct heater performance with the specified engine cooling system
conditions.
Radiator Backflushing
1. Remove the radiator.
2. Invert the radiator.
3. Connect a suitable hose pipe to the lower coolant hose connection of the radiator.
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radiator.
5. Allow water pressure to flow through the radiator for approximately five minutes.
6. Turn the water supply valve to the hose OFF and disconnect the hose pipe from the
radiator.
7. Allow the coolant to drain from the radiator.
8. Install the radiator.
Engine Backflushing
1. Remove the thermostat before backflushing the engine.
2. Position the high-pressure water hose into the engine through the engine return and
backflush the engine.
3. Connect a suitable hose pipe to the upper coolant hose connection of the engine.
engine.
5. Allow water pressure to flow through the engine for approximately five minutes.
6. Turn the water supply valve to the hose OFF and disconnect the hose pipe from the upper
coolant hose connection of the engine.
7. Connect the upper coolant hose to the engine.
8. Fill the cooling system as described using a 50% mixture of Jaguar Premium Cooling
System Fluid or equivalent, meeting Jaguar specification WSS M97B44-D and 50% distilled
water.
Cooling System Draining, Filling and
Bleeding
1.
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 (still with a
cloth) turn and remove the coolant pressure cap from the coolant expansion tank.
WARNING: To avoid the possibility of personal injury, do not operate the engine
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with the hood open until the fan blades have been examined for cracks and separation.
WARNING: Remove fuse 14 from the engine compartment fuse box 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
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.

• Remove the coolant expansion tank pressure cap.
2. Remove the radiator splash shield.

3. Remove the coolant drain plug.

• Drain the coolant into a suitable container.
4.
CAUTION: Do not over tighten the drain plug. Failure to follow this instruction
may cause damage to the vehicle.
Install the drain plug when all coolant has drained.

Remove the drain tray.
5. Install the radiator splash shield.

6. Remove the coolant expansion tank bleed screw.
7. Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty
percent mixture of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar
8.
CAUTION: Do not over tighten the coolant expansion tank bleed screw. Failure
to follow this instruction may cause damage to the vehicle.
Install the coolant expansion tank bleed screw.

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9. Install the coolant expansion tank pressure cap.
10.
CAUTION: Do not RUN the engine with the coolant expansion tank pressure cap
removed. Failure to follow this instruction may cause damage to the vehicle.
START and RUN the engine.
11. SET the heating system to MAX heat, the blower motor to MAX speed and the air
distribution to instrument panel registers.
12.
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
Allow the engine to RUN until hot air is emitted from the instrument panel registers, while
observing the engine temperature gauge.
13. Switch off the engine.
14. Allow the engine to cool.

15. Release the cooling system pressure.

Cooling System Draining and Vacuum
Filling
WARNING: 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 (still with a cloth) turn and remove the coolant pressure cap from the coolant
expansion tank. Failure to follow these instructions may result in personal injury.
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NOTE:
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
NOTE:
Engine coolant will damage paint finished surfaces. If spilled, immediately remove
coolant and clean area with water.
NOTE:
Vehicles fitted with supercharged engines shown, V8 NA and V6 engines similar.
1. Set the heater controls to maximum HOT.
2.
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.
Remove coolant expansion tank filler cap.
3.
WARNING: Do not work on or under a vehicle supported only by a jack. Always

Raise and support the vehicle.

5. Detach the electrical connectors.
6. Remove the radiator lower cowl.
7.
WARNING: Eye protection must be worn.
Position container to collect coolant.
8. Remove the coolant drain plug.

• Allow the coolant to drain.
9.
CAUTION: Do not over tighten the drain plug. Failure to follow this instruction
may cause damage to the vehicle.
Install the drain plug.
10. Disconnect the supercharger radiator bottom hose.

• Release the clip.
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• Disconnect the hose.

• Allow the coolant to drain.
11. Connect the supercharger bottom hose.

• Connect the hose.
• Secure the clip.
12. Install the radiator lower cowl.

13. Attach the electrical connectors.

15. Install the cooling system vacuum refill adaptor to the expansion tank.
16. Install the vacuum filler gauge to the cooling system vacuum refill adaptor.
17. Install the venturi tube assembly to the vacuum filler gauge.
18. 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.
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Connect a regulated compressed air supply to the venturi tube assembly.
19. Open air supply valve.
20. 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 coolant supply valve for 2 seconds to prime coolant supply hose.
21. Apply air pressure progressively until the arrow on the vacuum filler gauge reaches the
green segment.
22. Close air supply valve and disconnect air supply.
23. Allow 1 minute to check vacuum is held.

24. NOTE:
Close the coolant supply valve when the coolant expansion tank MAX mark is reached or
coolant movement has ceased.
Open coolant supply valve and allow coolant to be drawn into system.
25. When expansion tank is full and coolant movement has ceased close coolant supply
valve.
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26. Remove vacuum refill adaptor and gauge from expansion tank.
27. Install the coolant expansion tank filler cap.
28. Remove the engine cover.
29. Remove the supercharger coolant filler plug.

• Remove and discard the sealing washer.
30. NOTE:
Place a suitable cloth around supercharger fill port.
Top up the coolant through the supercharger fill port.

31.
CAUTION: Coolant may spill from supercharger fill port when ignition switched
on.
Switch ignition on.
32.
CAUTION: Do not allow the supercharger water 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 supercharger fill port.
33. Switch the ignition off.
34. Install the supercharger coolant fill plug.

• Install a new sealing washer.
• Clean off any spillages.
35. Install the engine cover.
36.
removed. Failure to follow this instruction may cause damage to the vehicle
37.
40.
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.
Check and top up the cooling system if required.

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Cooling System Flushing
1. Remove the air cleaner. <<303-12A>>
2. Remove the air cleaner. <<303-12B>>
3. Remove the thermostat.

Thermostat - 4.2L, Vehicles With: Supercharger (26.45.07)
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.
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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>>

Engine Cooling
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1 — Coolant expansion tank
2 — Auxiliary coolant flow pump
3 — Cooling fan motor
4 — Oil cooler inlet and outlet hoses
5 — Thermostat housing
6 — Engine coolant outlet
7 — Vent hose
1 — Engine oil cooler
2 — Retaining bolt
3 — Engine oil cooler connections


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1 — Vent hose
3 — Radiator
5 — Engine oil cooler connections
6 — Engine coolant inlet
7 — Engine coolant outlets

Vehicles with 4.2L engine with supercharger
1 — Vent hose (SC radiator)
3 — Vent hose
4 — Radiator

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 (still with a cloth) turn and remove the coolant pressure cap from the coolant expansion
tank. Failure to follow these instructions may result in personal injury.
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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
WARNING: Remove fuse 14 from the engine compartment fuse box 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.
The cooling system consists of the following:

• Radiator
• Coolant pressure cap
• Thermostat
• Water pump
• Electric cooling fan
• Coolant expansion tank
• Engine oil cooler
Water Pump
The water pump is of a conventional design and is driven by the crankshaft pulley through the
accessory drive belt. The water pump belt tension is maintained by an automatic drive belt tensioner.
<<303-05>>
Thermostat
The thermostat is located in the thermostat housing and allows rapid engine warm-up by restricting
coolant flow through the radiator below 82°C (180°F). The thermostat also assists in keeping the
engine operating temperature within predetermined limits. On the 4.2L supercharged engine the
thermostat begins to open at 84°C (183°F) and is fully open at 98°C (208°F), on the 3.5L or 4.2L and
3.0L engine the thermostat begins to open at 88°C - 92°C (190°F - 198°F) and is fully open at 102°C
(216°F).
When the engine is cold and the thermostat is closed, coolant flows from the water pump through
the engine. It then returns to the water pump through the upper coolant hose.
When the engine is warm and the thermostat is open, coolant flows into the radiator through the
upper coolant hose. It then returns to the water pump from the radiator through the lower coolant
hose and engine oil cooler.
The heater core is on a parallel circuit and is unaffected by the position of the thermostat.
Radiator
The radiator is of aluminium construction with plastic end tanks. Foam seals are fitted to the radiator
to prevent the cooling air from by passing the radiator core. A coolant drain plug is provided in the
lower coolant end tank of the radiator for the draining of the coolant. The cooling fan shroud is
attached to the radiator.
Cooling Fan
A single, variable speed cooling fan motor is attached to a fan shroud located behind the radiator.
The speed is determined by the Engine Coolant Temperature (ECT) and the air conditioning pressure
and transmission oil temperature.
Under hot operating conditions, the fan may continue to operate for four minutes after the engine
has been switched off.
Engine 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.
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.
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• 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 Oil Cooler

The engine oil cooler is a Modine oil to water type. The oil cooler on the 3.0L engine is fitted to the
oil filter housing. The oil cooler on the 3.5L or 4.2L engine is located at the front of the engine and is
fitted between the oil filter housing and the oil filter. The oil cooler on the 4.2L engine with a
supercharger is fitted behind the front bumper on the front of the cooling pack.
The coolant supply for the engine oil cooler is through the radiator bottom hose.
Engine Coolant
The long life engine coolant is formulated to last for five 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.
1 — Water pump
2 — Throttle body
3 — V6 engine
4 — Heater core
6 — Thermostat
7 — Lower hose
8 — Radiator
10 — Upper hose

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1 — EGR valve
2 — Throttle body
3 — Heater core
4 — Water pump
5 — Engine bank (left-hand)

6 — Thermostat
8 — Lower hose
10 — Radiator
12 — Upper hose
Vehicles with 4.2L engine with supercharger

1 — EGR valve
2 — Heater core
3 — Throttle body
4 — Charge air cooler (right-hand)
5 — Water pump
6 — Charge air cooler (left-hand)
7 — Engine bank (left-hand)
8 — Thermostat

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11 — Lower hose
12 — Radiator
13 — SC radiator
14 — SC coolant pump
15 — Upper hose
Engine Cooling

Leaks Fuse
Coolant expansion
Wiring harness
tank
Electric fan Loose or corroded connector(s)
Engine cooling temperature (ECT) sensor or engine cylinder head temperature

Radiator
(CHT) sensor
2 . If the concern is not visually evident, verify the symptom and refer to symptom chart.
DTC Condition Possible Source Action
• ECT sensor.
Concern with engine coolant • ECT sensor circuit(s). For V6 vehicles, <<303-
P0116 temperature • Low/contaminated coolant. 14A>> For V8 Vehicles,
(range/performance) • Thermostat failure. <<303-14B>>
• Overheating.
• ECT sensor. For V6 vehicles, <<303-

Concern with engine coolant
P0117 • ECT sensor circuit (short to 14A>> For V8 Vehicles,
temperature (low input) ground/open circuit). <<303-14B>>
• ECT sensor. For V6 vehicles, <<303-

Concern with engine coolant
P0118 • ECT sensor circuit (short to 14A>> For V8 Vehicles,
temperature (high input) ground/open circuit). <<303-14B>>
Concern with engine coolant • ECT sensor. For V6 vehicles, <<303-
P0125 temperature (insufficient for • ECT sensor circuit (short to 14A>> For V8 Vehicles,
close loop control) ground/open circuit). <<303-14B>>
Water Pump - 3.0L, VIN

Range: G00442-
>G45703 (26.50.01)
Water Pump - 4.2L,
Concern with engine coolant Vehicles With:
P1474 Water pump malfunction.
temperature Supercharger
(26.50.01)
Water Pump -
3.5L/4.2L, Vehicles
Without: Supercharger
(26.50.01)
•
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Hoses.
• Hose connections.
• Radiator.
• Water pump. GO to Pinpoint Test
None Concern with coolant loss
• Heater core. G234419p1.
• Gaskets.
• Engine casting cracks.
• Engine block core plugs.
• Engine coolant
(level/condition).
• Thermostat.
• Fan motor.
• Fan motor fuses and/or GO to Pinpoint Test
None Concern with overheating
circuits. G234419p2.
• ECT sensor.
• Engine control module
(ECM).
• Fan speed module.
• Thermostat.
Concern with engine not GO to Pinpoint Test
None • Electric fan.
reaching normal temperature • Fan speed module. G234419p3.
PINPOINT TEST G234419p1 : LOSS OF

COOLANT
G234419t1 : 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. TEST the system for normal operation.
-> No
Verify the customer complaint.

ENGINE OVERHEATS
G234419t2 : CHECK COOLANT
1. Check the coolant level and condition.
• Does the system contain sufficient coolant of the correct specification?
-> Yes
-> No
Top-up the system.
Cooling System Draining, Filling and Bleeding Check for coolant loss. GO to Pinpoint Test
G234419p1.
G234419t3 : CHECK THERMOSTAT

1. Check the thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) See component tests in this
section.
• Is the thermostat OK?
-> Yes
<<303-14A>> Cooling fans, modules, circuits, sensors, etc. are tested in this section.
-> No
INSTALL a new thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) TEST the system for normal
operation.

ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURE
G234419t4 : CHECK THERMOSTAT
1. Check the thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) See component tests in this
section.
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• Is the thermostat OK?
-> Yes
<<303-14A>> Cooling fans, modules, circuits, sensors, etc. are tested in this section.
-> No
INSTALL a new thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) TEST the system for normal
operation.
Component Tests
Pressure Test
WARNING: Never remove the coolant expansion tank cap under any circumstances while
the engine is operating. Failure to follow these instructions may result in damage to the cooling
system or engine and/or personal injury. To avoid having scalding hot water or steam blow out of
the cooling system, use extreme care when removing the coolant expansion tank cap from a hot
cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant
expansion tank 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 cap. Failure to follow these instructions may
1 . Switch the engine off.
2 . Open the hood and install protective fender covers.
3 . Carefully remove the coolant expansion tank cap from the coolant expansion tank to relieve
pressure in the cooling system. Add coolant to coolant expansion tank as necessary.
4 . Install the adapter fitting from Pressure Tester tightly between overflow/air purge nipple and
overflow/air purge hose at the coolant expansion tank. Reinstall the coolant expansion tank cap.
5 . Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to
the coolant expansion tank cap lower limit. Refer to Specification.
6 . Pressurize the cooling system. Observe the gauge reading for approximately two minutes.
Pressure should not drop during this time.
If system holds pressure, proceed to step 8.
If the pressure drops, check for leaks at the engine to heater core hoses, engine to radiator
hoses, bypass hose, water valve hose (if applicable), thermostat housing gasket, radiator and
heater core, etc. 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 by loosening the coolant expansion tank cap. Check the coolant level.
Replenish as necessary with the correct coolant solution.
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 remove the coolant expansion tank cap under any circumstances while
the engine is operating. Failure to follow these instructions may result in damage to the cooling
system or engine and/or personal injury. To avoid having scalding hot water or steam blow out of
the cooling system, use extreme care when removing the coolant expansion tank cap from a hot
cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant
expansion tank 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 cap. Failure to follow these instructions may
1 . Remove the expansion tank cap from the radiator coolant expansion tank.
2 . Use water to clean in area of rubber seal and vacuum relief valve. Immerse expansion tank cap in
water and install expansion tank cap pressure test adapter from Pressure Tester on the expansion
tank cap.
3 . NOTE:
If the plunger of the pump is depressed too quickly, an erroneous pressure reading will result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
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increasing, and note highest pressure reading obtained.
4 . Release pressure by turning the pressure relief screw counterclockwise. Then tighten the pressure
relief screw and repeat Step 5 at least twice to make sure the pressure test reading is repeatable and
within acceptable gauge reading limits of the expansion tank cap.
5 . If the pressure test gauge readings are not within acceptable gauge reading limits, install a new
expansion tank cap.
Thermostat Test - mechanical

Remove and inspect the thermostat, 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. Continue to heat the water until the thermostat fully opens, 5.8 mm
(0.2 in) or more off the valve seat. If it does not fully open, install a new thermostat.
Radiator Leak Test - removed from the vehicle
CAUTION: Do not leak test an aluminium radiator in the same water that is used to leak test
copper/brass radiators. Flux and caustic cleaners may be present in the test water which will
corrode aluminium.
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.
A separate clean test tank is recommended for aluminium radiators. If a separate tank is not
available for aluminium radiator testing, rinse the test tank each time before testing an aluminium
radiator.

Removal
1 . NOTE:
Cap the vent hose to minimize coolant loss.
Detach the vent hose.

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2 . NOTE:
Cap the vent hoses to minimize coolant loss.
Detach the vent hoses.

All vehicles
3 . Detach the coolant expansion tank.
4 . Disconnect the coolant expansion tank low level sensor electrical connector.
5 . NOTE:
Make sure the retaining clip is not removed.
NOTE:
Cap the coolant expansion tank lower hose to minimize coolant loss.
Detach the coolant expansion tank lower hose.
Remove the coolant expansion tank.

Installation
Tighten to 3 Nm.
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2 . Check and top up the cooling system as required.

Removal
All Vehicles
1 Remove fuse 14 from the engine compartment fuse box prior to performing any under hood
. service in the area of the cooling fan.
2 . Drain the cooling system.

3 . Detach the electrical connectors.
4 . Disconnect the electric fan electrical connectors.

6 . Disconnect the supercharger water pump electrical connector.
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All vehicles
8 . Remove the coolant expansion tank.


9 . Remove the air cleaner. <<303-12A>>

All Vehicles
11 . Remove the radiator grille opening panel. <<501-02>>
12 . Remove the radiator mounting brackets.
13 . Detach the upper coolant hose.

15 . Detach the auxiliary coolant flow pump.
All vehicles
16 . NOTE:
Remove the cooling fan motor and shroud retaining bolt.

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17
. CAUTION: Make sure that the retaining lugs of the radiator are not damaged when
detaching the cooling fan motor and shroud. Failure to follow this instruction may result
NOTE:
Detach the cooling fan motor and shroud retaining lugs from the radiator.
18
. CAUTION: Make sure that the radiator is not damaged when removing the cooling
fan motor and shroud. Failure to follow this instruction may result in damage to the
vehicle.
Remove the cooling fan motor and shroud.
Installation
All vehicles
1
. CAUTION: Make sure that the radiator is not damaged when installing the cooling
fan motor and shroud. Failure to follow this instruction may result in damage to the
vehicle.
CAUTION: Make sure that the retaining lugs of the radiator are not damaged when
installing the cooling fan motor and shroud. Failure to follow this instruction may result in
Tighten to 7 Nm.
All vehicles
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4 . Fill the cooling system.

Radiator (26.40.01)
Removal
All vehicles
2 . Detach the transmission oil cooler inlet and return pipes.
Cap the oil cooler inlet and return pipes and the oil cooler.
3 . Detach the lower coolant hose.

For additional information, refer to Oil Cooler - Vehicles With: Supercharger (12.60.68)
7 . Disconnect the water pump coolant hoses.

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8 . Remove the water pump retaining bolt.

10 . Remove the water pump retaining bracket.
11 . NOTE:
Detach the power assisted steering oil cooler.
12 NOTE:
.
Remove the cooling module retaining bolt.

Secure the supercharger cooling radiator, condenser core and engine oil
cooler using suitable retaining straps.

13 . NOTE:
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Detach the power steering oil cooler.
14 . NOTE:
Remove the condenser core retaining stud.
Secure the condenser core and PAS cooler using suitable retaining straps.
All vehicles
16 .
CAUTION: Make sure that the radiator is not damaged when removed.
Remove the radiator.
Installation
All vehicles
1.
CAUTION: Make sure that the radiator is not damaged when installed.

2 . NOTE:
Tighten to 7 Nm.
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3 . NOTE:
Tighten to 7 Nm.

4 . NOTE:
Tighten to 7 Nm.
All vehicles
6 . NOTE:
Tighten to 20 Nm.

For additional information, refer to Cooling System Draining, Filling and Bleeding
8 . Carry out transmission fluid level check.

For additional information, refer to Transmission Fluid Level Check
Thermostat - 3.0L (26.45.07)
Removal

4 . Remove the air cleaner outlet pipe. <<303-12A>>

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6 . Remove the thermostat.

Installation
Tighten to 18 Nm.

Thermostat - 3.5L/4.2L, Vehicles Without:
Removal
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and type of anti-freeze solution to prevent corrosion and frost damage. Failure to follow this
2 . Remove the air cleaner outlet tube.

3 . Detach the thermostat housing hose.
Clamp the relevant hoses, to minimise coolant loss.
4 . Detach the thermostat housing hose.
Clamp the relevant hoses, to minimise coolant loss.

Installation
Tighten to 9 Nm.
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2 . Remove the coolant expansion tank bleed screw.
3 Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty percent
. mixture of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar specification
WSS M97B44-D and fifty percent water.
4
. CAUTION: Do not over tighten the coolant expansion tank bleed screw. Failure to
follow this instruction may cause damage to the vehicle.
Tighten to 3 Nm.
5 . Install the coolant expansion tank pressure cap.
6
. CAUTION: Do not RUN the engine with the coolant expansion tank pressure cap
7 SET the heating system to MAX heat, the blower motor to MAX speed and the air distribution
. to instrument panel registers.
8
. 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
9 . Switch off the engine.
10 . Allow the engine to cool.
11 . Release the cooling system pressure.
12 Top up the cooling system.

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.
Fill the cooling system up to the MAX mark on the coolant expansion tank
using a fifty percent mixture of Jaguar Premium Cooling System Fluid or
equivalent, meeting Jaguar specification WSS M97B44-D and fifty percent
water.

Thermostat - 4.2L, Vehicles With:
Removal
and type of anti-freeze solution to prevent corrosion and frost damage. Failure to follow this
2 . Remove the air cleaner outlet tube.

3 . Detach the thermostat housing coolant hose.
Clamp the relevant hose, to minimise coolant loss.

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Installation
Tighten to 9 Nm.
2 . Remove the coolant expansion tank bleed screw.
3 Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty percent
. mixture of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar specification
WSS M97B44-D and fifty percent water.
4
. CAUTION: Do not over tighten the coolant expansion tank bleed screw. Failure to
follow this instruction may cause damage to the vehicle.
Tighten to 3 Nm.
6
. CAUTION: Do not RUN the engine with the coolant expansion tank pressure cap
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7 SET the heating system to MAX heat, the blower motor to MAX speed and the air distribution
. to instrument panel registers.
8
. 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
9 . Switch off the engine.
10 . Allow the engine to cool.

11 . Release the cooling system pressure.
12 Top up the cooling system.

.
Fill the cooling system up to the MAX mark on the coolant expansion tank
using a fifty percent mixture of Jaguar Premium Cooling System Fluid or
equivalent, meeting Jaguar specification WSS M97B44-D and fifty percent
water.

Water Pump - 3.0L, VIN Range: G00442-
>G45703 (26.50.01)
Removal


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.
tensioner.
6 . Remove the intake manifold support bracket.

8 . Detach the coolant hose from the housing assembly.

10 . Remove the hoses and thermostat housing assembly.

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12 . Remove the coolant hose from the water pump to lower housing.

Installation
Tighten to 25 Nm.

Water Pump - 3.0L, VIN Range: G45704-
>G99999 (26.50.01)
Removal
(12.10.40)

3 . Remove the secondary air injection (AIR) control valve.

For additional information, refer to Secondary Air Injection (AIR) Control Valve - 3.0L
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5 . NOTE:
This bracket retains the evaporative emission cannister purge valve.
Remove the intake manifold support bracket.

7 . Disconnect the coolant hose from the housing assembly.
9 . Remove the coolant hoses and thermostat housing assembly.

11 . Remove the coolant hose from the water pump to lower housing.
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Installation
Tighten to 25 Nm.

Water Pump - 3.5L/4.2L, Vehicles Without:
Removal


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4 . Remove the air cleaner outlet tube. <<303-12B>>
5 . Loosen the water pump pulley bolts.

.
tensioner.

Installation
Install a new water pump gasket and O-ring seal.

2 . Tighten to 8 Nm + 90°.
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Install new retaining bolts.

Water Pump - 4.2L, Vehicles With:
Removal

4 . Remove the air cleaner outlet tube. <<303-12B>>
Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.
6 . Loosen the water pump pulley bolts.

.
tensioner.
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Installation
Install a new water pump gasket and O-ring seal.
Install new retaining bolts.

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303-03B : Supercharger Cooling
Specifications
Specifications

Supercharger radiator retaining bolts 7 - 62
Supercharger water pump bracket retaining bolt 7 - 62
Supercharger radiator drain plug 1 - 9
Supercharger coolant fill plug 45 33 -
General procedures
Supercharger Cooling System Draining,

Filling and Bleeding
1.
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.
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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: 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.

2. Remove the radiator splash shield. <<501-02>>
3. Detach the electrical connectors.
4. Remove the radiator lower cowl.
5. Remove the radiator drain plug.

6.
CAUTION: Do not over tighten the radiator drain plug. Failure to follow this
instruction may cause damage to the vehicle.
Install the radiator drain plug when all coolant has drained.
• Remove the container.
7. Install the radiator lower cowl.

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8. Connect the electrical connectors.
9. Install the radiator splash shield. <<501-02>>

11.
CAUTION: The supercharger cooling system must be maintained with the

correct concentration and type of coolant solution to prevent corrosion and frost
damage. Failure to follow this instruction may result in damage to the vehicle.
Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty
12.
to follow this instruction may cause damage to the vehicle

15. Remove the supercharger coolant filler plug.

16. NOTE:
Place a suitable cloth around supercharger fill port.
Top up the coolant through the supercharger fill port.
17.
CAUTION: Coolant may spill from supercharger fill port when ignition switched
on.
Switch ignition on.
18. NOTE:
Do not allow the supercharger water pump to run dry for more than one minute. Failure to
Allow the supercharger pump to run and top up the coolant through supercharger fill port.
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19. Switch the ignition off.
20. Install the supercharger coolant fill plug.

22.
removed. Failure to follow this instruction may cause damage to the vehicle
23. SET the heating system to MAX heat, the blower motor to MAX speed and the air
distribution to instrument panel registers.
24.
27. Release the cooling system pressure.


2 . Visually inspect for obvious signs of mechanical and electrical damage.

• Leak(s)
• Hose(s)
• Fuse(S)
• Charge air cooler radiator
• Wiring harness
• Supercharger cooling water pump
• Electrical connector(S)
• Coolant expansion tank
• Engine coolant temperature sensor
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• Coolant pressure cap

• Cooling fan motor
• Radiator
• Supercharger cooling water pump
• Engine cooling water pump
• Cooling fan
2 . If the cause is not visually evident, verify the symptom and refer to the Jaguar Approved
Diagnostic System.
Component tests
Pressure test. <<303-03>> Coolant pressure cap pressure test. <<303-03>> Thermostat test. <<303-
03>> Radiator leak test. <<303-03>>
Radiator
Removal
3 . Remove the radiator grille opening panel. <<501-02>>
4 . Disconnect the radiator coolant vent hose.
6 . Disconnect the right-hand radiator hose.

7 . Disconnect the left-hand radiator hose.
8 . Remove the water pump retaining bracket.

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9 . NOTE:
Detach the power assisted steering oil cooler.
10 . NOTE:
Remove the radiator retaining bolt.

11 . Remove the radiator.
Installation
Tighten to 7 Nm.
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Water Pump
Removal
1 Carry out the supercharging cooling system draining procedure.
. For additional information, refer to Supercharger Cooling System Draining, Filling and
Bleeding
2 . Remove the engine oil cooler.

For additional information, refer to Oil Cooler - Vehicles With: Supercharger (12.60.68)
3 . Disconnect the water pump electrical connector.
4 . Disconnect the water pump coolant hoses.
5 . Remove the water pump retaining bolt.

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Installation
Tighten to 7 Nm.
2 Carry out the supercharging cooling system filling and bleeding procedure.
. For additional information, refer to Supercharger Cooling System Draining, Filling and
Bleeding
3 NOTE:
.
For NAS vehicles only.
If required, carry out a long drive cycle.

For additional information, refer to Powertrain Control Module (PCM) Long Drive Cycle Self-
Test
303-03C : Engine Cooling – 2.7L Diesel
Specifications
Specifications
Jaguar Premium Cooling System Flush EGR-M14P7-A
Capacities
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Description Liters
Cooling system refill 13.5

Coolant expansion tank retaining bolt 7 - 62
Cooling fan motor and shroud retaining bolts 7 - 62
Water pump retaining bolts 10 - 89
Water pump pulley retaining bolts 24 18 -
Charge air cooler to radiator retaining bolts 7 - 62
Air conditioning condenser retaining bolts 7 - 62
Radiator mounting bracket retaining bolts 7 - 62
Charge air cooler intake elbow 7 - 62
Radiator drain plug 2 - 13
General procedures
Cooling System Draining, Filling and

Bleeding
1.
WARNING: Relieve the cooling system pressure by unscrewing the coolant

pressure cap. Failure to follow these instructions may result in personal injury.
3. NOTE:
Remove and discard the radiator drain plug O-ring seal.
Remove the coolant drain plug.

4. Allow the coolant to drain.
5. NOTE:
NOTE:
Do not over tighten the drain plug. Failure to follow this instruction may result in damage
to the vehicle.
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Install the coolant drain plug.

• Remove the drain tray.
6. Lower the vehicle.
9.

10. Set the heating system to the COLD position.
11. Using an assistant, turn the ignition key to the ON position.
12. NOTE:
Do not allow the expansion tank to empty when the electric coolant pump starts.
Fill the cooling system up to the MAX mark on the coolant expansion tank using a fifty
13. After 3 minutes, set the heating system to the HOT position.
14. Maintain the coolant level in the coolant expansion tank at the MAX mark using a fifty
15. After four minutes, refit the coolant expansion tank pressure cap.
16. Start the engine and allow to idle for five minutes.
17. Raise the engine to 2500 RPM for 30 seconds.

18. Turn the ignition key to the OFF position.
20.
After two minutes, release the cooling system pressure.

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21. NOTE:
Make sure the heating system is set to the HOT position.
Turn the ignition key to the ON position.
22. Maintain the coolant level in the coolant expansion tank using a fifty percent mixture of
Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar specification WSS
M97B44-D and fifty percent water.
23. After three minutes, refit the coolant expansion tank pressure cap.
24. Drive the vehicle on the road at varying speeds until the engine reaches normal operating
temperature.
26.

27. Fill the cooling system up to the MAX mark on the coolant at the MAX mark expansion
tank using a fifty percent mixture of Jaguar Premium Cooling System Fluid or equivalent,
meeting Jaguar specification WSS M97B44-D and fifty percent water.
28. Raise the vehicle.
29. Check for water leaks.

Cooling System Draining and Vacuum
Filling
No data
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Engine Cooling
2.7 Diesel Engine Cooling System
3 — Vent hose
4 — Radiator
5 — Charge air cooler outlet
8 — Exhaust gas re-circulation coolant hose
9 — Transmission oil cooler coolant control valve

11 — Transmission oil cooler outlet
12 — Transmission oil cooler inlet
14 Charge air cooler inlet
Engine Cooling System Components

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1 — Engine coolant outlet assembly
2 — Engine coolant inlet assembly

3 — Water pump
Water Pump
The water pump is of a conventional design and is driven by the crankshaft pulley through the
accessory drive belt. The water pump belt tension is maintained by an automatic drive belt tensioner.
For additional information, refer to Accessory Drive Belt Tensioner - 2.7L Diesel (303-05)
Thermostat
The thermostat is located in the thermostat housing and allows rapid engine warm-up by restricting
coolant flow through the radiator below approximately 92°C (198°F). The thermostat also assists in
keeping the engine operating temperature within predetermined limits.
When the engine is cold and the thermostat is closed, coolant flows from the water pump through
the engine. It then returns to the water pump through the upper coolant hose.
When the engine is warm and the thermostat is open, coolant flows into the radiator through the
upper coolant hose. It then returns to the water pump from the radiator through the lower coolant
hose.
The heater core is on a parallel circuit and is unaffected by the position of the thermostat.
Radiator
The radiator is of aluminium construction with plastic end tanks. Foam seals are fitted to the radiator
to prevent the cooling air from by passing the radiator core. A coolant drain plug is provided in the
lower coolant end tank of the radiator for the draining of the coolant. The cooling fan shroud is
attached to the radiator.
Cooling Fan
A single, variable speed cooling fan motor is attached to a fan shroud located behind the radiator.
The speed is determined by the Engine Coolant Temperature (ECT) and the air conditioning pressure
and transmission oil temperature.
Under hot operating conditions, the fan may continue to operate for four minutes after the engine
has been switched off.
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.
A manual bleed point is 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
The long life engine coolant is formulated to last for five 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 Diagram (Thermostat open)

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1 — Radiator
4 — Auxiliary heater
5 — Engine oil and fuel cooler
6 — Heater matrix
7 — Right-hand exhaust gas recirculation cooler
8 — Left-hand exhaust gas recirculation cooler
11 — Water pump
12 — Transmission oil cooler
13 — Thermostat
14 — Transmission oil cooler coolant control valve

Engine Cooling
• Coolant leaks
• Hoses • Battery charge and condition
• Expansion tank • Fuses
• Radiator • Harnesses and connectors
• Accessory drive belt • Engine coolant temperature (ECT) sensor (if equipped)
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• Cooling fan
4 . If the cause is not visually evident, use the Jaguar approved diagnostic system or a scan tool to
retrieve the fault codes. For a full list of powertrain DTCs,
Pinpoint tests
PINPOINT TEST G557183p1 : LOSS OF

COOLANT
G557183t1 : VISUAL INSPECTION
1. Visually inspect for loss of coolant 2. Following the instructions for your workshop's pressure
tester, carry out a system pressure test.
• Is the engine cooling system leaking?
-> Yes
Rectify the source of the leak as indicated by the test.
Cooling System Draining, Filling and Bleeding TEST the system for normal operation.
-> No
Verify the customer complaint.

ENGINE OVERHEATS
G557183t2 : CHECK THE COOLANT LEVEL AND CONDITION
1. Check the coolant level and condition.
• Does the system contain sufficient coolant of the correct specification?
-> Yes
-> No
Top-up the system,
Cooling System Draining, Filling and Bleeding Check for coolant loss. GO to Pinpoint Test
G557183p1.
G557183t3 : CHECK THE OPERATION OF THE COOLING SYSTEM PRESSURE

CAP
1. Check the opening pressure of the cooling system pressure cap. 2. NOTE:
Make sure the pressure is built up steadily when testing the pressure cap. Rapid increases in
pressure may indicate a failure in a correctly operating pressure cap.
Following the instructions for your workshop pressure tester, test the pressure cap to the pressure
indicated. 3. Check that the pressure cap holds to the pressure indicated, and releases once that
pressure is reached.
• Does the pressure cap operate correctly?
-> Yes
-> No
INSTALL a new pressure cap. TEST the system for normal operation.
G557183t4 : CHECK THE OPERATION OF THE WATER PUMP

1. Remove the cooling system pressure cap and make sure there is sufficient coolant in the system. 2.
Make sure the parking brake is applied and Park or Neutral is selected. 3. Start the engine and hold
the engine speed at 1,500 to 2,000 rpm for one minute while observing the coolant through the
expansion tank filler neck. 4. Allow the engine to idle and switch off.
• Is there coolant movement in the expansion tank while the engine is running?
-> Yes
-> No
Check the accessory drive belt condition and tension,
G557183t5 : CHECK THAT THE THERMOSTAT OPENS

1. Remove and inspect the thermostat.
Thermostat (26.45.07) 2. Note the opening temperature and immerse the thermostat in water. 3.
Heat the water until this temperature is reached. The thermostat should begin to open.
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• Does the thermostat open?
-> Yes
Check the cooling fan, modules, circuits, sensors, etc,
-> No
INSTALL a new thermostat,
Thermostat (26.45.07) TEST the system for normal operation.

ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURE
G557183t6 : CHECK THAT THE THERMOSTAT CLOSES
1. Remove and inspect the thermostat.
Thermostat (26.45.07) 2. Allow the thermostat to cool.
• Does the thermostat fully close?
-> Yes
Check the cooling fans, modules, circuits, sensors, etc,
-> No
INSTALL a new thermostat,
Thermostat (26.45.07) TEST the system for normal operation.

Removal
1
. WARNING: 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 (still
with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank.
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2 . Using a suitable tool, drain the coolant out of the expansion tank.
3 . NOTE:
Cap the vent hose to minimize coolant loss.
Detach the vent hose.

4 . Remove the coolant expansion tank retaining bolt.
5 . Detach the coolant expansion tank.
6 . Disconnect the coolant expansion tank level sensor electrical connector.

7 . NOTE:
Make sure the retaining clip is not removed.
NOTE:
Clamp the coolant expansion tank lower hose to minimize coolant loss.
Remove the coolant expansion tank.
Detach the coolant expansion tank lower hose.

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Installation
Tighten to 7 Nm.

Removal

3 . Disconnect the cooling fan motor and shroud electrical connectors.
4 Detach the cooling fan motor and shroud electrical connectors from the cooling fan motor
. and shroud.
5 Detach the cooling fan motor and shroud wiring harness from the cooling fan motor and
. shroud.
6 . Detach the air conditioning pipe.
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7 . Detach the fuel fired heater hose.
8 . Disconnect the auxiliary coolant flow pump electrical connector.



For additional information, refer to Coolant Expansion Tank (26.15.01)
12 . Detach the auxiliary coolant flow pump.
13 . Detach the coolant hoses from the cooling fan motor and shroud.
14 . Remove the cooling fan motor and shroud retaining bracket.

15 . Remove the cooling fan motor and shroud retaining bolt.
Reposition the cooling fan motor and shroud wiring harness.

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Installation
Tighten to 7 Nm.
Radiator (26.40.01)
Removal

3 . Remove the air intake elbow pipe.

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4 . Disconnect the radiator top hose.

6 . Detach the charge air cooler intake elbow.
7 . Detach the thermostat.
8 . Remove the radiator mounting brackets.
9 . Using suitable tie straps, support the condensor.


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12 . Remove the right-hand air conditioning condensor retaining bolt.
1) Remove the foam insulation pad.
2) Remove the right-hand air conditioning condensor retaining bolt.
13 . Remove the left-hand air conditioning condensor retaining bolt.
1) Remove the foam insulation pad.
2) Remove the left-hand air conditioning condensor retaining bolt.

15 . Reposition the radiator rearwards.
16 . Reposition the radiator to the left.
17 . Remove the radiator assembly.

18 . Detach the foam insulation pads.
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19 . Remove the charge air cooler from the radiator.
1) Remove the charge air cooler retaining bolts.
2) Remove the charge air cooler from the radiator.
Installation
1 . Install the charge air cooler retaining bolts.
1) Install the charge air cooler to the radiator.

2) Install the charge air cooler retaining bolts.
Tighten to 7 Nm.
2 . Fit the foam insulation pads.
3 . Install the radiator assembly.
4 . Reposition the radiator forwards.

6 . Install the left-hand air conditioning condensor retaining bolt.
1) Install the foam insulation pad.

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2) Install the left-hand air conditioning condensor retaining bolt.
Tighten to 7 Nm.
7 . Install the right-hand air conditioning condensor retaining bolt.
1) Install the foam insulation pad.
2) Install the right-hand air conditioning condensor retaining bolt.
3) Tighten to 7 Nm.
8 . Install the radiator lower cowl.
10 . Remove the tie straps supporting the condensor.
11 . Install the radiator mounting brackets.
Tighten to 7 Nm.
12 . NOTE:
Make sure the retaining clip is fully installed.
Attach the thermostat.

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13 . Attach the charge air cooler intake elbow.
Tighten to 7 Nm.

15 . Connect the radiator top hose.
16 . Install the air intake elbow pipe.
Tighten to 4 Nm.

18 . Fill and bleed cooling system.

Thermostat (26.45.07)
Remover/Install, Cooling Hose Clamp

303-397
Removal
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4 . Detach the charge air cooler inlet hose.
5 . Remove the charge air cooler inlet elbow.

6 . Detach the coolant hoses.
7 . Detach the transmission cooler hose.


10 . Detach the thermostat and hose assembly.
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11 . Remove the thermostat and hose assembly.
Installation
1 . Install the thermostat and hose assembly.
2 . NOTE:
Make sure the retaining clip is fully installed.
Attach the thermostat and hose assembly.
4 . Install the coolant expansion tank.

5 . Attach the transmission cooler hose.

6 . Attach the coolant hoses.
7 . Install the charge air cooler inlet elbow.
Tighten to 7 Nm.
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8 . Attach the charge air cooler inlet hose.


Water Pump (26.50.01)

303-703
Removal




6 . NOTE:
Remove the water pump pulley.
Using a suitable 6mm bar, retain the water pump pulley.

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7
. CAUTION: Reposition the accessory drive belt to prevent contamination from the
coolant. Failure to follow this instruction may result in damage to the vehicle.
Reposition the accessory drive belt.

8 . NOTE:
Discard the water pump O-ring seal.
Remove the water pump.
Installation
1 . NOTE:
Install the water pump.
Tighten to 10Nm.
2 . Align the accessory drive belt.

3 . NOTE:
Install new water pump pulley retaining bolts.
Install the water pump pulley.
Using a suitable 6mm bar, retain the water pump pulley.

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Tighten to 24 Nm.
Align the accessory drive belt.
4 . Attach the accessory drive belt.
2) Attach the accessory drive belt.



8 . Reconnect the battery ground cable.

303-04A : Fuel Charging and Controls – 3.0L
Specifications
Specifications

Lower intake manifold retaining bolts 10 - 89
Fuel injection supply manifold retaining bolts 10 - 89
Fuel pressure sensor 10 - 89
Throttle body 10 - 89
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Fuel pressure sensor bracket retaining bolts, lower 10 - 89

Fuel pressure sensor bracket retaining bolts, upper 6 - 53

1 — Fuel charging wiring harness
2 — Fuel injector
3 — Fuel pressure sensor
4 — Fuel injection supply manifold
5 — Throttle body
The electronic returnless fuel system has the advantages of reduced fuel temperature and fuel
tank vapor caused by constant fuel recirculation. The system delivers the correct amount of
fuel to the engine under all conditions and at a constant pressure differential with respect to
manifold absolute pressure.
Fuel is supplied at high pressure to the fuel injectors via a fuel injection supply manifold
which incorporates fuel injectors, a fuel pressure sensor and a fuel temperature sensor. The
engine control module (ECM) increases the fuel pressure to minimize fuel vapor formation to
maintain fuel flow across the injectors.
The throttle body assembly is calibrated during assembly, no adjustments are required or
permitted. The throttle motor is a 12 volt DC motor which, via movement of the throttle
blade, controls the amount of air flowing into the engine.
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Fuel Charging and Controls - VIN Range:

G00442->G45703
NOTE:
If any warning lights and/or messages were displayed when the fault occurred, refer to the
Driver Information table for DTCs associated with the display, then to the DTC index table for
possible sources and actions. Some warnings will appear to clear when the ignition is cycled. This
is often because the warning has flagged as a result of one of the vehicle's on-board diagnostic
routines having run to detect the fault. If the same routine is not run when the ignition is
switched ON, the warning will not reflag until the routine does run. See the DTC summaries for
drive cycle routines.

• Engine oil level • Fuses

• Cooling system coolant level • Wiring harness
• Fuel level • Electrical connector(s)
• Fuel contamination/grade/quality • Sensor(s)
• Throttle body • Engine control module (ECM)
• Poly-vee belt • Transmission control module
1 . Verify the following systems are working correctly:
• Air intake system

• Cooling system
• Charging system
• Ignition system
3 . Where the Jaguar approved diagnostic system is available, complete the S93 report before
clearing any or all fault codes from the vehicle.
NOTE:
If a DTC cannot be cleared, then there is a permanent fault present that flags again as soon as it
is cleared. (The exception to this is P1260, which will only clear following an ignition OFF/ON
cycle after rectification).
a fault code reader to retrieve the fault codes before proceeding to the Diagnostic Trouble Code
(DTC) Index Chart, or the Symptom Chart if no DTCs are set.
5 . Using the Jaguar approved diagnostic system where available, and a scan tool where not, check
the freeze frame data for information on the conditions applicable when the fault was flagged. The
format of this will vary, depending on the tool used, but can provide information useful to the
technician in diagnosing the fault.
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NOTE:
NOTE:
Symptom Possible source Action
• Engine breather system

disconnected/restricte Check engine breather system, <<303-08>>
d
For ignition system, <<303-07>> Check fuel
Engine cranks, but does • Ignition system
pressure, <<310-01>> For CKP tests, <<303-
not fire • Fuel system
• Harness 14>> Contact dealer technical support for
• CKP sensor advice on possible ECM failure.
• ECM fault
• Purge valve
• Fuel pump
• Engine coolant
temperature (ECT)
sensor For evaporative emissions components,
Engine cranks and fires, • Spark plugs <<303-13>> Check fuel pressure, <<310-
but will not start • HT short to ground 01>> For ECT sensor tests, <<303-14>> For
(tracking) check rubber ignition system <<303-07>>
boots for
cracks/damage
• Ignition coil failure(s)
• Harness
• Check coolant anti-

freeze content Check engine coolant level and condition.
• Battery For battery information, <<414-01>> For
• CKP sensor
CKP sensor tests, <<303-14>> For EGR
• EGR valve stuck open
Difficult to start cold system information, <<303-08>> Check fuel
• Fuel pump
• Engine coolant pressure. <<310-01>> For ECT sensor tests,
temperature (ECT) <<303-14>> For evaporative emissions
sensor components, <<303-13>>
• Purge valve
• Injector leak
• Fuel temperature For fuel injector information,
sensor Fuel Injectors (18.10.02) For fuel
• IAT sensor temperature sensor, IAT sensor and MAF
• MAF sensor
sensor tests, <<303-14>> For evaporative
• Purge valve
Difficult to start hot emissions components, <<303-13>> Check
• Fuel pump
• Ignition system fuel pressure. <<310-01>> For ignition
• Engine coolant system, <<303-07>> For ECT sensor tests,
temperature (ECT) <<303-14>> For EGR information, <<303-
sensor 08>>
• Injector leak
• Fuel temperature
For fuel injector information,
sensor
• IAT sensor For fuel temperature sensor, IAT sensor
Difficult to start after
• MAF sensor and MAF sensor tests, <<303-14>> For
hot soak (vehicle
• Purge valve evaporative emissions components, <<303-
standing after engine
• Fuel pump 13>> Check fuel pressure. <<310-01>> For
has reached operating • Ignition system ignition system, <<303-07>> For ECT sensor
temperature) • Engine coolant
tests, <<303-14>> For EGR information,
temperature (ECT)
sensor <<303-08>>
• Breather system
disconnected/restricte
d For breather system information, <<303-
• ECM relay 08>> For ECM relay, MAF sensor and ECT
• Harness sensor tests, <<303-14>> For ignition
• MAF sensor system, <<303-07>> For air filter
• Engine coolant
Engine stalls soon after information, <<303-12>> For fuel line
temperature (ECT)
start sensor information, <<310-01>> For fuel rail
• Ignition system pressure sensor tests, GO to Pinpoint Test
• Air filter restricted G206886p2.
• Fuel lines . For intake system information, <<303-
• Fuel rail pressure 12>>
sensor
• Air leakage
• Fuel pump
• Injector leak Check fuel pressure. <<310-01>> For fuel
• Fuel pressure rail pressure sensor tests, GO to Pinpoint
• Fuel lines Test G206886p2.
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• Air leakage . For fuel line information, <<310-01>> For

• Throttle sensors intake system, <<303-12>> For throttle
• Throttle motor
position sensor and throttle motor tests,
Engine hesitates/poor • Ignition system
<<303-14>> For ignition system, <<303-
acceleration • Exhaust gas
recirculation 07>> For exhaust gas recirculation, <<303-
• HO2 sensors 08>> Check for DTCs indicating a faulty HO2
• Transmission sensor. Refer to the DTC index. For
malfunction transmission information, <<307-01>>
• Restricted pedal travel Check accelerator pedal travel. For APP
(carpet, etc)
sensor tests, <<303-14>>
• APP sensor
Check fuel pressure. <<310-01>> For fuel

• Fuel pump line information, <<310-01>> For intake
• Fuel lines system, <<303-12>> For MAF sensor tests,
• Air leakage
<<303-14>> Check for DTCs indicating a
• MAF sensor
Engine backfires faulty HO2 sensor. Refer to the DTC index.
• Oxygen sensors
• Ignition system For ignition system, <<303-07>> Check
• Sticking VCT hub DTCs for VCT range/performance fault. For
• APP sensor VCT information, <<303-01>> For APP
• Fuel pump Check fuel pressure. <<310-01>> For fuel

• Fuel lines line information, <<310-01>> For MAF
Engine surges • MAF sensor sensor, throttle sensor, and throttle motor
• Harness relay tests, <<303-14>> For ignition system,
• Throttle sensors <<303-07>>
• Throttle motor
• Ignition system
For KS circuit tests, <<303-14>> Check fuel

• KS/circuit malfunction pressure. <<310-01>> For fuel line
• Fuel pump information, <<310-01>> For fuel rail
• Fuel lines pressure sensor tests, GO to Pinpoint Test
• FRP sensor
G206886p2.
Engine • MAF sensor
. For MAF sensor and oxygen sensor tests,
detonates/knocks • Oxygen sensors
• Air leakage <<303-14>> For intake system, <<303-12>>
• Sticking VCT hub Check DTCs for VCT range/performance
• BARO sensor fault. For VCT information, <<303-01>> For
malfunction BARO sensor, contact dealer technical
support for advice on possible ECM failure
• APP sensor malfunction

For APP sensor, throttle position sensor
No throttle response • Throttle sensors
• Throttle motor and throttle motor relay tests, <<303-14>>

• Throttle sensors
• Engine coolant
temperature (ECT)
sensor For APP sensor, throttle position sensor,
• MAF sensor ECT sensor and MAF sensor tests, <<303-
Poor throttle response • Transmission 14>> For transmission information, <<307-
malfunction 01>> For intake system, <<303-12>> For
• Traction control event breather system information, <<303-08>>
• Air leakage
• Breather system
d

Warning
Message Default Mode DTC
light
Engine shut-down (all

Red Engine systems fault P1224
cylinders fuel cut)
Red Engine systems fault Limp-Home P1229
P0121, P0122, P0123, P0222,

Red Engine systems fault Limp-Home
P0223
Red Engine systems fault Limp-Home P1251, P1631
P1344, P1122, P1123, P1215,

Red Engine systems fault High idle
P1216
Red Restricted Performance Limp-Home unavailable P1254
Red Restricted Performance Safety redundancy P1657, P1658
Red Restricted Performance Safety redundancy P16634
Amber Restricted Performance Engine speed limited P0116, P0117, P0118, P0125
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P0300, P0301, p0302, P0303,

Amber Restricted Performance Engine speed limited P0304, P0305, P0306, P0307,
P0308, P1313, P1314
P0327, P0328, P0332, P0333,

Amber Restricted Performance Engine speed limited
P1648
P0351, P0352, P0353, P0354,

P1367, P1368
P0201, P0202, P0203, P0204,

P0205, P0206, P0207, P0208
Amber Restricted Performance Engine speed limited P0335, P0336
Engine speed limited,

Amber Restricted Performance Reverse throttle progression P1642
enabled
Amber Restricted Performance Engine speed limited, P1643

Reverse throttle progression
enabled

Amber Restricted Performance Reverse throttle progression P0096, P0097, P0098
enabled

enabled
Amber Restricted Performance Engine speed limited P1234, P1236, P1338
Amber None None P0506, P0507
Amber None None P1656
Gearbox
Amber fault/Restricted Gearbox default to set gear P0725
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Amber Gearbox Gearbox default to set gear P0715

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
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Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
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Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox Engine speed limited,

Amber fault/Restricted reverse throttle progression P1797
performance enabled
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
Amber fault/Restricted Limp-home P1783
performance
Default mode Definitions

LIMP-HOME MODE
• Throttle motor off

• Throttle motor relay off
• Throttle motor circuit off
• Fuel intervention
• Cruise control inhibited
LIMP-HOME UNAVAILABLE
• Power limitation
• Vehicle speed limited to 120 kph
• Reverse throttle progression enabled
• Cruise control Inhibited
REVERSE THROTTLE PROGRESSION
• Throttle opening limited to maximum 30%
NOTE:
The throttle operation uses the same map as for reverse gear.
ENGINE SPEED LIMITED
• Engine runs normally, up to 3000 rpm

• Engine speed restricted to 3000 rpm maximum, by fuel cut-off
HIGH IDLE
• Throttle valve kept in fixed position by motor

• Cruise control Inhibited
SAFETY REDUNDANCY
• Power limitation
• Vehicle speed limited to 120 kph
• Reverse throttle progression enabled
• Cruise Control Inhibited
DTC Condition Possible Causes Action
• Air intake leak between

mass air flow (MAF) sensor
and cylinder head
• Fuel filter/system
For intake system, <<303-
restriction
• Fuel injector restriction 12>> For fuel injector,
• Fuel rail pressure (FRP) Fuel Injectors (18.10.02)
sensor fault (low fuel For fuel filter and pump,
pressure) <<310-01>> For FRP sensor
• Low fuel pump output circuit tests, GO to Pinpoint
• HO2S/catalyst monitor
Test G206886p2.
Right-hand cylinders sensor harness wiring
P0171 . For HO2S/Catalyst
combustion too lean condition fault
• EFT sensor fault (low fuel monitor sensor tests,
temperature) <<303-14>> For exhaust
• Mass air flow (MAF) sensor system, <<309-00>> For
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fault (low intake air flow) sensor tests, <<303-14>> *

• Exhaust leak (before If this DTC is flagged, pay
catalyst)
particular attention to the
• ECM receiving incorrect
signal from one or more of MAF sensor.
the following sensors; ECT,
MAF*, IAT, fuel rail
temperature
• Engine misfire
• Restricted air filter
• Leaking fuel injector(s) Check for "misfire
• FRP sensor failure (high detected" DTCs in this
fuel pressure) section; For intake system,
• EFT sensor fault (high fuel <<303-12>> For fuel
temperature)
injector,
Right-hand cylinders • MAF sensor fault (high
P0172 Fuel Injectors (18.10.02)
combustion too rich intake air flow)
• HO2S/catalyst monitor For FRP sensor circuit tests,
sensor harness wiring GO to Pinpoint Test
condition fault G206886p2.
• ECM receiving incorrect . For other sensor tests,
signal from one or more of <<303-14>>
MAF, IAT, FRP, EFT.
• Air intake leak between For intake system, <<303-

Left-hand cylinders MAF sensor and cylinder 12>> For fuel injectors,
P0174
combustion too lean head
restriction For fuel filter, pump and
• Fuel injector restriction lines, <<310-01>> For
• FRP sensor failure (low fuel HO2S/catalyst monitor
pressure) sensor tests, <<303-14>>
• Low fuel pump output
For exhaust system, <<309-
• HO2S/catalyst monitor
sensor harness wiring 00>> For FRP sensor tests,
condition fault GO to Pinpoint Test
• EFT sensor fault (low fuel G206886p2.
temperature) . For other sensor tests,
• Mass air flow (MAF) sensor <<303-14>> * If this DTC is
fault (low intake air flow) flagged, pay particular
• Exhaust leak (before
attention to the MAF
catalyst)
• ECM receiving incorrect sensor.
signal from one or more of
MAF*, IAT, FRP, EFT, TP.
Check for "misfire

• Engine misfire
detected" DTCs in this
• Restricted air filter
• Leaking fuel injector(s) section. For intake system,
• FRP sensor failure (high <<303-12>> For fuel
Left-hand cylinders fuel pressure) injectors,
P0175
combustion too rich • ECM receiving incorrect Fuel Injectors (18.10.02)
signal from one or more of For FRP sensor tests, GO to
MAF, IAT, fuel rail pressure,
fuel rail temperature . For other sensor tests,
<<303-14>>
restriction
• Fuel system leak
• Incorrect fuel pump output
• FRP sensor to ECM sensing
circuit; high resistance,
open circuit, short circuit For fuel filter, pump and
Fuel rail pressure (FRP) to high voltage lines, <<310-01>> For FRP
P0191 sensor circuit • FRP sensor to splice in sensor tests, GO to Pinpoint
range/performance sensor supply circuit; high Test G206886p2.
resistance, open circuit .
• FRP sensor to splice in
sensor ground circuit; high
short circuit to ground,
short circuit to high voltage
• FRP sensor failure
P0192 Fuel rail pressure (FRP) • FRP sensor disconnected For FRP sensor tests, GO to
sensor circuit low voltage • FRP sensor to ECM sensing Pinpoint Test G206886p2.
(low pressure) circuit; open circuit or .
short circuit to ground
• FRP sensor to splice in
sensor supply circuit; high
resistance, open circuit
• FRP sensor to ECM wiring

(supply/sense); short
circuit to each other
• FRP sensor to ECM sense
Fuel rail pressure (FRP) For FRP sensor tests, GO to
circuit; short circuit to high
P0193 sensor circuit high voltage Pinpoint Test G206886p2.
voltage
(high pressure) • FRP sensor to splice in .
sensor ground circuit; open
circuit
For fuel injectors,

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• Injector disconnected Fuel Injectors (18.10.02)

Fuel injector circuit • Injector wiring open or For fuel injector circuit
P0201 short circuit
malfunction, Cyl 1 tests, GO to Pinpoint Test
• Injector failure G206886p1.
.
For fuel injectors,

P0202 short circuit
.
For fuel injectors,

P0203 short circuit
.
For fuel injectors,

P0204 short circuit
.
For fuel injectors,
P0205
malfunction, Cyl 5 short circuit tests, GO to Pinpoint Test
.
For fuel injectors,

P0206
malfunction, Cyl 6 short circuit tests, GO to Pinpoint Test
.
• ECM to ignition coil

primary circuit fault
(cylinder misfire detected
DTC also flagged)
• Ignition coil failure For ignition system, <<303-
• Spark plug 07>> For injector circuit
failure/fouled/incorrect tests, GO to Pinpoint Test
gap G206886p1.
• Fuel injector circuit fault(s)
. Check fuel pressure,
P0300 Random misfire detected (injector DTCs also flagged)
• Fuel delivery pressure <<310-01>> For fuel
high/low injectors,
• Fuel injectors Fuel Injectors (18.10.02)
restricted/leaking For engine information,
• Fuel injectors continuously <<303-01>>
open
• Fuel contamination
• Worn camshaft/broken
valve springs

primary circuit fault For ignition system, <<303-
07>> For injector circuit
DTC also flagged)
• Ignition coil failure tests, GO to Pinpoint Test
• Spark plug G206886p1.
failure/fouled/incorrect . Check fuel pressure,
P0301 Misfire detected, cylinder 1
gap <<310-01>> For fuel
• Fuel injector circuit fault(s) injectors,
(injector DTCs also flagged)
• Fuel delivery pressure
For engine information,
high/low
• Fuel injectors <<303-01>>
restricted/leaking
• Fuel injectors continuously
open
valve springs

DTC also flagged)
gap G206886p1.
P0302 Misfire detected, cylinder 2 (injector DTCs also flagged)
high/low injectors,
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<<303-01>>
open
valve springs

DTC also flagged)
gap G206886p1.
high/low injectors,
open
valve springs
• ECM to ignition coil For ignition system, <<303-

primary circuit fault 07>> For injector circuit
DTC also flagged)
• Ignition coil failure G206886p1.
• Spark plug . Check fuel pressure,
failure/fouled/incorrect <<310-01>> For fuel
gap injectors,
• Fuel delivery pressure For engine information,
high/low <<303-01>>
• Fuel injectors
restricted/leaking
open
valve springs

DTC also flagged)
gap G206886p1.
high/low injectors,
open
valve springs

primary circuit fault For ignition system, <<303-
07>> For injector circuit
DTC also flagged)
• Ignition coil failure tests, GO to Pinpoint Test
• Spark plug G206886p1.
failure/fouled/incorrect . Check fuel pressure,
gap <<310-01>> For fuel
• Fuel injector circuit fault(s) injectors,
• Fuel delivery pressure
high/low
• Fuel injectors <<303-01>>
restricted/leaking
open
valve springs
• Fuel level sensor to rear

electronic control module
circuit(s); intermittent
short circuit, open circuit,
Fuel level sensor circuit For fuel level sensor and
P0460 high resistance
range/performance • Fuel level sensor failure circuit tests, <<310-01>>
• Rear electronic control
module fault (incorrect fuel
level data)
This DTC can only be

accurately diagnosed using
the Jaguar approved
diagnostic system. If this is
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not available, INSTALL a

Throttle control position • Throttle motor failure
P1224 new throttle body.
error • Throttle body failure
Throttle Body - VIN Range:
G00442->G45703
(19.70.04) CLEAR the DTC,
TEST the system for normal
operation.
• Throttle motor
disconnected For throttle motor and
• Throttle motor to ECM circuit tests, and for ECM
drive circuits; short circuit ground tests, <<303-14>>
Throttle motor control
P1229 or open circuit For throttle body,
circuit malfunction • ECM ground circuit fault(s) Throttle Body - VIN Range:
(EM80-04, 05, 54) G00442->G45703
• Throttle motor failure
(19.70.04)
• Throttle body failure
• ECM to fuel pump module

drive circuit; open circuit,
No fuel pump commands For fuel pump module
P1234 short circuit, high
received by ECM resistance circuit tests, <<310-01>>
• Fuel pump module failure
• ECM to fuel pump module

Fuel pump not activated For fuel pump module
P1236 drive circuit; open circuit,
when requested by ECM short circuit, high circuit tests, <<310-01>>
resistance

the Jaguar approved
Throttle return spring Throttle return spring failure
P1250 new throttle body.
failure malfunction (throttle body failure)
G00442->G45703
operation.
• Throttle motor relay coil

power supply circuit; open
circuit
Throttle motor relay OFF • Throttle motor relay failure For throttle motor relay
P1251
failure • Throttle motor relay coil to tests, <<303-14>>
ECM circuit; open circuit
• ECM ground circuit fault
(relay coil drive)

the Jaguar approved
Throttle limp-home spring
P1254 Throttle body new throttle body.
malfunction
G00442->G45703
operation.
Right-hand cylinders misfire

rate catalyst damage (this
DTC will flag only when
P1313 Refer to P0300 possible sources Refer to P0300 Actions
accompanied by an
individual cylinder misfire
DTC; P0300-P0306)
Left-hand cylinders misfire

P1314 rate catalyst damage (this Refer to P0300 possible sources Refer to P0300 Actions
accompanied by an
individual cylinder misfire
DTC; P0300-P0306)
Misfire excess emission

(Note: This DTC will flag
only when accompanied by
an individual cylinder
misfire DTC; P0300 to
P0306)
• Fuel pump module to fuel

pump drive circuit; open
Fuel pump drive circuit circuit, short circuit, high For fuel pump module
P1338
low/high voltage resistance circuit tests, <<310-01>>
• Fuel pump failure
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• Throttle motor relay coil to

• Throttle motor relay failure
Throttle motor power relay For throttle motor relay
P1631 • Throttle motor relay coil to
coil activation circuit failure ECM drive circuit; open tests, <<303-14>>
ground

Throttle watchdog circuit
P1634 • ECM failure support for advice on
malfunction
possible ECM failure.
Throttle position (TP) Contact dealer technical

P1656 sensor amplifier circuit • ECM failure support for advice on
malfunction possible ECM failure.

Throttle motor relay coil • Throttle motor relay coil to For throttle motor relay
P1657
drive circuit ON failure ECM drive circuit; short tests, <<303-14>>
circuit to B+ voltage

Throttle motor relay ON • Throttle motor relay coil to For throttle motor relay
P1658
failure ECM drive circuit; short tests, <<303-14>>
Pinpoint Tests

P0201, P0202, P0203, P0204, P0205, P0206;
FUEL INJECTORS
G206886t1 : CHECK THE INJECTOR COIL RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the battery negative terminal. 3.
Disconnect the relevant injector electrical connector (IL03 to IL08). 4. Measure the resistance
between the injector pins.
-> Yes
-> No
INSTALL a new injector.
Fuel Injectors (18.10.02) CLEAR the DTC. TEST the system for normal operation.
G206886t2 : CHECK THE INJECTOR COIL INSULATION

1. Measure the resistance between the injector pin 01 and the injector body. 2. Measure the
resistance between the injector pin 02 and the injector body.
-> Yes
-> No
G206886t3 : CHECK THE INJECTOR SUPPLY VOLTAGE

1. Reconnect the battery negative terminal. 2. Turn the ignition switch to the ON position. 3.
Disconnect the relevant injector harness electrical connector (IL03 to IL08). 4. Measure the voltage
between the relevant injector harness electrical connector (IL03 to IL08) pin 02 and GROUND.
• Is the voltage less than 10 Volts?
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector (IL03 to IL08) pin 02
and battery. This circuit includes the front power distribution box, fuse 13, and the EMS relay. For
additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
-> No
G206886t4 : CHECK THE INJECTOR GROUND CIRCUIT

Disconnect the ECM electrical connector PI01. 4. Measure the resistance between the relevant
injector harness electrical connector (IL03 to IL08) pin 01 and PI01 pins as follows:
• Injector Cyl 1 pin 01 (BG) and PI01, pin 115 (BG).

• Injector Cyl 2 pin 01 (BR) and PI01, pin 120 (BR).
• Injector Cyl 3 pin 01 (BK) and PI01, pin 114 (BK).
• Injector Cyl 4 pin 01 (BO) and PI01, pin 119 (BO).
• Injector Cyl 5 pin 01 (BG) and PI01, pin 113 (BG).
•
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Injector Cyl 6 pin 01 (U) and PI01, pin 118 (U).
-> Yes
-> No
G206886t5 : CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT

TO BATTERY
Measure the voltage between the relevant injector harness electrical connector (IL03 to IL08) pin 01
and GROUND.
-> Yes
-> No
TO GROUND
1. Measure the resistance between the relevant injector harness electrical connector (IL03 to IL08)
pin 01 and GROUND.
-> Yes
-> No
Contact dealer technical support for advice on possible ECM failure.

P0190, P0192, P0193; FUEL RAIL
PRESSURE (FRP) SENSOR
G206886t7 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR HIGH
RESISTANCE
Disconnect the FRP sensor electrical connector, IL12. 4. Measure the resistance between IL12 pin 03
(U) and PI01 pin 73 (U).
-> Yes
-> No
G206886t8 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR SHORT TO HIGH
VOLTAGE
Measure the voltage between IL12 pin 03 (U) and GROUND.
-> Yes
-> No
G206886t9 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between the FRP sensor
electrical connector IL12 pin 03 (U) and GROUND.
-> Yes
-> No
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Recheck the DTCs. Check the sensor supply and ground circuits. <<303-14>>
G45704->G99999
Overview
There are changes to the engine management system (EMS) for 2006 my, the most obvious of which
will be the change to 7-digit diagnostic trouble codes (DTCs) from the familiar 5-digit.

• Fuel leaks
• Damaged fuel lines • Fuses
• Damaged push connect fittings • Inertia switch
• Fuel level • Loose or corroded electrical connectors
• Fuel contamination/grade/quality • Harnesses
• Throttle body • Sensor(s)
• Damaged fuel tank filler pipe cap • Engine control module (ECM)
• Damaged fuel tank filler pipe
Symptom Chart
• Engine breather system Check the engine breather system,

disconnected/restricted Engine Emission Control - VIN
• Ignition system Range: G45704->G99999 For
Engine cranks, but does not • Fuel system ignition system tests,
fire • Harness
Engine Ignition - VIN Range:
• Crankshaft position (CKP)
sensor G45704->G99999 Check the fuel
• ECM fault pressure,
Fuel Tank and Lines - 3.0L/3.5L/4.2L,
VIN Range: G45704->G99999 For
CKP tests,
Range: G45704->G99999 Refer to
the warranty policy and procedures
manual if an ECM is suspect.
For purge valve tests,

• Evaporative emissions
purge valve Evaporative Emissions - VIN Range:
• Fuel pump G45704->G99999 Check the fuel
• Spark plugs pressure,
Engine cranks and fires, but
• HT short circuit to ground Fuel Tank and Lines - 3.0L/3.5L/4.2L,
will not start (tracking) check rubber VIN Range: G45704->G99999 For
boots for cracks/damage ignition system tests,
• Ignition coil failure(s)
• Harness
G45704->G99999
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Check the engine coolant level and

condition. For battery information,
Battery For CKP sensor tests,
• Check coolant anti-freeze
content Range: G45704->G99999 For EGR
• Battery system information,
• CKP sensor Engine Emission Control - VIN
Difficult to start cold • Exhaust gas recirculation Range: G45704->G99999 Check the
(EGR) valve stuck open fuel pressure,
• Fuel pump
• Purge valve
purge valve tests,
Evaporative Emissions - VIN Range:
G45704->G99999

Fuel Injectors (18.10.02) For EFT,
• Injector leak IAT and MAF sensor tests,
• Engine fuel temperature
(EFT) sensor
• Intake air temperature Range: G45704->G99999 For purge
(IAT) sensor valve tests,
Difficult to start hot
• Mass air flow (MAF) sensor Evaporative Emissions - VIN Range:
• Purge valve G45704->G99999 Check the fuel
• Fuel pump pressure,
• Ignition system Fuel Tank and Lines - 3.0L/3.5L/4.2L,
ignition system tests,
G45704->G99999 For EGR system
information,
Engine Emission Control - VIN
Range: G45704->G99999

Fuel Charging and Controls - VIN
Range: G45704->G99999 For EFT,
IAT and MAF sensor tests,
Range: G45704->G99999 For purge
• Injector leak
• EFT sensor valve tests,
Difficult to start after hot • IAT sensor Evaporative Emissions - VIN Range:
soak (vehicle standing after • MAF sensor G45704->G99999 Check the fuel
engine has reached • Purge valve pressure,
operating temperature) • Fuel pump Fuel Tank and Lines - 3.0L/3.5L/4.2L,
• Ignition system
information,
Range: G45704->G99999
For breather system information,

Range: G45704->G99999 For ECM
• Breather system
relay, MAFand FRP sensor tests,
disconnected/restricted
• ECM relay Electronic Engine Controls - VIN
• Harness Range: G45704->G99999 For
• MAF sensor ignition system tests,
Engine stalls soon after
• Fuel rail pressure (FRP) Engine Ignition - VIN Range:
start sensor G45704->G99999 For air filter and
• Ignition system intake system information,
• Air filter restricted
Intake Air Distribution and Filtering -
• Air leakage
• Fuel lines VIN Range: G45704->G99999 For
fuel line information,
VIN Range: G45704->G99999
• Fuel pump Check the fuel pressure, check the

Engine hesitates/poor • Fuel pressure fuel lines,
acceleration • Fuel lines Fuel Tank and Lines - 3.0L/3.5L/4.2L,
• Injector leak VIN Range: G45704->G99999 For
• Air leakage injector information,
• Throttle position (TP) Fuel Injectors (18.10.02) For intake
sensors system information,
• Accelerator pedal position Intake Air Distribution and Filtering -
(APP) sensor
• Throttle motor
• Restricted pedal travel TP, APP sensor and throttle motor
(carpet, etc) tests,
• Ignition system Electronic Engine Controls - VIN
• EGR valve stuck open Range: G45704->G99999 Check the
• HO2 sensors accelerator pedal travel. For ignition
• Transmission malfunction system tests,
information,
Range: G45704->G99999 Check for
DTCs indicating a faulty HO2 sensor.
Refer to the DTC index. For
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transmission information,
Check the fuel pressure, check the

fuel lines,
intake system,
• Fuel pump Intake Air Distribution and Filtering -
• Fuel lines VIN Range: G45704->G99999 For
• Air leakage MAF and APP sensor tests,
• MAF sensor
Engine backfires • APP sensor
• HO2 sensors Range: G45704->G99999 Check for
• Ignition system DTCs indicating a faulty HO2 sensor.
• Sticking variable camshaft Refer to the DTC index. For ignition
timing (VCT) hub system tests,
G45704->G99999 Check DTCs for
VCT range/performance fault. For
VCT information,
Engine
• Fuel pump Check the fuel pressure, check the

• Fuel lines fuel lines,
Engine surges • MAF sensor
• Harness
• TP sensors
• Throttle motor MAF, TP sensor, and throttle motor
• Ignition system tests,
Range: G45704->G99999 For
G45704->G99999
For KS, FRP, MAF and HO2 sensor

tests,
• Knock sensor (KS) circuit
Range: G45704->G99999 Check the
malfunction
• FRP sensor fuel pressure, check the fuel lines,
• MAF sensor Fuel Tank and Lines - 3.0L/3.5L/4.2L,
• HO2 sensors VIN Range: G45704->G99999 For
Engine detonates/knocks • Fuel pump intake system information,
• Fuel lines Intake Air Distribution and Filtering -
• Air leakage VIN Range: G45704->G99999 Check
• Sticking VCT hub
DTCs for VCT range/performance
• BARO sensor malfunction
(internal ECM fault) fault. For VCT information,
Engine Refer to the warranty policy
and procedures manual if an ECM is
suspect.
For APP, TP sensor and throttle

motor tests,
No throttle response • TP sensors
• Throttle motor Electronic Engine Controls - VIN
Range: G45704->G99999
For APP, TP, ECT and MAF sensor

tests,
• TP sensors Electronic Engine Controls - VIN
• ECT sensor Range: G45704->G99999 For
• MAF sensor transmission information,
Poor throttle response • Transmission malfunction For intake system,
• Traction control event Intake Air Distribution and Filtering -
• Air leakage VIN Range: G45704->G99999 For
• Breather system
breather system information,
Range: G45704->G99999
Diagnostic trouble code (DTC) index
NOTE:
NOTE:
For a full list of DTCs,

• FRP sensor disconnected For FRP sensor circuit

• FRP sensor to ECM sensing tests,
circuit: open circuit or short Electronic Engine Controls
circuit to ground
- VIN Range: G45704-
Fuel rail/system • FRP sensor supply circuit:
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P008700 >G99999 For fuel pump

pressure - too low high resistance
• FRP sensor failure circuit and fuel line tests,
• Fuel pump failure Fuel Tank and Lines -
• Fuel line leak 3.0L/3.5L/4.2L, VIN Range:
• Restricted fuel line G45704->G99999
• FRP sensor to ECM wiring

(supply/sense): short circuit
For FRP sensor tests,
to each other
• FRP sensor to ECM sense Electronic Engine Controls
circuit: short circuit to high - VIN Range: G45704-
Fuel rail/system voltage >G99999 For fuel pump
P008800 • FRP sensor ground circuit:
pressure - too high circuit and fuel line tests,
high resistance Fuel Tank and Lines -
3.0L/3.5L/4.2L, VIN Range:
• Restricted fuel line
• Fuel pump short circuit to G45704->G99999
battery
• Air intake leak between MAF For intake system

sensor and cylinder head information,
• Fuel filter/system restriction Intake Air Distribution and
• Low fuel pressure Filtering - VIN Range:
System too lean (right • Fuel injector restriction
P017100 G45704->G99999 Check
hand bank) • MAF sensor fault (low intake
the fuel pressure, check
air flow)
• Exhaust leak (before catalyst) the fuel lines,
• Evaporative emission system Fuel Tank and Lines -
fault 3.0L/3.5L/4.2L, VIN Range:
G45704->G99999 For fuel
injector information,
For MAF sensor circuit
tests,
>G99999 Check the
exhaust system (before
catalyst) for condition and
security,
For evaporative emission
system tests,
Evaporative Emissions -
VIN Range: G45704-
>G99999
For intake system

information,
Intake Air Distribution and
Filtering - VIN Range:
G45704->G99999 Check
the fuel pressure,
• Restricted air filter Fuel Tank and Lines -
• High fuel pressure 3.0L/3.5L/4.2L, VIN Range:
• Leaking fuel injector(s) G45704->G99999 For fuel
• Oil contaminated with fuel injector information,
(too many cold starts with
System too rich (right vehicle subsequently not
P017200 Check the oil condition, if
hand bank) getting hot enough for long
enough) contamination is present,
• MAF sensor fault (high intake renew the engine oil and
air flow) filter. For MAF sensor
• Evaporative emission system circuit tests,
fault Electronic Engine Controls
>G99999 For evaporative
emission system tests,
VIN Range: G45704-
>G99999
• Air intake leak between MAF For intake system

System too lean (left sensor and cylinder head information,
P017400
hand bank) • Fuel filter/system restriction Intake Air Distribution and
• Low fuel pressure Filtering - VIN Range:
• Fuel injector restriction G45704->G99999 Check
• MAF sensor fault (low intake the fuel pressure, check
air flow) the fuel lines,
• Exhaust leak (before catalyst) Fuel Tank and Lines -
• Evaporative emission system
fault
G45704->G99999 For fuel
tests,
>G99999 Check the
exhaust system (before
catalyst) for condition and
security,
system tests,
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VIN Range: G45704-
>G99999
For intake system

information,
G45704->G99999 Check
the fuel pressure,
• Restricted air filter Fuel Tank and Lines -
• High fuel pressure 3.0L/3.5L/4.2L, VIN Range:
• Leaking fuel injector(s) G45704->G99999 For fuel
• Oil contaminated with fuel injector information,
(too many cold starts with
System too rich (left vehicle subsequently not
P017500 Check the oil condition, if
hand bank) getting hot enough for long
enough) contamination is present,
• MAF sensor fault (high intake renew the engine oil and
• Evaporative emission system circuit tests,
fault Electronic Engine Controls
VIN Range: G45704-
>G99999
• Injector disconnected
For injector circuit tests,
Cylinder 1 injector • Injector harness wiring: short
P020100 GO to Pinpoint Test
circuit/open circuit
For ignition coil circuit

tests,
Engine Ignition - VIN
• ECM to ignition coil primary Range: G45704->G99999
circuit fault (cylinder misfire Check the fuel pressure,
detected DTC also flagged) Fuel Tank and Lines -
• Fuel delivery pressure low 3.0L/3.5L/4.2L, VIN Range:
P131500 Persistent misfire G45704->G99999 For
injector circuit tests, GO to
• Ignition coil failure
• Spark plug Pinpoint Test G531324p1.
failure/fouled/incorrect gap For ignition coil circuit and
• Cylinder compression low spark plug tests,
Range: G45704->G99999
Check the cylinder
compressions.
Engine - 3.0L/3.5L/4.2L
Injector driver misfire - • Injector driver module codes Check for associated DTCs
P131600
emissions damage detected and refer to the DTC index.
Check for a message in the

instrument cluster.
Throttle range
• Jammed throttle blade, Replace the throttle body.
P210129 performance - sub-
gearing or motor Throttle Body - VIN Range:
processor
G45704->G99999
(19.70.04)

instrument cluster.
Throttle range • Jammed throttle blade, Replace the throttle body.
P210164
performance gearing or motor Throttle Body - VIN Range:
G45704->G99999
(19.70.04)
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For throttle actuator

motor circuit tests, GO to
• Control circuit: short circuit Pinpoint Test G531324p3.
Throttle actuator motor
P210329 to power Refer to the warranty
control circuit high • ECM fault policy and procedures
manual if an ECM is
suspect.

Throttle actuator motor • Control circuit: short circuit Pinpoint Test G531324p3.
P210364 control circuit high - to power Refer to the warranty
signal plausibility failure • ECM fault policy and procedures
manual if an ECM is
suspect.
Check for DTCs indicating

Throttle actuator
• Throttle MIL request due to the reason for the fuel cut.
P210500 control system - forced
fuel cut Follow the action indicated
engine shutdown
for those DTCs.

Throttle actuator instrument cluster.
P210629 control system - forced • Signal invalid
Replace the throttle body.
limited power Throttle Body - VIN Range:
G45704->G99999
(19.70.04)

instrument cluster.
Throttle actuator
P210664 control system - forced • Signal plausibility failure
limited power
G45704->G99999
(19.70.04)

• Control circuit: short circuit
Throttle actuator motor Pinpoint Test G531324p3.
to power, short circuit to
P211800 control current Refer to the warranty
ground, high resistance
range/performance • ECM fault policy and procedures
manual if an ECM is
suspect.

instrument cluster.
Throttle actuator
P211900 control throttle body • Throttle spring faulty
range/performance
G45704->G99999
(19.70.04)
Pinpoint Tests
NOTE:
NOTE:
PINPOINT TEST G531324p1 : FUEL
INJECTORS
1. Disconnect the relevant injector electrical connector:
Injector connector
Cylinder 1, IL03
Cylinder 2, IL06
Cylinder 3, IL04
Cylinder 4, IL07
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Cylinder 5, IL05
Cylinder 6, IL08
2. Measure the resistance between the injector pins.
-> Yes
-> No
Fuel Injectors (18.10.02) CLEAR the DTC and test the system for normal operation.

Injector, component side Injector body
Pin 01 Injector body

-> Yes
-> No

1. Key on, engine off. 2. Make sure the EMS relay is energized. 3. Measure the voltage between:
Injector connector, harness side Battery
• Is the voltage less than 10 Volts?
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector pin 02 and battery. This
circuit includes fuse 13 of the front power distribution box and the EMS relay. For additional
information, refer to the wiring diagrams. CLEAR the DTC and test the system for normal operation.
-> No
G531324t4 : CHECK THE INJECTOR CONTROL CIRCUIT FOR SHORT CIRCUIT

TO GROUND
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC and
-> No

TO POWER
-> Yes
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-> No
G531324t6 : CHECK THE INJECTOR CONTROL CIRCUIT FOR HIGH

RESISTANCE
1. Disconnect the ECM electrical connector PI300. 2. Measure the resistance between:
Cylinder 1 injector connector, harness side ECM connector PI300, harness side
IL03, pin 01 Pin 78
IL06, pin 01 Pin 79
IL04, pin 01 Pin 80

IL07, pin 01 Pin 81
IL05, pin 01 Pin 82
IL08, pin 01 Pin 83
-> Yes
DTC and test the system for normal operation.
-> No

THROTTLE BODY
G531324t14 : CHECK THE THROTTLE ACTUATOR CONTROL MOTOR SUPPLY
1. Disconnect the throttle body electrical connector, PI26. 2. Measure the resistance between:
Throttle body connector PI26, harness side Battery
-> Yes
-> No


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-> Yes
-> No
G531324t16 : CHECK THE THROTTLE ACTUATOR CONTROL MOTOR

NEGATIVE CIRCUIT FOR SHORT CIRCUIT TO GROUND
-> Yes
-> No
NEGATIVE CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No

1. Disconnect the ECM electrical connector, PI300. 2. Measure the resistance between:
Throttle body connector PI26, harness side ECM connector PI300, harness side
Pin 02 Pin 75
-> Yes
-> No

NEGATIVE CIRCUIT FOR HIGH RESISTANCE
Pin 01 Pin 74
-> Yes
-> No
INSTALL a new throttle body assembly.
Throttle Body - VIN Range: G45704->G99999 (19.70.04) CLEAR the DTC and test the system for
normal operation.
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Fuel Charging Wiring Harness (86.70.22)

Removal
1 . Remove the intake manifold. <<303-01A>>
2 . Disconnect the spring lock coupling. <<310-00>>
Detach the fuel charging wiring harness.
4 . Disconnect the fuel pressure sensor connector.
5 . Detach the fuel pressure sensor vacuum line.

6 . Disconnect the fuel charging wiring harness.
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7 . NOTE:
Fuel may still be present in the fuel injection supply manifold.
Remove the fuel injection supply manifold, lower intake manifold and place to one side.
Remove and discard the lower intake manifold O-ring seals.
8 . Remove the lower intake manifolds.
Remove and discard the fuel injector O-ring seals.

9 . Remove the fuel charging wiring harness.
Disconnect the electrical connectors.
Installation
1 . NOTE:
Install new fuel injector O-ring seals.
NOTE:
Install new lower intake manifold O-ring seals.
Tighten to 10 Nm.

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Removal
1 . Remove the fuel charging wiring harness.
Remove the fuel injector locating clips.
3 . Remove and discard the O-ring seals.
Installation
1 . NOTE:
Install new fuel injector O-ring seals.
Lubricate the fuel injector O-ring seals with clean engine oil.
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Removal
For additional information, refer to Fuel Injectors (18.10.02)
2 . Remove the fuel pressure sensor.
Installation
1 . NOTE:
Tighten to 10 Nm.
Throttle Body - VIN Range: G00442-
>G45703 (19.70.04)
Removal
1
Remove the expansion tank cap to relieve the cooling system pressure.
2
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Remove the air cleaner outlet tube. <<303-12A>>
4 . Disconnect the throttle position (TP) sensor electrical connector.

5 . NOTE:
7 . Remove and discard the O-ring seal.
Installation
1

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Throttle Body - VIN Range: G45704-
>G99999 (19.70.04)
Removal
1
2
Remove the air cleaner outlet pipe.

4 . NOTE:
Clamp the coolant hose to minimize coolant loss.

5 . NOTE:
Clamp the coolant hose to minimize coolant loss.

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7 . Remove and discard the O-ring seal.

Installation
1

303-04B : Fuel Charging and Controls – 3.5L/4.2L
Specifications
Specifications

Fuel injection supply manifold vehicles with supercharger 7 - 62
Fuel injection supply manifold vehicles without supercharger 22 16 -
Fuel pressure sensor 5 - 44
Throttle body 10 - 89
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Engine cover bracket 6 - 53


3.5L/4.2L Engines without Supercharger
1 — Fuel pressure sensor

2 — Fuel injector
4 — Throttle body
4.2L Engines with Supercharger

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1 Fuel injection supply manifold
2 Throttle body
3 Fuel pressure sensor
4 Fuel injector
The electronic returnless fuel system has the advantages of reduced fuel temperature and fuel tank
vapor caused by constant fuel recirculation. The system delivers the correct amount of fuel to the
engine under all conditions and at a constant pressure differential with respect to manifold absolute
pressure.
Fuel is supplied at high pressure to the fuel injectors via a fuel injection supply manifold which
incorporates fuel injectors, a fuel pressure sensor and a fuel temperature sensor. The engine control
module (ECM) increases the fuel pressure to minimize fuel vapor formation to maintain fuel flow
across the injectors.
The throttle body assembly is calibrated during assembly, no adjustments are required or permitted.
The throttle motor is a 12 volt DC motor which, via movement of the throttle blade, controls the
amount of air flowing into the engine.

G00442->G45703

Engine oil level Fuses

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Cooling system coolant level Wiring harness
Fuel level Electrical connector(s)
Fuel contamination/grade/quality Sensor(s)
Throttle body Engine control module (ECM)
Poly-vee belt Transmission control module (TCM)
Air intake system
Cooling system
Charging system
Ignition system
a fault code reader to retrieve the fault codes before proceeding to the diagnostic trouble code (DTC)
index chart, or the symptom chart if no DTCs are set.
NOTE:
NOTE:
Check engine breather system,

Engine Emission Control - VIN Range:
Engine breather system
G00442->G45703 For ignition
system,
Ignition system Engine Ignition - VIN Range: G00442-
>G45703 Check fuel pressure,
Engine cranks, but does not
Fuel system Fuel Tank and Lines - 3.0L/3.5L/4.2L,
fire
VIN Range: G00442->G45703 For CKP
Harness tests,
CKP sensor
Range: G00442->G45703 Contact
ECM fault dealer technical support for advice on
Purge valve For evaporative emissions

components,
Fuel pump
Engine coolant temperature G00442->G45703 Check fuel
(ECT) sensor pressure.
Spark plugs VIN Range: G00442->G45703 For ECT
will not start
sensor tests,
HT short to ground (tracking) Electronic Engine Controls - VIN
check rubber boots for
Range: G00442->G45703 For ignition
cracks/damage
system
Ignition coil failure(s) Engine Ignition - VIN Range: G00442-
>G45703
Harness
For battery information,
Check coolant anti-freeze Electronic Engine Controls - VIN
content Range: G00442->G45703 For EGR
system information,
Battery Engine Emission Control - VIN Range:
G00442->G45703 Check fuel
CKP sensor
pressure.
Difficult to start cold
EGR valve stuck open Fuel Tank and Lines - 3.0L/3.5L/4.2L,
VIN Range: G00442->G45703 For ECT
Fuel pump sensor tests,
ECT sensor Range: G00442->G45703 For
evaporative emissions components,
Purge valve Evaporative Emissions - VIN Range:
G00442->G45703
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Fuel Injectors (18.10.02) For FT
sensor, IAT sensor and MAF sensor
Injector leak tests,
Fuel temperature (FT) sensor
IAT sensor evaporative emissions components,
MAF sensor G00442->G45703 Check fuel
pressure.
Purge valve Fuel Tank and Lines - 3.0L/3.5L/4.2L,
Fuel pump ignition system,
Engine Ignition - VIN Range: G00442-
Ignition system
>G45703 For ECT sensor tests,
ECT sensor Electronic Engine Controls - VIN
Range: G00442->G45703 For EGR
EGR valve stuck open information,
G00442->G45703

Difficult to start after hot Injector leak Fuel Injectors (18.10.02) For FT
soak (vehicle standing after sensor, IAT sensor and MAF sensor
FT sensor
engine has reached tests,
operating temperature) Electronic Engine Controls - VIN
IAT sensor
evaporative emissions components,
MAF sensor Evaporative Emissions - VIN Range:
G00442->G45703 Check fuel
Purge valve pressure.
Fuel pump
Ignition system ignition system,
ECT sensor >G45703 For ECT sensor tests,
EGR valve stuck open Range: G00442->G45703 For EGR
information,
G00442->G45703
For breather system,

Breather system
G00442->G45703 For ECM relay,
ECM relay MAF sensor and ECT sensor tests,
Harness Range: G00442->G45703 For ignition
system,
MAF sensor Engine Ignition - VIN Range: G00442-
>G45703 For air filter information,
Engine stalls soon after ECT sensor
start
Ignition system VIN Range: G00442->G45703 For fuel
line information,
Air filter restricted Fuel Tank and Lines - 3.0L/3.5L/4.2L,
VIN Range: G00442->G45703 For FRP
Fuel lines sensor tests, GO to Pinpoint Test
G290117p2.
Fuel Rail Pressure (FRP)
For intake system information,
sensor
Air leakage VIN Range: G00442->G45703
Fuel pump Check fuel pressure.

Injector leak VIN Range: G00442->G45703 For FRP
sensor tests, GO to Pinpoint Test
Fuel pressure G290117p2.
Engine hesitates/poor
acceleration For fuel line information,
Fuel lines
Air leakage VIN Range: G00442->G45703 For
intake system,
Throttle sensors Intake Air Distribution and Filtering -
Throttle motor throttle position sensor and throttle
motor tests,
Ignition system Electronic Engine Controls - VIN
Range: G00442->G45703 For ignition
EGR system
system,
HO2 sensors Engine Ignition - VIN Range: G00442-
>G45703 For EGR system,
Transmission malfunction Engine Emission Control - VIN Range:
G00442->G45703 Check for DTCs
Restricted pedal travel relating to HO2 sensors. Refer to the
(carpet, etc) DTC index for pinpoint tests. For
APP sensor
Check accelerator pedal travel. For
APP sensor tests,
Range: G00442->G45703
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Check fuel pressure.

VIN Range: G00442->G45703 For fuel
line information,
Fuel pump Fuel Tank and Lines - 3.0L/3.5L/4.2L,
Fuel lines
intake system,
Air leakage Intake Air Distribution and Filtering -
MAF sensor MAF sensor tests,
Engine backfires
HO2 sensors Range: G00442->G45703 Check for
DTCs relating to HO2 sensors. Refer
Ignition system
to the DTC index for pinpoint tests.
Sticking VCT hub For ignition system,
APP sensor >G45703 For VCT information,
Engine For APP sensor tests,
Range: G00442->G45703
Check fuel pressure.

VIN Range: G00442->G45703 For fuel
Engine surges Fuel lines
line information,
MAF sensor
MAF sensor, throttle sensor, and
Harness throttle motor relay tests,
Throttle sensors Range: G00442->G45703 For ignition
system,
Throttle motor
Ignition system >G45703
For KS circuit tests,

KS/circuit malfunction Range: G00442->G45703 Check fuel
pressure. For fuel line information,
VIN Range: G00442->G45703 For FRP
Fuel lines sensor tests, GO to Pinpoint Test
G290117p2.
FRP sensor
. For MAF and HO2 sensor tests,
Engine detonates/knocks Electronic Engine Controls - VIN
MAF sensor
Range: G00442->G45703 For intake
HO2 sensors system,
Air leakage VIN Range: G00442->G45703 Check
Sticking VCT hub fault. For VCT information,
Engine For BARO sensor, contact
BARO sensor malfunction
dealer technical support for advice on
APP sensor malfunction For APP sensor, throttle position

sensor and throttle motor relay tests,
No throttle response
Throttle sensors Electronic Engine Controls - VIN
Range: G00442->G45703
Throttle motor
APP sensor malfunction For APP sensor, throttle position
sensor, ECT sensor and MAF sensor
Throttle sensors tests,
ECT sensor Range: G00442->G45703 For
Poor throttle response MAF sensor
For intake system,
Transmission malfunction Intake Air Distribution and Filtering -
Traction control event breather system information,
Air leakage G00442->G45703
Breather system

DTC Condition Possible Causes Action
Air intake leak between mass For intake system,

air flow (MAF) sensor and Intake Air Distribution
cylinder head and Filtering - VIN Range:
G00442->G45703 For
Fuel filter/system restriction
fuel injector information,
Fuel injector restriction
For fuel filter and pump,
FRP sensor fault (low fuel Fuel Tank and Lines -
pressure) 3.0L/3.5L/4.2L, VIN
Range: G00442-
Low fuel pump output
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>G45703 For FRP sensor

tests, GO to Pinpoint
HO2S/Catalyst monitor sensor
Right-hand cylinders Test G290117p2.
P0171 harness wiring condition
combustion too lean fault For HO2S/catalyst
monitor sensor tests,
EFT sensor fault (low fuel Electronic Engine
temperature) Controls - VIN Range:
G00442->G45703 For
Mass air flow (MAF) sensor exhaust system,
fault (low intake air flow)
For sensor tests,
Electronic Engine
Exhaust leak (before catalyst)
Controls - VIN Range:
ECM receiving incorrect signal G00442->G45703 * If
from one or more of the this DTC is flagged, pay
following sensors: ECT, particular attention to
MAF*, IAT, FRP, fuel rail the MAF sensor.
temperature, TP
Check for "misfire
Engine misfire detected" DTCs in this
section. For intake
Restricted air filter
system,
Right-hand cylinders Leaking fuel injector(s) Intake Air Distribution
P0172 and Filtering - VIN Range:
combustion too rich
FRP sensor failure (high fuel G00442->G45703 For
pressure) fuel injector information,
Engine fuel temperature (EFT)
For FRP sensor tests, GO
sensor fault (high fuel
to Pinpoint Test
temperature) G290117p2.
For other sensor tests,
MAF sensor fault (high intake Electronic Engine
air flow) Controls - VIN Range:
G00442->G45703
harness wiring condition
fault
ECM receiving incorrect signal

from one or more of the
following sensors; ECT,
MAF, IAT, FRP, EFT
For intake system,
Intake Air Distribution
Air intake leak between MAF and Filtering - VIN Range:
sensor and cylinder head G00442->G45703 For
fuel injector information,
For fuel filter, pump and
lines,
FRP sensor failure (low fuel Fuel Tank and Lines -
pressure) 3.0L/3.5L/4.2L, VIN
Range: G00442-
Low fuel pump output >G45703 For
HO2S/catalyst monitor
Left-hand cylinders sensor tests,
P0174 harness wiring condition
combustion too lean fault Electronic Engine
EFT sensor fault (low fuel G00442->G45703 For
temperature) exhaust system,
Mass air flow (MAF) sensor to Pinpoint Test
fault (low intake air flow)
G290117p2.
Electronic Engine
ECM receiving incorrect signal Controls - VIN Range:
from one or more of the G00442->G45703 * If
following sensors; ECT, this DTC is flagged, pay
MAF*, IAT, FRP, EFT, TP particular attention to
the MAF sensor.
Engine misfire Check for "misfire

Left-hand cylinders detected" DTCs in this
P0175
combustion too rich Restricted air filter section. For intake
system,
Leaking fuel injector(s) Intake Air Distribution
and Filtering - VIN Range:
FRP sensor failure (high fuel G00442->G45703 For
pressure) fuel injectors,
ECM receiving incorrect signal
from one or more of the For FRP sensor tests, GO
following sensors; ECT, to Pinpoint Test
MAF, IAT, FRP, EFT G290117p2.
Electronic Engine
G00442->G45703
Fuel system leak
Incorrect fuel pump output

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FRP sensor to ECM sensing For fuel filter, pump and

circuit; high resistance, lines,
open circuit, short circuit to Fuel Tank and Lines -
high voltage
Fuel rail pressure (FRP) sensor 3.0L/3.5L/4.2L, VIN
P0191
circuit range/performance FRP sensor to splice in sensor Range: G00442-
supply circuit; high >G45703 For FRP sensor
resistance, open circuit tests, GO to Pinpoint
Test G290117p2.
FRP sensor to splice in sensor
ground circuit; high
short circuit to high voltage
FRP sensor failure

FRP sensor disconnected
FRP sensor to ECM sensing

circuit; open circuit or short
Fuel rail pressure (FRP) sensor For FRP sensor tests, GO
circuit to ground
P0192 circuit low voltage (low to Pinpoint Test
pressure) FRP sensor to splice in sensor G290117p2.
supply circuit; high
FRP sensor failure

P0193 Fuel rail pressure (FRP) sensor FRP sensor to ECM wiring For FRP sensor tests, GO
circuit high voltage (high (supply/sense); short circuit to Pinpoint Test
pressure) to each other G290117p2.
FRP sensor to ECM sense

circuit; short circuit to high
voltage
FRP sensor to splice in sensor

ground circuit; open circuit
FRP sensor failure

For injector circuit tests
for vehicles without
Injector disconnected supercharger, GO to
Pinpoint Test
Fuel injector circuit
P0201 Injector wiring open or short G290117p1.
malfunction, Cyl 1 circuit For vehicles with
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

Injector disconnected
Fuel injector circuit supercharger, GO to
P0204 Injector wiring open or short
malfunction, Cyl 7 circuit Pinpoint Test
G290117p1.
Injector failure For vehicles with
supercharger, GO to
Pinpoint Test
G290117p3.

Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

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Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.

Pinpoint Test
supercharger, GO to
Injector failure
Pinpoint Test
G290117p3.
For ignition system,
ECM to ignition coil primary Engine Ignition - VIN
circuit fault (cylinder misfire
Range: G00442-
detected DTC also flagged)
>G45703 For injector
Ignition coil failure circuit tests for vehicles
without supercharger,
Spark plug GO to Pinpoint Test
failure/fouled/incorrect gap G290117p1.
For vehicles with
Fuel injector circuit fault(s)
supercharger, GO to
P0300 Random misfire detected Pinpoint Test
Fuel delivery pressure high/low G290117p3.
Check fuel pressure,
Fuel injectors restricted/leaking Fuel Tank and Lines -
3.0L/3.5L/4.2L, VIN
Fuel injectors continuously Range: G00442-
open >G45703 For fuel
Fuel contamination
Worn camshaft/broken valve For engine information,
springs Engine

Range: G00442-
For vehicles with
supercharger, GO to
P0301 Misfire detected, cylinder 1 Pinpoint Test
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine
Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
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Fuel contamination
springs Engine

Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine
Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine

Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine
Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
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Fuel contamination
springs Engine

Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine
Range: G00442-
For vehicles with
supercharger, GO to
3.0L/3.5L/4.2L, VIN
Fuel contamination
springs Engine
Fuel level sensor to rear

electronic control module
circuit(s); intermittent short For fuel level sensor and
circuit, open circuit, high circuit tests,
Fuel level sensor circuit resistance Fuel Tank and Lines -
P0460
range/performance 3.0L/3.5L/4.2L, VIN
Fuel level sensor failure Range: G00442-
>G45703
Rear electronic control module
fault (incorrect fuel level
data)
accurately diagnosed
using the Jaguar
approved diagnostic
system. If this is not
Throttle motor failure available, INSTALL a new
P1224 Throttle control position error
throttle body.
Throttle body failure Throttle Body - VIN
Range: G00442->G45703
(19.70.04) CLEAR the
DTC, TEST the system for
normal operation.
Throttle motor disconnected For throttle motor and
circuit tests, and for ECM
Throttle motor to ECM drive ground tests,
circuits; short circuit or Electronic Engine
open circuit
Throttle motor control circuit Controls - VIN Range:
P1229
malfunction ECM ground circuit fault(s) G00442->G45703 For
(EM80-04, 05, 54) throttle body,
Throttle Body - VIN
Throttle motor failure Range: G00442->G45703
(19.70.04)
Throttle body failure
For fuel pump module
ECM to fuel pump module drive circuit tests,
No fuel pump commands circuit; open circuit, short Fuel Tank and Lines -
P1234
received by ECM circuit, high resistance 3.0L/3.5L/4.2L, VIN
Range: G00442-
Fuel pump module failure
>G45703
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For fuel pump module

ECM to fuel pump module drive circuit tests,
Fuel pump not activated when circuit; open circuit, short Fuel Tank and Lines -
P1236 circuit, high resistance
requested by ECM 3.0L/3.5L/4.2L, VIN
Range: G00442-
>G45703

using the Jaguar
approved diagnostic
Throttle return spring failure Throttle return spring failure available, INSTALL a new
P1250
malfunction (throttle body failure) throttle body.
Throttle Body - VIN
Range: G00442->G45703
normal operation.
Throttle motor relay coil power

supply circuit; open circuit For throttle motor relay
tests,
Throttle motor relay OFF
P1251 Throttle motor relay failure Electronic Engine
failure
Throttle motor relay coil to G00442->G45703
ECM ground circuit fault (relay
coil drive)
using the Jaguar
approved diagnostic
Throttle limp-home spring available, INSTALL a new
P1254 Throttle body
malfunction throttle body.
Throttle Body - VIN
Range: G00442->G45703
normal operation.
Right-hand cylinders misfire

rate catalyst damage (Note:
this DTC will flag only when
P1313 Refer to P0300 possible sources Refer to P0300 Actions.
accompanied by an individual
cylinder misfire DTC; P0300-
P0308)
Left-hand cylinders misfire

rate catalyst damage (Note:
this DTC will flag only when
accompanied by an individual
cylinder misfire DTC; P0300-
P0308)
Misfire excess emission (Note:

This DTC will flag only when
P1316 accompanied by an individual Refer to P0300 possible sources Refer to P0300 Actions.
cylinder misfire DTC; P0300 to
P0308)
Fuel pump module to fuel For fuel pump module

pump drive circuit; open and pump circuit tests,
circuit, short circuit, high
Fuel pump drive circuit Fuel Tank and Lines -
P1338 resistance
low/high voltage 3.0L/3.5L/4.2L, VIN
Fuel pump module failure Range: G00442-
>G45703
Fuel pump failure
Throttle motor power relay Throttle motor relay coil to For throttle motor relay
P1631
coil activation circuit failure ECM circuit; open circuit
tests,
Throttle motor relay failure Electronic Engine
Throttle motor relay coil to G00442->G45703
ECM drive circuit; open
ground
Throttle watchdog circuit
P1634 support for advice on
malfunction ECM failure

Throttle position (TP) sensor
P1656 support for advice on
amplifier circuit malfunction ECM failure
For throttle motor relay

Throttle motor relay failure
tests,
Throttle motor relay coil drive
P1657 Electronic Engine
circuit ON failure Throttle motor relay coil to
ECM drive circuit; short Controls - VIN Range:
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circuit to B+ voltage G00442->G45703
For throttle motor relay

tests,
Throttle motor relay ON
P1658 Electronic Engine
failure Throttle motor relay coil to
ECM drive circuit; short Controls - VIN Range:
circuit to B+ voltage G00442->G45703
Pinpoint Tests

P0201, P0202, P0203, P0204, P0205, P0206,
P0207, P0208; FUEL INJECTORS,
VEHICLES WITHOUT
SUPERCHARGER
1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant injector electrical
connector (IS01 to IS04 for right-hand cylinders, IS07 to IS10 for left-hand cylinders). 3. Measure the
resistance between the injector pins.
Is the resistance between 12 and 16 ohms?

-> Yes
-> No

Is either resistance less than 10,000 ohms?
-> Yes
-> No

1. Turn the ignition switch to the ON position. 2. Disconnect the relevant injector harness electrical
connector (IS01 to IS04 for right-hand cylinders, IS07 to IS10 for left-hand cylinders). 3. Measure the
voltage between the relevant injector harness electrical connector (IS01 to IS04 for right-hand
cylinders, IS07 to IS10 for left-hand cylinders) pin 02 and GROUND.
Is the voltage less than 10 Volts?
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector (IS01 to IS04 for right-
hand cylinders, IS07 to IS10 for left-hand cylinders) pin 02 and battery. This circuit includes the front
power distribution fuse box, fuse 13, and the EMS control relay. For additional information, refer to
the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No

injector harness electrical connector (IS01 to IS04 for right-hand cylinders, IS07 to IS10 for left-hand
cylinders) pin 001 and the ECM electrical connector PI01, pins as follows:
Injector Cyl 1, IS01 pin 01 (BG) and PI01 pin 120 (BG).
Injector Cyl 2, IS07 pin 01 (BR) and PI01 pin 115 (BR).
Injector Cyl 3, IS02 pin 01 (BK) and PI01 pin 114 (BK).
Injector Cyl 4, IS08 pin 01 (BO) and PI01 pin 119 (BO).
Injector Cyl 5, IS03 pin 01 (BG) and PI01 pin 113 (BG).
Injector Cyl 6, IS09 pin 01 (U) and PI01 pin 118 (U).
Injector Cyl 7, IS04 pin 01 (BW) and PI01 pin 117 (BW).
Injector Cyl 8, IS10 pin 01 (UY) and PI01 pin 112 (UY).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector pin 01 and the engine
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control module electrical connector. For additional information, refer to wiring diagrams. CLEAR the
-> No

TO BATTERY
1. Reconnect the battery negative terminal. 2. Measure the voltage between the relevant injector
harness electrical connector (PI32 to PI39) pin 01 and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST
-> No

TO GROUND
1. Measure the resistance between the relevant injector harness electrical connector (PI32 to PI39)
pin 01 and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
-> No

P0190, P0192, P0193; FUEL PRESSURE
(FRP) SENSOR
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the FRP sensor electrical connector PI28.
3. Disconnect the ECM electrical connector PI01. 4. Measure the resistance between PI28 pin 03 (U)
and PI01 pin 73 (U).
-> Yes
-> No
G290117t8 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR SHORT TO HIGH
VOLTAGE
Measure the voltage between PI28 pin 03 (U) and GROUND.
-> Yes
-> No
G290117t9 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR SHORT TO
GROUND
1. Disconnect the ECM electrical connector PI01. 2. Measure the resistance between the FRP sensor
electrical connector PI28 pin 03 (U) and GROUND.
-> Yes
-> No
Recheck the DTCs. Check the sensor supply and ground circuits.

P0201, P0202, P0203, P0204, P0205, P0206,
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P0207, P0208; FUEL INJECTORS,

VEHICLES WITH SUPERCHARGER
1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant injector electrical
connector (PI32 to PI39). 3. Measure the resistance between the injector pins.
-> Yes
-> No

-> Yes
-> No

1. Turn the ignition switch to the ON position. 2. Disconnect the relevant injector harness electrical
connector (PI32 to PI39). 3. Measure the voltage between the relevant injector harness electrical
connector (PI32 to PI39) pin 02 and GROUND.
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector (PI32 to PI39) pin 02
and battery. This circuit includes the front power distribution fuse box, fuse 13, and the EMS control
relay. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
-> No

injector harness electrical connector (PI32 to PI39) pin 001 and the ECM electrical connector PI01,
pins as follows:
Injector Cyl 1, PI32 pin 01 (BG) and PI01 pin 120 (BG).
Injector Cyl 2, PI36 pin 01 (BR) and PI01 pin 115 (BR).
Injector Cyl 3, PI33 pin 01 (BK) and PI01 pin 114 (BK).
Injector Cyl 4, PI37 pin 01 (BO) and PI01 pin 119 (BO).
Injector Cyl 5, PI34 pin 01 (BG) and PI01 pin 113 (BG).
Injector Cyl 6, PI38 pin 01 (U) and PI01 pin 118 (U).
Injector Cyl 7, PI35 pin 01 (BW) and PI01 pin 117 (BW).
Injector Cyl 8, PI39 pin 01 (UY) and PI01 pin 112 (UY).
-> Yes
REPAIR the circuit between the relevant injector harness electrical connector pin 01 and the engine
control module electrical connector. For additional information, refer to wiring diagrams. CLEAR the
-> No

TO BATTERY
1. Reconnect the battery negative terminal. 2. Measure the voltage between the relevant injector
harness electrical connector (PI32 to PI39) pin 01 and GROUND.
-> Yes
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-> No

TO GROUND
1. Measure the resistance between the relevant injector harness electrical connector (PI32 to PI39)
pin 01 and GROUND.
-> Yes
-> No
G45704->G99999
Overview

Fuel leaks
Damaged fuel lines Fuses
Damaged push connect fittings Inertia switch
Fuel level Loose or corroded electrical connectors
Fuel contamination/grade/quality Harnesses
Throttle body Sensor(s)
Damaged fuel tank filler pipe cap Engine control module (ECM)
Damaged fuel tank filler pipe
retrieve the fault codes before proceeding to the diagnostic trouble code (DTC) Index.
Symptom Chart
Engine cranks, but does not Engine breather system Check the engine breather system,
fire disconnected/restricted Engine Emission Control - VIN Range:
G45704->G99999 For ignition
Ignition system system tests,
Fuel system >G99999 Check the fuel pressure,
Harness
Crankshaft position (CKP) CKP tests,
sensor Electronic Engine Controls - VIN
Range: G45704->G99999 Refer to
ECM fault the warranty policy and procedures
Evaporative emissions purge

valve
Fuel pump Evaporative Emissions - VIN Range:
G45704->G99999 Check the fuel
Spark plugs pressure,
will not start
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HT short to ground (tracking) VIN Range: G45704->G99999 For

check rubber boots for ignition system tests,
cracks/damage
Ignition coil failure(s) >G99999
Harness
Check the engine coolant level and
condition. For battery information,
Check coolant anti-freeze
content
Battery Range: G45704->G99999 For EGR
system information,
CKP sensor Engine Emission Control - VIN Range:
Exhaust gas recirculation pressure,
(EGR) valve stuck open Fuel Tank and Lines - 3.0L/3.5L/4.2L,
Fuel pump
purge valve tests,
G45704->G99999

Injector leak
Fuel Injectors (18.10.02) For EFT, IAT
Difficult to start hot Engine fuel temperature and MAF sensor tests,
(EFT) sensor Electronic Engine Controls - VIN
Intake air temperature (IAT) valve tests,
sensor Evaporative Emissions - VIN Range:
Mass air flow (MAF) sensor pressure,
Purge valve
Fuel pump ignition system tests,
Ignition system >G99999 For EGR system
information,
EGR valve stuck open Engine Emission Control - VIN Range:
G45704->G99999

Range: G45704->G99999 For EFT,
Injector leak IAT and MAF sensor tests,
EFT sensor
IAT sensor valve tests,
Difficult to start after hot Evaporative Emissions - VIN Range:
soak (vehicle standing after MAF sensor G45704->G99999 Check the fuel
engine has reached pressure,
operating temperature) Purge valve Fuel Tank and Lines - 3.0L/3.5L/4.2L,
Fuel pump
Ignition system Engine Ignition - VIN Range: G45704-
>G99999 For EGR system
EGR valve stuck open information,
G45704->G99999
For breather system information,

Breather system Engine Emission Control - VIN Range:
disconnected/restricted G45704->G99999 For ECM relay,
MAF and FRP sensor tests,
ECM relay
Harness Range: G45704->G99999 For
Engine stalls soon after ignition system tests,
start MAF sensor Engine Ignition - VIN Range: G45704-
>G99999 For air filter and intake
Fuel rail pressure (FRP) system information,
sensor
Ignition system
fuel line information,
Air filter restricted VIN Range: G45704->G99999
Air leakage
Fuel lines
Fuel pump Check the fuel pressure, check the
fuel lines,
Fuel pressure Fuel Tank and Lines - 3.0L/3.5L/4.2L,
Fuel lines
Injector leak Fuel Injectors (18.10.02) For intake
system information,
Air leakage Intake Air Distribution and Filtering -
VIN Range: G45704->G99999 For TP,
Throttle position (TP) sensors APP sensor and throttle motor tests,
Engine hesitates/poor Accelerator pedal position
acceleration (APP) sensor
accelerator pedal travel. For ignition
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Throttle motor system tests,

Restricted pedal travel >G99999 For EGR system
(carpet, etc) information,
Ignition system
indicating a faulty HO2 sensor. Refer
EGR valve stuck open
to the DTC index. For transmission
HO2 sensors information,
Transmission malfunction
Check the fuel pressure, check the
Fuel pump fuel lines,
Fuel lines VIN Range: G45704->G99999 For
intake system,
Air leakage
MAF sensor VIN Range: G45704->G99999 For
Engine backfires MAF and APP sensor tests,
APP sensor Electronic Engine Controls - VIN
Range: G45704->G99999 Check for
HO2 sensors DTCs indicating a faulty HO2 sensor.
Refer to the DTC index. For ignition
Ignition system
system tests,
Sticking variable camshaft Engine Ignition - VIN Range: G45704-
timing (VCT) hub >G99999 Check DTCs for VCT
range/performance fault. For VCT
information,
Engine
Fuel pump Check the fuel pressure, check the

fuel lines,
Fuel lines Fuel Tank and Lines - 3.0L/3.5L/4.2L,
MAF sensor
MAF, TP sensor and throttle motor
Engine surges tests,
Harness
TP sensors Range: G45704->G99999 For
Throttle motor Engine Ignition - VIN Range: G45704-
>G99999
Ignition system
Knock sensor (KS) circuit
malfunction For KS, FRP, MAF and HO2 sensor
tests,
FRP sensor Electronic Engine Controls - VIN
MAF sensor fuel pressure, check the fuel lines,
HO2 sensors
Engine detonates/knocks intake system information,
Fuel pump
Fuel lines VIN Range: G45704->G99999 Check
Air leakage fault. For VCT information,
Engine Refer to the warranty policy
Sticking VCT hub and procedures manual if an ECM is
suspect.
(internal ECM fault)
APP sensor malfunction For APP, TP sensor and throttle
motor tests,
TP sensors Electronic Engine Controls - VIN
Range: G45704->G99999
Throttle motor
APP sensor malfunction For APP, TP, ECT and MAF sensor
tests,
TP sensors Electronic Engine Controls - VIN
Poor throttle response Range: G45704->G99999 For
ECT sensor
MAF sensor For intake system,
Transmission malfunction VIN Range: G45704->G99999 For
breather system information,
Traction control event Engine Emission Control - VIN Range:
G45704->G99999
Air leakage
Breather system
DTC index
NOTE:
NOTE:
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circuit: open circuit or short For FRP sensor circuit tests,
circuit to ground Electronic Engine Controls -
VIN Range: G45704-
FRP sensor supply circuit: high
Fuel rail/system >G99999 For fuel pump
P008700 resistance
pressure - too low circuit and fuel line tests,
FRP sensor failure Fuel Tank and Lines -
Fuel pump failure G45704->G99999
Fuel line leak
Restricted fuel line
FRP sensor to ECM wiring For FRP sensor tests,

Fuel rail/system (supply/sense): short circuit Electronic Engine Controls -
P008800 VIN Range: G45704-
pressure - too high to each other
>G99999 For fuel pump
FRP sensor to ECM sense circuit: circuit and fuel line tests,
short circuit to high voltage Fuel Tank and Lines -
FRP sensor ground circuit: high G45704->G99999
resistance
FRP sensor failure
Fuel pump short circuit to

battery
For intake system
information,
Air intake leak between MAF G45704->G99999 Check the
sensor and cylinder head fuel pressure, check the fuel
lines,
Fuel filter/system restriction Fuel Tank and Lines -
Low fuel pressure G45704->G99999 For fuel
System too lean (right injector information,
P017100 Fuel injector restriction
hand bank) Fuel Injectors (18.10.02)
MAF sensor fault (low intake air For MAF sensor circuit tests,
flow) Electronic Engine Controls -
VIN Range: G45704-
Exhaust leak (before catalyst) >G99999 Check the exhaust
system (before catalyst) for
Evaporative emission system condition and security,
fault
system tests,
Evaporative Emissions - VIN
Range: G45704->G99999
Restricted air filter For intake system

information,
High fuel pressure Intake Air Distribution and
Leaking fuel injector(s) G45704->G99999 Check the
System too rich (right fuel pressure,
P017200
hand bank) Oil contaminated with fuel (too
Fuel Tank and Lines -
many cold starts with
vehicle subsequently not 3.0L/3.5L/4.2L, VIN Range:
getting hot enough for long G45704->G99999 For fuel
enough) injector information,
MAF sensor fault (high intake air Check the oil condition, if
flow) contamination is present,
renew the engine oil and
Evaporative emission system filter. For MAF sensor circuit
fault tests,
Electronic Engine Controls -
VIN Range: G45704-
Range: G45704->G99999
For intake system

information,
Air intake leak between MAF G45704->G99999 Check the
sensor and cylinder head fuel pressure, check the fuel
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lines,
Fuel filter/system restriction Fuel Tank and Lines -
Low fuel pressure G45704->G99999 For fuel
System too lean (left injector information,
P017400 Fuel injector restriction
hand bank) Fuel Injectors (18.10.02)
MAF sensor fault (low intake air For MAF sensor circuit tests,
flow) Electronic Engine Controls -
VIN Range: G45704-
Exhaust leak (before catalyst) >G99999 Check the exhaust
Evaporative emission system condition and security,
fault
system tests,
Range: G45704->G99999

information,
High fuel pressure Intake Air Distribution and
Leaking fuel injector(s) G45704->G99999 Check the
System too rich (left
P017500 fuel pressure,
hand bank) Oil contaminated with fuel (too
many cold starts with
vehicle subsequently not 3.0L/3.5L/4.2L, VIN Range:
getting hot enough for long G45704->G99999 For fuel
enough) injector information,
MAF sensor fault (high intake air Check the oil condition, if
flow) contamination is present,
Evaporative emission system filter. For MAF sensor circuit
fault
tests,
VIN Range: G45704-
Range: G45704->G99999
For injector circuit tests on

vehicles without
Cylinder 1 injector Pinpoint Test G240048p1.
P020100 Injector harness wiring: short
circuit/open circuit For injector circuit tests on
vehicles with supercharger,
Injector failure GO to Pinpoint Test
G240048p3.

vehicles without
G240048p3.

vehicles without
G240048p3.
Injector disconnected For injector circuit tests on

vehicles without
Cylinder 4 injector supercharger, GO to
circuit/open circuit Pinpoint Test G240048p1.
Injector failure vehicles with supercharger,
GO to Pinpoint Test
G240048p3.

vehicles without
G240048p3.

vehicles without
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G240048p3.

vehicles without
G240048p3.

vehicles without
G240048p3.
ECM to ignition coil primary For ignition coil circuit tests,

circuit fault (cylinder misfire Engine Ignition - VIN Range:
detected DTC also flagged) G45704->G99999 Check the
P131500 Persistent misfire
fuel pressure,
Fuel delivery pressure low
Fuel injector circuit fault(s) 3.0L/3.5L/4.2L, VIN Range:
(injector DTCs also flagged) G45704->G99999 For
injector circuit tests
Ignition coil failure (vehicles without
supercharger), GO to
Spark plug
failure/fouled/incorrect gap
Cylinder compression low (vehicles with
supercharger), GO to
For spark plug tests,
G45704->G99999
Injector driver misfire - Check for associated DTCs

P131600 Injector driver module codes
emissions damage detected and refer to the DTC index.

instrument cluster. Replace
the throttle body.
Throttle Body - Vehicles
Throttle With: Supercharger, VIN
P210129 range/performance - Jammed throttle blade, gearing Range: G45704->G99999
sub-processor or motor (19.70.04)
Without: Supercharger, VIN
Range: G45704->G99999
(19.70.04)

the throttle body.
With: Supercharger, VIN
Throttle
P210164 Jammed throttle blade, gearing Range: G45704->G99999
range/performance or motor (19.70.04)
Range: G45704->G99999
(19.70.04)
For throttle actuator motor

Control circuit: short circuit to circuit tests on vehicles
P210329 power
control circuit high without supercharger, GO
to Pinpoint Test
ECM fault
G240048p4.
circuit tests on vehicles with
supercharger, GO to
Refer to the warranty policy
and procedures manual if an
ECM is suspect.

circuit tests on vehicles
without supercharger, GO
to Pinpoint Test
G240048p4.
Throttle actuator motor Control circuit: short circuit to
P210364 control circuit high - power
circuit tests on vehicles with
signal plausibility failure
ECM fault supercharger, GO to
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ECM is suspect.

Throttle actuator
the reason for the fuel cut.
P210500 control system - forced Throttle MIL request due to fuel
cut Follow the action indicated
engine shutdown
for those DTCs.

the throttle body.
Throttle actuator With: Supercharger, VIN
P210629 control system - forced Range: G45704->G99999
Signal invalid
limited power (19.70.04)
Range: G45704->G99999
(19.70.04)

Throttle actuator the throttle body.
P210664 control system - forced Throttle Body - Vehicles
Signal plausibility failure
limited power With: Supercharger, VIN
Range: G45704->G99999
(19.70.04)
Range: G45704->G99999
(19.70.04)

circuit tests on vehicles
without supercharger, GO
to Pinpoint Test
Control circuit: short circuit to G240048p4.
power, short circuit to For throttle actuator motor
P211800 control current
ground, high resistance circuit tests on vehicles with
range/performance
supercharger, GO to
ECM fault Pinpoint Test G240048p5.
ECM is suspect.

the throttle body.
Throttle actuator With: Supercharger, VIN
P211900 control throttle body Range: G45704->G99999
Throttle spring faulty
range/performance (19.70.04)
Range: G45704->G99999
(19.70.04)
Pinpoint Tests
NOTE:
NOTE:

INJECTOR CIRCUITS (VEHICLES
WITHOUT SUPERCHARGER)
Injector connector
Cylinder 1, PI32
Cylinder 2, PI36
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Cylinder 3, PI33
Cylinder 4, PI37
Cylinder 5, PI34
Cylinder 6, PI38
Cylinder 7, PI35
Cylinder 8, PI39
-> Yes
-> No

-> Yes
-> No

-> Yes
-> No

TO GROUND

-> Yes
-> No

TO POWER

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-> Yes
-> No

RESISTANCE
PI32, pin 01 Pin 78
PI36, pin 01 Pin 79

PI33, pin 01 Pin 80
PI37, pin 01 Pin 81
PI34, pin 01 Pin 82
PI38, pin 01 Pin 83
PI35, pin 01 Pin 84
PI39, pin 01 Pin 85
-> Yes
-> No
INJECTOR CIRCUITS (VEHICLES
WITH SUPERCHARGER)
Injector connector
Injector Cylinder 1, IS01

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-> Yes
-> No


-> Yes
-> No

-> Yes
-> No

TO GROUND

-> Yes
-> No

TO POWER

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-> Yes
-> No

RESISTANCE
IS01, pin 01 Pin 78
IS07, pin 01 Pin 79

IS02, pin 01 Pin 80
IS08, pin 01 Pin 81
IS03, pin 01 Pin 82
IS09, pin 01 Pin 83
IS04, pin 01 Pin 84
IS10, pin 01 Pin 85
-> Yes
-> No
THROTTLE BODY MOTOR CIRCUIT
(VEHICLES WITHOUT
SUPERCHARGER)

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-> Yes
-> No

-> Yes
-> No

-> Yes
-> No

-> Yes
-> No

Pin 05 Pin 75
-> Yes
-> No

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Pin 06 Pin 74
-> Yes
-> No
INSTALL a new throttle body assembly
Throttle Body - Vehicles Without: Supercharger, VIN Range: G45704->G99999 (19.70.04) CLEAR the

THROTTLE BODY MOTOR CIRCUIT
(VEHICLES WITH SUPERCHARGER)
-> Yes
-> No

-> Yes
-> No


-> Yes
-> No

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-> Yes
-> No

Pin 01 Pin 75

-> Yes
-> No

Pin 02 Pin 74
-> Yes
-> No
INSTALL a new throttle body assembly
Throttle Body - Vehicles With: Supercharger, VIN Range: G45704->G99999 (19.70.04) CLEAR the DTC
and test the system for normal operation.

Removal
1
. 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 can result in 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 ignite.
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Remove the fuel injection supply manifold.

Remove the securing bolts.

Installation
1
present and may ignite. Failure to follow these instructions can result in personal injury.
To install, reverse removal procedure.
Install new fuel pressure sensor O-ring seals. Lubricate the O-ring seals with
clean engine oil to aid installation.
Tighten to 5 Nm.
Removal
1 . Remove the charge air coolers. <<303-12B>>

3 . NOTE:

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Remove the engine cover bracket.
All vehicles
4 . Disconnect the fuel line. <<310-00>>
5 . Disconnect the fuel pressure sensor.
2) Detach the vacuum hose.

6 . NOTE:
7 . NOTE:
Disconnect the electrical connectors.

9 . Remove the fuel injection supply manifold.
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10 . NOTE:
Remove the fuel injection supply manifold.
All vehicles

Installation
All vehicles
1
Install new fuel injector O-ring seals. Lubricate the O-ring seals with clean
engine oil to aid installation.

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Throttle Body - Vehicles With:
Supercharger, VIN Range: G00442-
>G45703 (19.70.04)
Removal
1
2
Remove the air outlet pipe.


4 . Remove the throttle body intake pipe.
5 . Detach the brake servo pipe.

6 . Disconnect the throttle body electrical connectors.
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7 . NOTE:

Installation
1
Install a new throttle body gasket.
Tighten to 10 Nm.

Throttle Body - Vehicles With:
>G99999 (19.70.04)
Removal
1
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3
Remove the throttle body intake pipe.
4 . Disconnect the brake servo pipe.

5 . Remove the throttle body intake duct.
7 . Detach the throttle body.

8 . NOTE:
9 . NOTE:
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Remove the throttle body.
10 . Remove and discard the gasket.

Installation
1
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Throttle Body - Vehicles Without:
>G45703 (19.70.04)
Removal
1
2
Remove the air outlet pipe.



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7 . NOTE:

Installation
1
Install a new throttle body gasket.
Tighten to 10 Nm.

Throttle Body - Vehicles Without:
>G99999 (19.70.04)
Removal
1
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2
Remove the air outlet tube.


6 . NOTE:

Installation
1
Install the new throttle body gasket.
Tighten to 10 Nm.
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303-04C : Fuel Charging and Controls – 2.7L Diesel
Specifications
Specifications

High-pressure fuel supply line unions A – –
High-pressure fuel supply line support bracket retaining nut 10 – 89
Fuel injector retaining bolts 10 – 89
Fuel injector high pressure fuel inlet adaptor union 42 31 –
Fuel injection diverter rail retaining bolts 23 16 –
Fuel injection supply manifold retaining bolts 23 16 –
Fuel injection supply manifold support bracket retaining bolts 23 16 –
Fuel pump retaining bolts 23 16 –
Fuel injection pump belt rear cover retaining bolts 7 – 62
Camshaft rear pulley retaining bolt A – –
Fuel injection pump belt tensioner retaining bolt 25 18 –
Fuel injection pump pulley retaining nut 50 37 –
Fuel injection pump high pressure fuel outlet adaptor union 37 27 –
Exhaust gas recirculation (EGR) valve retaining bolts 10 – 89
Intake manifold retaining nuts 15 11 –
A = refer to the procedure for the correct torque sequence

General procedures

WARNING: Do not carry out any repairs to the fuel system with the engine
running. The fuel pressure within the system can be as high as 2000 bar. Failure to
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.
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WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.
WARNING: Place the vehicle in a well ventilated, quarantined area and arrange '
No Smoking/Petrol Fumes' signs about the vehicle.
WARNING: Wait at least 30 seconds after the engine stops before commencing
any repair to the high-pressure fuel injection system. Failure to follow this instruction
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical attention.
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
CAUTION: Before using the cleaning fluid, protect all electrical components and
connectors with lint-free non-flocking material.
CAUTION: Make sure that all parts removed from the vehicle are placed on the
lint-free non-flocking material.
CAUTION: Make sure that any protective clothing worn is clean and made from
lint-free non-flocking material.
CAUTION: Make sure that clean non-plated tools are used. Clean tools using a
new brush that will not lose its bristles and fresh cleaning fluid, prior to starting work
on the vehicle.
CAUTION: Use a steel topped workbench and cover it with clean, lint-free non-
flocking material.
CAUTION: Make sure the workshop area in which the vehicle is being worked on
is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or
from machining or welding operations can contaminate the fuel system and may result
in later malfunction.
NOTE:
Pneumatic vacuum gun
1. Using a new brush that will not lose its bristles, brush cleaning fluid onto the components
being removed and onto the surrounding area.
2. Using a pneumatic vacuum gun, remove all traces of cleaning fluid and foreign material.
3. Dispose of any used cleaning fluid and the brush after completing the repair.

High Pressure Fuel Injection Components
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Part
Item Description
Number
1 — Fuel rail pressure pressure sensor
2 — Fuel injection diverter rail
3 — Fuel injection pump
High-pressure fuel supply line (fuel injection diverter rail to fuel injection supply
4 —
manifold)
6 — Pressure control valve (PCV)
7 — Fuel injector
8 — High-pressure fuel supply line (fuel injection supply manifold to fuel injector)
9 — Volume control valve (VCV)
10 High-pressure fuel supply line (fuel injection pump to fuel injection diverter rail)
Fuel Injection Pump

The fuel injection pump is located at the rear of the engine between the cylinder heads and is driven
by a toothed drive belt attached to a pulley on the left hand exhaust camshaft. The fuel injection
pump is not timed to the engine. The fuel injection pump assembly contains two different types of
pump, a transfer pump and a high pressure pump.
Fuel is supplied to the fuel injection pump by an electric fuel pump in the fuel tank via the fuel filter.
Fuel then passes through the transfer pump to the high pressure pump. The amount of fuel supplied
to the high pressure pump from the transfer pump is determined by the volume control valve (VCV)
which is controlled using a pulse width modulated (PWM) signal from the engine control module
(ECM). The VCV makes it possible to match the high pressure pump delivery to the requirements of
the engine from the low pressure side. This keeps the amount of fuel flowing back to the main supply
line to a minimum and reduces the load on the high pressure pump, improving engine efficiency.
The high pressure pump contains three radial pumping elements, capable of generating a fuel
pressure of up to 1650 Bar (23,200 lb ft), connected together which leads via a pressure control valve
(PCV) to the high pressure outlet of the pump.
The PCV is located between the high pressure and the fuel return line outlet of the pump. The PCV is
controlled using a PWM signal from the ECM, and controls the fuel pressure in the fuel diverter rail
and fuel injection supply manifolds. Opening of the PCV diverts fuel to the fuel return line and back
to the fuel filter. At the same time as the PCV opens to reduce fuel pressure, the ECM closes the VCV
to reduce the amount of fuel delivered to the high pressure pump. When the engine is stopped the
VCV closes and the PCV opens, this relieves the pressure in the system and returns the fuel to the
main fuel supply line.
The PCV and VCV must not be disassembled from fuel injection pump. If either of these components
are found to be faulty, the fuel injection pump must be replaced.
CAUTION: If any of the high pressure fuel pipe retaining nuts are loosened, the high
pressure fuel pipe it is installed to must be renewed. Failure to follow this instruction may allow
metal fragments to enter the fuel system and result in damage to the fuel system components or
engine.
CAUTION: The high pressure fuel line olive end deforms and work hardens during
installation. If any of the high pressure fuel pipe retaining nuts are loosened, the high pressure fuel
pipe it is installed to must be renewed. Failure to follow this instruction may allow the high-
pressure fuel line to leak.
Fuel Injection Supply Manifold

The fuel injection supply manifolds are reservoirs for the pressurized fuel that is produced by the fuel
pump. The two fuel injection supply manifolds are connected by high pressure fuel pipes to a fuel
injection diverter rail mounted on the fuel injection pump. The fuel injection diverter rail also
incorporates a pressure sensor so that the ECM can monitor/adjust the pressure of the fuel to be
injected into the each cylinder. The fuel injection diverter rail and the pressure sensor are serviced as
an assembly and must not under any circumstances be disassembled.
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Fuel Injector
1 — Electrical connector
2 — Fuel injector body
3 — Fuel injector leak-off retaining clip
4 — Fuel injector nozzle

5 — Fuel injector sealing washer
6 Fuel injector retaining clamp
7 High pressure fuel line connection
CAUTION: If any of the high pressure fuel pipe retaining nuts are loosened, the high
pressure fuel pipe it is installed to must be renewed. Failure to follow this instruction may allow
metal fragments to enter the fuel system and result in damage to the fuel system components or
engine.
CAUTION: The high pressure fuel line olive end deforms and work hardens during
installation. If any of the high pressure fuel pipe retaining nuts are loosened, the high pressure fuel
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pipe it is installed to must be renewed. Failure to follow this instruction may allow the high-
pressure fuel line to leak.
Fuel Injectors
The fuel injectors are operated electrically by the engine control module (ECM) and inject a precise
amount of fuel into the combustion chamber at the required time.
The injectors have been designed to:
allow pilot and main injections with short intervals between each injection.
be fully electrically controlled.
Fuel Filter
The diesel fuel filter is located on the left-hand side of the engine compartment. Incorporated in to
the fuel filter housing is a bimetallic valve which will start to close at 30°C (86°F) and will fully close at
50°C (122°F).
When the bimetallic valve is open, warm fuel is directed in to the fuel filter to prevent waxing. When
the fuel temperature increases, the bimetallic valve closes, diverting fuel through the under-floor
fuel cooler which then lowers the fuel temperature before returning the fuel back to the fuel filter.
This allows fuel to be supplied to the fuel injection pump at the optimum inlet temperature of
between -30°C to 80°C.

Common rail diesel

The 2.7L fuel injection system is a common-rail design, running at the high-pressures (up to 1,650 bar
or 23,930 lb/in²) typical of such systems.
The fuel is drawn from the fuel tank by an electric fuel pump module and delivered to the transfer
pump side of a fuel injection pump driven by the engine. For additional information on the fuel
injection pump,
The fuel volume control valve (FVCV) regulates the amount of fuel supplied to the high-pressure side
of the fuel injection pump, while the fuel pressure control valve (FPCV) regulates the pressure.
The high-pressure fuel is delivered to the fuel rail where it is stored, ready for use by the fuel
injectors.
The fuel injectors are Piezo type, and are controlled by the engine control module (ECM) from inputs
from the engine management sensors.
The fuel injectors operate in stages, giving a pilot injection before the main injection to reduce
detonation noise and help improve the efficiency of the engine.

Overview
WARNING: Do NOT carry out any work on the fuel system with the engine running. The fuel
pressure within the system can be as high as 1650 bar (23,930 lb/in²). Failure to follow this
WARNING: Eye protection must be worn at all times when working on or near any fuel
related components. Failure to follow this instruction may result in personal injury.
personal injury.
WARNING: After carrying out repairs, the fuel system must be checked visually for leaks.
This should be done after the engine has been run, but with the engine switched OFF. Failure to
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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. Failure to follow this instruction may result in personal injury.
WARNING: Wash hands thoroughly after handling, as prolonged contact may cause
irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may
CAUTION: Before disconnecting any part of the system, it is imperative that all dust, dirt
and debris is removed from around components to prevent ingress of foreign matter into the fuel
system. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: The fuel pipes between the injectors and the rail must be discarded after each
use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: It is essential that absolute cleanliness is observed when working with these
components. Always install blanking plugs to any open orifices or lines. Failure to follow this
CAUTION: Make sure that the workshop area in which the vehicle is being worked on is as
clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or
machining are carried out are not suitable in view of the risk of contamination to the fuel system.
CAUTION: Make sure that any protective clothing worn is clean and made from lint-free
non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that any protective gloves worn are new and are of the non-powdered
latex type. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that clean, non-plated tools are used. Clean tools using a new brush
that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure
CAUTION: Use a steel-topped work bench and cover it with clean, lint-free, non-flocking
material. Failure to follow this instruction may result in damage to the vehicle.
tests, use the adaptor kit, part number 3548-1358-00. Failure to follow this instruction may result
NOTE:
This section contains references to Parameter Identifiers (PIDs). Where the Jaguar approved
diagnostic system is not available, a scantool may be used to access these PIDs, all of which give
information, and some of which can be used to both read information and to activate
components. The format of the information may vary, depending on the tool used.
NOTE:
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NOTE:
NOTE:
If diagnostic trouble codes (DTCs) are recorded and the symptom is not present when
performing the pinpoint tests, an intermittent concern may be the cause. Always check for loose
connections and corroded terminals.
Fuel level Glow plug indicator
Contaminated fuel Inertia fuel shutoff (IFS) switch
Fuel supply line(s) Fuel pump module

Fuel return line(s) Sensor(s)
High-pressure fuel supply line(s) Engine control module (ECM)
Fuel tank filler pipe Fuel volume control valve (FVCV)
Fuel leak(s) Fuel pressure control valve (FPCV)
Fuel tank Fuel rail pressure (FRP) sensor
Fuel filler cap Fuel temperature sensor
Fuel filter Fuel injector(s)
Push connect fittings EGR system
Fuel rail
Fuel injection pump
Exhaust gas recirculation (EGR) system
retrieve the fault codes before proceeding to the DTC index, or the symptom chart if no DTCs are set.
Symptom Chart
IFS switch
Check that the inertia switch has not tripped.
Low/contaminated fuel Check the fuel level/condition, GO to Pinpoint
Test G552275p3.
Air ingress Check the low pressure circuit for
leaks/damage,
Low pressure circuit fault Fuel Tank and Lines - 2.7L Diesel Check the
Engine cranks, but fuel pump module operation, GO to Pinpoint
Fuel pump module fault
does not start Test G552275p2.
Check the fuel filter, GO to Pinpoint Test
Blocked fuel filter
G552275p4.
FVCV blocked/contaminated Check the FVCV and FPCV, GO to Pinpoint
Test G552275p5.
FPCV blocked/contaminated GO to Pinpoint Test G552275p7.
Check the fuel injection pump,
Fuel injection pump failure Fuel Injection Pump For CKP sensor cicuit
Crankshaft position (CKP) tests,
sensor Electronic Engine Controls Refer to the
warranty policy and procedures manual if an
ECM fault ECM is suspect.
Low/Contaminated fuel
Check the fuel level/condition, GO to Pinpoint
Fuel pump module fault Test G552275p3.
Check the fuel pump module operation, GO to
Air ingress Pinpoint Test G552275p2.
Check the low pressure circuit for
Low pressure circuit fault
leaks/damage,
Difficult to start Fuel Tank and Lines - 2.7L Diesel Check the
Blocked fuel filter
fuel filter, GO to Pinpoint Test G552275p4.
Test G552275p5.
For EGR tests,
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Low pressure circuit fault Engine Emission Control
EGR valve(s) fault

Low/Contaminated fuel Check the fuel level/condition, GO to Pinpoint
Test G552275p3.
leaks/damage,
Fuel Tank and Lines - 2.7L Diesel Check the
Rough idle fuel filter, GO to Pinpoint Test G552275p4.
Blocked fuel filter
Check the FVCV and FPCV, GO to Pinpoint
FVCV blocked/contaminated Test G552275p5.
FPCV blocked/contaminated For EGR tests,
EGR valve(s) fault
Check the air intake circuit,
Air intake circuit fault Intake Air Distribution and Filtering Check for
a blocked catalytic converter,
Catalyst converter blocked
Exhaust System Check the fuel pressure PID,
Lack of power
when accelerating Low fuel pressure
For EGR tests,
EGR valve(s) fault Engine Emission Control For turbocharger
tests,
Turbocharger(s) fault Turbocharger
Engine stops/stalls Low/Contaminated fuel Check the fuel level/condition, GO to Pinpoint

Test G552275p3.
leaks/damage,
Low pressure circuit fault Fuel Tank and Lines - 2.7L Diesel Check the
FVCV and FPCV, GO to Pinpoint Test
FVCV blocked/contaminated
G552275p5.
Check for fuel system leaks, GO to Pinpoint
High pressure fuel leak Test G552275p1.
For EGR tests,
EGR valve(s) fault Engine Emission Control
Air ingress Test G552275p3.
Low pressure circuit fault leaks/damage,
Fuel metering valve
Engine judders blocked/contaminated
G552275p5.
FVCV blocked/contaminated GO to Pinpoint Test G552275p7.
FPCV blocked/contaminated Test G552275p1.
High pressure fuel leak Fuel Injection Pump
Fuel injection pump fault

Low pressure circuit fault Check the low pressure circuit for
leaks/damage,
FVCV blocked/contaminated Fuel Tank and Lines - 2.7L Diesel Check the
FPCV blocked/contaminated
G552275p5.
Excessive fuel
consumption Fuel temperature sensor leak
Check the fuel temperature sensor, fuel
High pressure fuel leak injection pump, etc for leaks, GO to Pinpoint
Test G552275p1.
Injector(s) failure Check for injector DTCs. For EGR tests,
EGR valve(s) fault
DTC index
NOTE:
NOTE:
For a full list of powertrain DTCs,

DTC Condition Possible source Action
FVCV circuit: high

resistance For FVCV tests, GO to Pinpoint
Test G552275p5.
Fuel volume control valve FVCV circuit: short circuit
P000100 Refer to the warranty policy
(FVCV) control circuit open to ground
FVCV failure ECM is suspect.
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ECM failure
FVCV circuit: high
resistance
FVCV circuit: short circuit For FVCV tests, GO to Pinpoint

Fuel volume control valve to ground Test G552275p5.
P000200 (FVCV) circuit Refer to the warranty policy
range/performance FVCV circuit: short circuit and procedures manual if an
to power ECM is suspect.
FVCV failure
ECM failure
FVCV circuit: high
Test G552275p5.
(FVCV) control circuit low to ground
ECM failure
to power Test G552275p5.
Fuel volume control valve
(FVCV) control circuit high FVCV failure and procedures manual if an
ECM is suspect.
ECM failure
Pressure too low
Fuel rail/system pressure Fuel rail pressure (FRP) For FRP tests, GO to Pinpoint
P008700
too low sensor circuit failure Test G552275p6.
Fuel rail pressure (FRP)

sensor failure
Pressure too high
P008800
too high sensor circuit failure Test G552275p6.

sensor failure
FPCV circuit: high
resistance For FPCV tests, GO to Pinpoint
Test G552275p7.
Fuel pressure control valve FPCV circuit: short circuit
(FPCV) control circuit open to ground
FPCV failure ECM is suspect.
ECM failure
FPCV circuit: high
Test G552275p7.
(FPCV) control circuit low to ground
ECM failure
FPCV circuit: short circuit For FPCV tests, GO to Pinpoint
Fuel pressure control valve
(FPCV) control circuit high FPCV failure and procedures manual if an
ECM is suspect.
ECM failure
Fuel temperature sensor
circuit: high resistance For fuel temperature sensor
and circuit tests,
Fuel temperature sensor Fuel temperature sensor Electronic Engine Controls
P018100
circuit range/performance circuit: short circuit to Refer to the warranty policy
ground and procedures manual if an
ECM is suspect.
power

failure
ECM failure

circuit: short circuit to For fuel temperature sensor
ground and circuit tests,
Fuel temperature sensor Electronic Engine Controls
P018200
circuit low input Fuel temperature sensor Refer to the warranty policy
circuit: short circuit to and procedures manual if an
power
ECM is suspect.
failure
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ECM failure

P018300
circuit high input Fuel temperature sensor Refer to the warranty policy
power
ECM is suspect.
failure
ECM failure
Fuel temperature sensor For fuel temperature sensor

circuit: short circuit to and circuit tests,
ground
P018400
circuit intermittent Fuel temperature sensor Refer to the warranty policy
power ECM is suspect.

failure
ECM failure
FRP sensor circuit: high
resistance
FRP sensor circuit: short For FRP sensor tests, GO to

Fuel rail pressure (FRP) circuit to ground Pinpoint Test G552275p6.
P019100 sensor circuit Refer to the warranty policy
range/performance FRP sensor circuit: short and procedures manual if an
circuit to power ECM is suspect.
FRP sensor failure
ECM failure
resistance

circuit to ground Pinpoint Test G552275p6.
sensor circuit low input FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
resistance

sensor circuit high input FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
resistance

intermittent/erratic FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
Fuel injector circuit: high
resistance
For cylinder 1 fuel injector
Fuel injector circuit: short tests, GO to Pinpoint Test
circuit to ground
Fuel injector high- G552275p8.
P020100
resistance, cylinder 1 Fuel injector circuit: short Refer to the warranty policy
circuit to power and procedures manual if an
ECM is suspect.
Fuel injector failure
ECM failure
resistance
circuit to ground
P020200
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circuit to power
ECM is suspect.
ECM failure
resistance
circuit to ground
P020300
ECM is suspect.
ECM failure
resistance
circuit to ground
P020400
ECM is suspect.
ECM failure
resistance
circuit to ground
P020500
ECM is suspect.
ECM failure
resistance
circuit to ground
P020600
ECM is suspect.
ECM failure
resistance
circuit to ground
Fuel injection timing, G552275p8.
P020A00
cylinder 1 Fuel injector circuit: short Refer to the warranty policy
ECM is suspect.
ECM failure
resistance
circuit to ground
P020B00
ECM is suspect.
ECM failure
resistance
circuit to ground
P020C00
ECM is suspect.
ECM failure
resistance
circuit to ground
P020D00
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circuit to power
ECM is suspect.
ECM failure
resistance
circuit to ground
P020E00
ECM is suspect.
ECM failure
resistance
circuit to ground
P020F00
ECM is suspect.
ECM failure
Fuel injector circuit: For cylinder 1 fuel injector
Fuel injector circuit,
P026300 range/performance tests, GO to Pinpoint Test
cylinder 1
G552275p8.
cylinder 2
G552275p9.
cylinder 3
G552275p10.
cylinder 4
G552275p11.
cylinder 5
G552275p12.
cylinder 6
G552275p13.
Injector(s) disconnected
Identify the fuel injector
Injector circuit(s): high concerned from the DTC
Fuel injector driver circuit resistance, short stored in the ECM. Refer to the
P062D00 performance (right hand circuit to ground, relevant test for the code
bank) short circuit to power logged. Refer to the warranty
policy and procedures manual
Injector failure
ECM failure
P062E00 performance (left hand circuit to ground, relevant test for the code
Injector failure
ECM failure
FRP sensor circuit: high For FRP sensor tests, GO to
P120E00 Fuel rail pressure (FRP) Pinpoint Test G552275p6.
resistance
sensor - excessive fuel
pressure variation FRP sensor circuit: short and procedures manual if an
circuit to ground ECM is suspect.
FRP sensor failure
ECM failure
resistance
FRP sensor circuit: short

circuit to ground
For FRP sensor tests, GO to
Fuel rail pressure (FRP) FRP sensor circuit: short Pinpoint Test G552275p6.
P120F00 regulator - fuel pressure circuit to power Refer to the warranty policy
low at start and procedures manual if an
FRP sensor failure ECM is suspect.

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Fuel pump failure
ECM failure
Fuel injector disconnected
Fuel injector harness For cylinder 1 fuel injector

wiring: high tests, GO to Pinpoint Test
resistance, short G552275p8.
P150A00 range/performance
circuit to ground, Refer to the warranty policy
cylinder 1 short circuit to power and procedures manual if an
ECM is suspect.
ECM failure

P150B00 range/performance circuit to ground, Refer to the warranty policy
ECM is suspect.
ECM failure
Fuel injector disconnected For cylinder 3 fuel injector

Fuel injector circuit tests, GO to Pinpoint Test
P150C00 range/performance G552275p10.
Fuel injector harness
cylinder 3 wiring: high Refer to the warranty policy
resistance, short and procedures manual if an
circuit to ground, ECM is suspect.
short circuit to power
ECM failure

P155400 range/performance
ECM is suspect.
ECM failure

ECM is suspect.
ECM failure

ECM is suspect.
ECM failure
Fuel injector control For fuel pressure and fuel
pressure: too high pump module circuit tests,
Injector control pressure Fuel Tank and Lines - 2.7L
FPCV circuit fault
too high - fuel pressure Diesel For FPCV and circuit
P228800
control valve (FPCV) FPCV failure tests, GO to Pinpoint Test
minimum limit reached G552275p7.
Fuel pump module circuit: For fuel injection pump,
short circuit to power Fuel Injection Pump
Fuel injection pump failure

Fuel injector control
pressure: too low
Fuel line leak

For fuel lines, fuel pressure
Fuel filter/system and fuel pump module circuit
restriction tests,
Injector control pressure
Fuel Tank and Lines - 2.7L
too low - fuel pressure
P229000 FPCV circuit fault Diesel For FPCV and circuit
control valve (FPCV)
maximum limit reached FPCV failure G552275p7.
For fuel injection pump,
Fuel pump module circuit:
short circuit to ground Fuel Injection Pump

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pressure: erratic
FPCV circuit fault
and fuel pump module circuit
FPCV failure tests,
erratic - fuel pressure
P229200 Fuel pump module Diesel For FPCV and circuit
control valve (FPCV) circuit(s): high tests, GO to Pinpoint Test
dynamic resistance, short G552275p7.
circuit to ground,
Fuel Injection Pump
Pinpoint test
the high pressure fuel injection system. Failure to follow this instruction may result in personal
injury.
personal injury.
NOTE:
NOTE:
NOTE:
terminals.

FOR FUEL SYSTEM LEAKS
G552275t1 : CHECK FOR FUEL SYSTEM LEAKS
1. Start and run the engine for five minutes. 2. Key off. 3. Inspect the fuel lines, pump, etc, in the
engine bay for cracks/damage. 4. Raise and support the vehicle.
Lifting 5. Inspect the fuel lines for cracks/damage. 6. Check the integrity of the joints in the supply
and return lines between the fuel tank and the fuel pump. 7. Carefully check around the fuel pipes,
injectors and pump for evidence of leakage. 8. If there is evidence of a significant leak, clean the
engine and repeat the test.
Is there any evidence of leakage?
-> Yes
RECTIFY the leak as necessary. Test the system for normal operation.
-> No
CHECK for other possible causes for the customer concern.

THE FUEL PUMP MODULE FUNCTION
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G552275t2 : CHECK THE FUEL PUMP MODULE FUNCTION

1. After thoroughly cleaning around the connections, disconnect the inlet pipe from the fuel filter. 2.
Position a suitable container beneath the fuel filter inlet pipe to collect fuel. 3. Key on, engine off (the
pump should run for a short period, depending on temperature, etc). 4. Check that fuel is pumped
from the fuel filter inlet pipe.
Is fuel pumped from the fuel filter inlet pipe?
-> Yes
CHECK the drive belt to the fuel injection pump.
Fuel Injection Pump Belt Check for DTCs. Test the system for normal operation.
-> No
CHECK the fuel pump module and circuit,
Fuel Tank and Lines - 2.7L Diesel

FOR CONTAMINATED FUEL
G552275t3 : CHECK FOR UNUSUAL ODOURS FROM THE FUEL FILLER
1. Gather as much information as possible from the owner/driver regarding refuelling practices. 2.
Remove the fuel filler cap and check for unusual odours.
Are there any unusual odours from the fuel filler neck?
-> Yes
DRAIN the fuel tank and refill with fresh fuel. Install a new fuel filter.
Fuel Filter - 2.7L Diesel (19.25.02) Test the vehicle for normal operation.
-> No
G552275t4 : CHECK FOR WATER IN THE FUEL

Position a suitable clear container beneath the fuel filter inlet pipe to collect fuel. 3. Key on, engine
off (the pump should run for a short period, depending on temperature, etc. It may be necessary to
turn the ignition on and off more than once to obtain the desired amount of fuel). 4. Collect
approximately one liter of fuel. 5. Allow the fuel to stand for at least one minute. 6. Without
disturbing the fuel, check for separation of the fuel into layers (a significant amount of water in the
fuel will result in a clear separation between the two fluids, with the water being at the bottom).
Does the fuel show clear separation?
-> Yes
-> No
CHECK for other contaminants in the fuel.

FOR BLOCKED FUEL FILTER
G552275t5 : CHECK THE FLOW OF FUEL THROUGH THE FILTER
1. After thoroughly cleaning around the connections, disconnect the fuel filter outlet pipe to the fuel
injection pump. 2.
WARNING: During this test, fuel will flow backwards through the fuel filter because of the
fuel cooler circuit.
Position a suitable container beneath the fuel filter outlet to collect fuel. 3. Key on, engine off (the
pump should run for a short period, depending on temperature, etc).
Is there an unrestricted flow of fuel through the filter?
-> Yes
CHECK for DTCs, check for another cause of customer complaint.
-> No
INSTALL a new fuel filter.

VOLUME CONTROL VALVE AND
CIRCUIT
G552275t6 : CHECK FOR POWER TO THE FVCV
1.
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Circuit Pin
Power 01
Signal from ECM 02
2.
Circuit Pin
Fuel volume control valve - signal J4
3. Key off. 4. Disconnect the FVCV connector, C42. 5. Key on, engine off. 6. Measure the voltage
between:
C42, harness side Battery

Is the voltage between 9 and 15 volts?
-> Yes
-> No
REPAIR the power circuit. For additional information, refer to the wiring diagrams. Clear any DTCs,
G552275t7 : CHECK THE FVCV CONTROL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
Is the resistance greater than 100 Kohms?
-> Yes
-> No

POWER

-> Yes
-> No
G552275t9 : CHECK THE FVCV CONTROL CIRCUIT FOR HIGH RESISTANCE

1. Key off. 2. Disconnect the ECM connector, C100. 3. Measure the resistance between:
C42, harness side C100, harness side
Pin 02 J4
Is the resistance less than 10 ohms?

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-> Yes
-> No
REPAIR the high-resistance circuit. For additional information, refer to the wiring diagrams. Clear any
DTCs, test the system for normal operation.
G552275t10 : CHECK THE COMPONENT RESISTANCE

C42, component side C42, component side
Pin 02 Pin 01
Is the resistance between 1.5 and 15 ohms?
-> Yes
component(s): - FVCV connector - FVCV - ECM connector - ECM
-> No
INSTALL a new fuel injection pump.
Fuel Injection Pump Clear any DTCs, test the system for normal operation.
G552275t11 : CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE
HARNESS OR THE MODULE
1. Key off. 2. Disconnect the ECM connector, C100. 3. Key on, engine off. 4. Measure the resistance
between:
-> Yes
Harness is OK. Suspect: - ECM
-> No
G552275t12 : CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE

between:
-> Yes
-> No

RAIL PRESSURE (FRP) SENSOR AND
CIRCUIT
G552275t13 : CHECK THE FRP SENSOR RETURN CIRCUIT
1.
Circuit Pin
Signal from ECM 01
Ground from ECM 02
Power from ECM 03

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2.
Circuit Pin
FRP sensor - signal D1
FRP sensor - ground E2
FRP sensor - power D2
3. Key off. 4. Disconnect the FRP sensor connector, C30. 5. Key on, engine off. 6. Measure the
resistance between:

-> Yes
-> No
G552275t14 : CHECK THE POWER SUPPLY TO THE FRP

Is the voltage between 4.8 and 5.2 volts?
-> Yes
-> No
G552275t15 : CHECK THE FRP SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
-> Yes
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-> No

SENSOR POWER
Pin 01 Pin 03
-> Yes
-> No
G552275t18 : CHECK THE FRP SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin D1
-> Yes
component(s): - FRP connector - ECM connector - FRP - ECM
-> No
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Clear any
G552275t19 : CHECK FOR SIGNAL AND RETURN CIRCUITS SHORT CIRCUIT

TO EACH OTHER
between:
Pin 01 Pin 02
-> Yes
-> No


-> Yes
component(s): - ECM
-> No

between:
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-> Yes
component(s): - ECM
-> No

OR THE MODULE
between:
Pin 01 Pin 03
-> Yes
component(s): - ECM
-> No
G552275t23 : CHECK THE 5 VOLT SUPPLY CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G552275t25 : CHECK THE FRP 5 VOLT SUPPLY CIRCUIT FOR HIGH

RESISTANCE
Pin 03 Pin D2
-> Yes
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component(s): - ECM connector - ECM
-> No
G552275t26 : CHECK THE FRP SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G552275t27 : CHECK FOR 5 VOLT SUPPLY AND SIGNAL RETURN CIRCUITS
SHORT CIRCUIT TO EACH OTHER
between:
Pin 03 Pin 02
-> Yes
-> No
G552275t28 : CHECK THE FRP SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
Pin 02 Pin E2
-> Yes
-> No

Pin 03 Pin 02
-> Yes
-> No

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-> Yes
component(s): - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

PRESSURE CONTROL VALVE (FPCV)
AND CIRCUIT
G552275t33 : CHECK THE POWER SUPPLY TO THE FPCV
1.
Circuit Pin
Power 01
Signal from ECM 02
2.
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Circuit Pin
Fuel pressure control valve - signal K3
3. Key off. 4. Disconnect the FPCV connector, C43. 5. Key on, engine off. 6. Measure the voltage
between:
-> Yes
-> No
No supply to the FPCV circuit. Check and repair the circuit as necessary. For additional information,
refer to the wiring diagrams. Clear any DTCs, test the system for normal operation.
G552275t34 : CHECK THE FPCV CONTROL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G552275t36 : CHECK THE FPCV CONTROL CIRCUIT FOR HIGH RESISTANCE
Pin 02 Pin K3
-> Yes
-> No
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Pin 01 Pin 02
Is the resistance between 0 and 5.5 ohms?
-> Yes
component(s): - FPCV connector - FPCV - ECM connector - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

INJECTOR AND CIRCUIT, CYLINDER 1
1.
Circuit Pin
Fuel injector, cylinder 1 - ground 01
Fuel injector, cylinder 1 - control 02
2.
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Circuit Pin
Fuel injector, cylinder 1 - ground L3
Fuel injector, cylinder 1 - control M3
3. Key off. 4. Disconnect the fuel injector 1 (INJ0) connector, C44. 5. Measure the resistance between:
Pin 02 Pin 01
Is the resistance between 180 and 220 Kohms?
-> Yes
-> No
INSTALL a new fuel injector.
Fuel Injector (18.10.01) Clear any DTCs, test the system for normal operation.
G552275t41 : CHECK THE COMBINED FUEL INJECTOR AND HARNESS

RESISTANCE
1. Key off. 2. Connect the fuel injector 1 (INJ0) connector, C44. 3. Disconnect the ECM connector,
C101. 4. Measure the resistance between:
Pin M3 Pin L3
-> Yes
-> No

TO EACH OTHER
Pin M3 Pin L3
-> Yes
-> No
G552275t43 : CHECK THE FUEL INJECTOR CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the fuel injector 1 (INJ0) connector, C44. 2. Measure the resistance between:
Pin 02 Pin M3
Pin 01 Pin L3
Are the resistances less than 10 ohms?
-> Yes
component(s): - Fuel injector 1 (INJ0) connector - ECM connector - Fuel injector 1 (INJ0)
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-> No
G552275t44 : CHECK THE FUEL INJECTOR CIRCUIT FOR SHORT CIRCUIT TO

GROUND
Pin M3 Negative terminal
Pin L3 Negative terminal
Are the resistances greater than 100 Kohms?
-> Yes
-> No
HARNESS OR THE FUEL INJECTOR
1. Key off. 2. Disconnect the fuel injector 1 (INJ0) connector, C44. 3. Key on, engine off. 4. Measure
the resistance between:
-> Yes
component(s): - Fuel injector 1 (INJ0)
-> No

POWER
Pin M3 Positive terminal
Pin L3 Positive terminal
-> Yes
component(s): - Fuel injector 1 (INJ0) connector - Fuel injector 1 (INJ0) - ECM connector - ECM
-> No
-> Yes
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-> No

OR THE THE FUEL INJECTOR
Pin M3 Pin L3
-> Yes
-> No
1.
Circuit Pin
2.
Circuit Pin
Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
1. Key off. 2. Connect the fuel injector 2 (INJ2) connector, C46 connected. 3. Disconnect the ECM
connector, C101. 4. Measure the resistance between:
Pin M2 Pin L2
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-> Yes
-> No
G552275t51 : CHECK for short CIRCUIT BETWEEN THE SIGNAL AND

RETURN CIRCUITS
Pin M2 Pin L2
-> Yes
-> No

Pin 02 Pin M2
Pin 01 Pin L2
-> Yes
-> No
REPAIR the high-resistance. For additional information, refer to the wiring diagrams. Clear any DTCs,

GROUND
-> Yes
-> No


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-> Yes
-> No

POWER
-> Yes
-> No

-> Yes
-> No

OR THE FUEL INJECTOR
Pin M2 Pin L2
-> Yes
-> No

1.
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Circuit Pin
2.
Circuit Pin

Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
Pin M4 Pin L4
-> Yes
-> No

TO EACH OTHER
Pin M4 Pin L4

-> Yes
-> No

Pin 02 Pin M4
Pin 01 Pin L4
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-> Yes
-> No

GROUND
-> Yes
-> No

-> Yes
-> No

POWER
-> Yes
-> No


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-> Yes
-> No

Pin M4 Pin L4
-> Yes
-> No

1.
Circuit Pin
2.
Circuit Pin
Fuel injector, cylinder 4 - control L1
Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
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Pin L1 Pin L2
-> Yes
-> No

TO EACH OTHER
Pin L1 Pin L2
-> Yes
-> No

Pin 02 Pin L1
Pin 01 Pin L2
Are the resistances less than 10 ohm?
-> Yes
-> No

GROUND

-> Yes
-> No


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-> Yes
-> No

POWER

-> Yes
component(s): - Fuel injector 4 (INJ1) connector - Fuel Injector 4 (INJ1) - ECM connector - ECM
-> No

-> Yes
-> No

Pin L1 Pin L2

-> Yes
-> No

1.
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Circuit Pin
2.
Circuit Pin

Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
Pin M1 Pin L3
-> Yes
-> No
G552275t78 : CHECK FOR SHORT CIRCUIT BETWEEN THE SIGNAL AND

RETURN CIRCUITS
Pin M1 Pin L3
-> Yes
-> No

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Pin 02 Pin M1
Pin 01 Pin L3
-> Yes
-> No

GROUND

-> Yes
-> No

-> Yes
-> No

POWER

-> Yes
-> No

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-> Yes
-> No


Pin M1 Pin L3
-> Yes
-> No

1.
Circuit Pin
2.
Circuit Pin
Fuel injector, cylinder 6 - ground M3
Pin 02 Pin 01
-> Yes
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-> No

RESISTANCE
Pin M2 Pin M3
-> Yes
-> No
RETURN CIRCUITS
Pin M2 Pin M3
-> Yes
-> No

Pin 02 Pin M2
Pin 01 Pin M3
-> Yes
-> No

GROUND
-> Yes
-> No
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HARNESS OR the Fuel injector
-> Yes
-> No

POWER
-> Yes
-> No

-> Yes
-> No
Pin M2 Pin M3
-> Yes
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-> No
Common rail diesel

The 2.7L fuel injection system is a common-rail design, running at the high-pressures (up to 1,650 bar
or 23,930 lb/in²) typical of such systems.
The fuel is drawn from the fuel tank by an electric fuel pump module and delivered to the transfer
pump side of a fuel injection pump driven by the engine. For additional information on the fuel
injection pump,
The fuel volume control valve (FVCV) regulates the amount of fuel supplied to the high-pressure side
of the fuel injection pump, while the fuel pressure control valve (FPCV) regulates the pressure.
The high-pressure fuel is delivered to the fuel rail where it is stored, ready for use by the fuel
injectors.
The fuel injectors are Piezo type, and are controlled by the engine control module (ECM) from inputs
from the engine management sensors.
The fuel injectors operate in stages, giving a pilot injection before the main injection to reduce
detonation noise and help improve the efficiency of the engine.

Overview
WARNING: Do NOT carry out any work on the fuel system with the engine running. The fuel
pressure within the system can be as high as 1650 bar (23,930 lb/in²). Failure to follow this
WARNING: Eye protection must be worn at all times when working on or near any fuel
related components. Failure to follow this instruction may result in personal injury.
personal injury.
This should be done after the engine has been run, but with the engine switched OFF. Failure to
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WARNING: If taken internally, DO NOT induce vomiting. Seek immediate medical attention.
seek medical attention. Failure to follow this instruction may result in personal injury.
irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may
CAUTION: Before disconnecting any part of the system, it is imperative that all dust, dirt
and debris is removed from around components to prevent ingress of foreign matter into the fuel
system. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: The fuel pipes between the injectors and the rail must be discarded after each
use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that the workshop area in which the vehicle is being worked on is as
clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or
machining are carried out are not suitable in view of the risk of contamination to the fuel system.
CAUTION: Make sure that any protective clothing worn is clean and made from lint-free
non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that any protective gloves worn are new and are of the non-powdered
latex type. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure that clean, non-plated tools are used. Clean tools using a new brush
that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure
CAUTION: Use a steel-topped work bench and cover it with clean, lint-free, non-flocking
material. Failure to follow this instruction may result in damage to the vehicle.
NOTE:
NOTE:
NOTE:
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NOTE:
Fuel level Glow plug indicator
Contaminated fuel Inertia fuel shutoff (IFS) switch
Fuel supply line(s) Fuel pump module
Fuel return line(s) Sensor(s)
High-pressure fuel supply line(s) Engine control module (ECM)
Fuel tank filler pipe Fuel volume control valve (FVCV)

Fuel leak(s) Fuel pressure control valve (FPCV)
Fuel tank Fuel rail pressure (FRP) sensor
Fuel filler cap Fuel temperature sensor
Fuel filter Fuel injector(s)
Push connect fittings EGR system
Fuel rail
Fuel injection pump
Exhaust gas recirculation (EGR) system
Symptom Chart
IFS switch Check that the inertia switch has not tripped.
Low/contaminated fuel Test G552275p3.
Air ingress
leaks/damage,
fuel pump module operation, GO to Pinpoint
Check the fuel filter, GO to Pinpoint Test
Engine cranks, but
Blocked fuel filter G552275p4.
does not start
Fuel injection pump failure Fuel Injection Pump For CKP sensor cicuit
tests,
Crankshaft position (CKP) Electronic Engine Controls Refer to the
sensor warranty policy and procedures manual if an
ECM is suspect.
ECM fault
Check the fuel pump module operation, GO to
Air ingress Pinpoint Test G552275p2.
leaks/damage,
Difficult to start Fuel Tank and Lines - 2.7L Diesel Check the
Blocked fuel filter
fuel filter, GO to Pinpoint Test G552275p4.
Test G552275p5.
For EGR tests,
Low pressure circuit fault Engine Emission Control
EGR valve(s) fault

Test G552275p3.
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leaks/damage,
Rough idle fuel filter, GO to Pinpoint Test G552275p4.
Blocked fuel filter
FPCV blocked/contaminated For EGR tests,
EGR valve(s) fault
Check the air intake circuit,
Air intake circuit fault Intake Air Distribution and Filtering Check for
a blocked catalytic converter,
Catalyst converter blocked
Exhaust System Check the fuel pressure PID,
Lack of power
when accelerating Low fuel pressure
For EGR tests,
EGR valve(s) fault Engine Emission Control For turbocharger
tests,
Turbocharger(s) fault Turbocharger

Test G552275p3.
Engine stops/stalls leaks/damage,
FVCV blocked/contaminated FVCV and FPCV, GO to Pinpoint Test
G552275p5.
High pressure fuel leak Test G552275p1.
For EGR tests,
EGR valve(s) fault
Air ingress Test G552275p3.
Low pressure circuit fault leaks/damage,
Fuel metering valve
Engine judders blocked/contaminated
G552275p5.
FVCV blocked/contaminated GO to Pinpoint Test G552275p7.
FPCV blocked/contaminated Test G552275p1.
High pressure fuel leak Fuel Injection Pump

Low pressure circuit fault Check the low pressure circuit for
leaks/damage,
FVCV blocked/contaminated Fuel Tank and Lines - 2.7L Diesel Check the
G552275p5.
Excessive fuel
consumption Fuel temperature sensor leak
Check the fuel temperature sensor, fuel
High pressure fuel leak injection pump, etc for leaks, GO to Pinpoint
Test G552275p1.
Injector(s) failure Check for injector DTCs. For EGR tests,
EGR valve(s) fault
DTC index
NOTE:
NOTE:
FVCV circuit: high

Test G552275p5.
ECM failure
FVCV circuit: high
resistance
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Fuel volume control valve to ground Test G552275p5.
FVCV failure
ECM failure
FVCV circuit: high
Test G552275p5.
ECM failure
(FVCV) control circuit high FVCV failure and procedures manual if an
ECM is suspect.
ECM failure
Pressure too low
Fuel rail/system pressure For FRP tests, GO to Pinpoint
P008700
too low Fuel rail pressure (FRP) Test G552275p6.
sensor circuit failure
sensor failure
Pressure too high
P008800
too high sensor circuit failure Test G552275p6.

sensor failure
FPCV circuit: high
Test G552275p7.
(FPCV) control circuit open to ground
ECM failure
FPCV circuit: high
Test G552275p7.
ECM failure
FPCV circuit: short circuit For FPCV tests, GO to Pinpoint
ECM is suspect.
ECM failure

P018100
circuit range/performance Fuel temperature sensor Refer to the warranty policy
power
ECM is suspect.
failure
ECM failure

P018200
circuit low input Fuel temperature sensor Refer to the warranty policy
power
ECM is suspect.
failure
ECM failure

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P018300
circuit high input Fuel temperature sensor Refer to the warranty policy
power
ECM is suspect.
failure
ECM failure

P018400
power
ECM is suspect.
failure
ECM failure
Fuel rail pressure (FRP) FRP sensor circuit: high For FRP sensor tests, GO to
P019100 sensor circuit resistance Pinpoint Test G552275p6.
range/performance Refer to the warranty policy
FRP sensor circuit: short and procedures manual if an

circuit to power
FRP sensor failure
ECM failure
resistance

sensor circuit low input FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
resistance

sensor circuit high input FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
resistance

intermittent/erratic FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
Fuel injector circuit: high For cylinder 1 fuel injector
Fuel injector high- tests, GO to Pinpoint Test
P020100 resistance
resistance, cylinder 1 G552275p8.
Fuel injector circuit: short Refer to the warranty policy
circuit to ground and procedures manual if an
ECM is suspect.
Fuel injector circuit: short
circuit to power
ECM failure
resistance
circuit to ground
P020200
ECM is suspect.
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ECM failure
resistance
circuit to ground
P020300
ECM is suspect.
ECM failure
resistance
circuit to ground
P020400
ECM is suspect.
ECM failure
Fuel injector high- tests, GO to Pinpoint Test
P020500 resistance
resistance, cylinder 5 G552275p12.
ECM is suspect.
circuit to power
ECM failure
resistance
circuit to ground
P020600
ECM is suspect.
ECM failure
resistance
circuit to ground
P020A00
ECM is suspect.
ECM failure
resistance
circuit to ground
P020B00
ECM is suspect.
ECM failure
Fuel injection timing, tests, GO to Pinpoint Test
P020C00 resistance
cylinder 3 G552275p10.
ECM is suspect.
circuit to power
ECM failure
resistance
circuit to ground
P020D00
ECM is suspect.
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ECM failure
resistance
circuit to ground
P020E00
ECM is suspect.
ECM failure
resistance
circuit to ground
P020F00
ECM is suspect.
ECM failure
cylinder 1
G552275p8.
cylinder 2
G552275p9.
cylinder 3
G552275p10.
cylinder 4
G552275p11.
cylinder 5
G552275p12.
cylinder 6
G552275p13.
P062D00 performance (right hand circuit to ground, relevant test for the code
Injector failure
ECM failure
P062E00 performance (left hand circuit to ground, relevant test for the code
Injector failure
ECM failure
FRP sensor circuit: high For FRP sensor tests, GO to
Fuel rail pressure (FRP) resistance Pinpoint Test G552275p6.
P120E00 sensor - excessive fuel Refer to the warranty policy
pressure variation FRP sensor circuit: short and procedures manual if an
FRP sensor failure
ECM failure
resistance

circuit to ground
For FRP sensor tests, GO to
Fuel rail pressure (FRP) FRP sensor circuit: short Pinpoint Test G552275p6.
P120F00 regulator - fuel pressure circuit to power Refer to the warranty policy
low at start and procedures manual if an
FRP sensor failure ECM is suspect.
Fuel pump failure
ECM failure
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P150A00 range/performance
ECM is suspect.
ECM failure

P150B00 range/performance
ECM is suspect.
ECM failure
Fuel injector disconnected For cylinder 3 fuel injector
Fuel injector circuit Fuel injector harness
G552275p10.
P150C00 range/performance wiring: high
resistance, short Refer to the warranty policy
cylinder 3
circuit to ground, and procedures manual if an
short circuit to power ECM is suspect.
ECM failure

ECM is suspect.
ECM failure

ECM is suspect.
ECM failure

ECM is suspect.
ECM failure
pressure: too high
For fuel pressure and fuel
FPCV circuit fault pump module circuit tests,
Injector control pressure Fuel Tank and Lines - 2.7L
too high - fuel pressure FPCV failure Diesel For FPCV and circuit
P228800
control valve (FPCV) tests, GO to Pinpoint Test
minimum limit reached Fuel pump module circuit: G552275p7.
short circuit to power For fuel injection pump,
Fuel Injection Pump

pressure: too low
Fuel line leak

Fuel filter/system and fuel pump module circuit
restriction tests,
too low - fuel pressure
P229000 FPCV circuit fault Diesel For FPCV and circuit
control valve (FPCV)
maximum limit reached FPCV failure G552275p7.
Fuel pump module circuit:
short circuit to ground Fuel Injection Pump

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pressure: erratic
FPCV circuit fault
and fuel pump module circuit
FPCV failure tests,
erratic - fuel pressure
P229200 Fuel pump module Diesel For FPCV and circuit
control valve (FPCV) circuit(s): high tests, GO to Pinpoint Test
dynamic resistance, short G552275p7.
circuit to ground,
Fuel Injection Pump
Pinpoint test
injury.
personal injury.
NOTE:
NOTE:
NOTE:
terminals.

FOR FUEL SYSTEM LEAKS
G552275t1 : CHECK FOR FUEL SYSTEM LEAKS
1. Start and run the engine for five minutes. 2. Key off. 3. Inspect the fuel lines, pump, etc, in the
engine bay for cracks/damage. 4. Raise and support the vehicle.
Lifting 5. Inspect the fuel lines for cracks/damage. 6. Check the integrity of the joints in the supply
and return lines between the fuel tank and the fuel pump. 7. Carefully check around the fuel pipes,
injectors and pump for evidence of leakage. 8. If there is evidence of a significant leak, clean the
engine and repeat the test.
Is there any evidence of leakage?
-> Yes
RECTIFY the leak as necessary. Test the system for normal operation.
-> No
CHECK for other possible causes for the customer concern.

THE FUEL PUMP MODULE FUNCTION
G552275t2 : CHECK THE FUEL PUMP MODULE FUNCTION
Position a suitable container beneath the fuel filter inlet pipe to collect fuel. 3. Key on, engine off (the
pump should run for a short period, depending on temperature, etc). 4. Check that fuel is pumped
from the fuel filter inlet pipe.
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Is fuel pumped from the fuel filter inlet pipe?
-> Yes
CHECK the drive belt to the fuel injection pump.
Fuel Injection Pump Belt Check for DTCs. Test the system for normal operation.
-> No
CHECK the fuel pump module and circuit,
Fuel Tank and Lines - 2.7L Diesel

FOR CONTAMINATED FUEL
G552275t3 : CHECK FOR UNUSUAL ODOURS FROM THE FUEL FILLER
1. Gather as much information as possible from the owner/driver regarding refuelling practices. 2.
Remove the fuel filler cap and check for unusual odours.
Are there any unusual odours from the fuel filler neck?
-> Yes
-> No
G552275t4 : CHECK FOR WATER IN THE FUEL
Position a suitable clear container beneath the fuel filter inlet pipe to collect fuel. 3. Key on, engine
off (the pump should run for a short period, depending on temperature, etc. It may be necessary to
turn the ignition on and off more than once to obtain the desired amount of fuel). 4. Collect
approximately one liter of fuel. 5. Allow the fuel to stand for at least one minute. 6. Without
disturbing the fuel, check for separation of the fuel into layers (a significant amount of water in the
fuel will result in a clear separation between the two fluids, with the water being at the bottom).
Does the fuel show clear separation?
-> Yes
-> No
CHECK for other contaminants in the fuel.

FOR BLOCKED FUEL FILTER
G552275t5 : CHECK THE FLOW OF FUEL THROUGH THE FILTER
1. After thoroughly cleaning around the connections, disconnect the fuel filter outlet pipe to the fuel
injection pump. 2.
WARNING: During this test, fuel will flow backwards through the fuel filter because of the
fuel cooler circuit.
Position a suitable container beneath the fuel filter outlet to collect fuel. 3. Key on, engine off (the
pump should run for a short period, depending on temperature, etc).
Is there an unrestricted flow of fuel through the filter?
-> Yes
CHECK for DTCs, check for another cause of customer complaint.
-> No
INSTALL a new fuel filter.
VOLUME CONTROL VALVE AND
CIRCUIT
G552275t6 : CHECK FOR POWER TO THE FVCV
1.
Circuit Pin
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Power 01
Signal from ECM 02
2.
Circuit Pin
Fuel volume control valve - signal J4
3. Key off. 4. Disconnect the FVCV connector, C42. 5. Key on, engine off. 6. Measure the voltage
between:

-> Yes
-> No

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G552275t9 : CHECK THE FVCV CONTROL CIRCUIT FOR HIGH RESISTANCE

Pin 02 J4
-> Yes
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-> No
REPAIR the high-resistance circuit. For additional information, refer to the wiring diagrams. Clear any

Pin 02 Pin 01
Is the resistance between 1.5 and 15 ohms?
-> Yes
component(s): - FVCV connector - FVCV - ECM connector - ECM
-> No
between:
-> Yes
-> No

between:
-> Yes
-> No

RAIL PRESSURE (FRP) SENSOR AND
CIRCUIT
G552275t13 : CHECK THE FRP SENSOR RETURN CIRCUIT
1.
Circuit Pin
Signal from ECM 01
Ground from ECM 02
Power from ECM 03

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2.
Circuit Pin
FRP sensor - signal D1
FRP sensor - ground E2
FRP sensor - power D2
3. Key off. 4. Disconnect the FRP sensor connector, C30. 5. Key on, engine off. 6. Measure the
resistance between:

-> Yes
-> No
G552275t14 : CHECK THE POWER SUPPLY TO THE FRP

-> Yes
-> No

GROUND
-> Yes
-> No

POWER
-> Yes
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-> No

SENSOR POWER
Pin 01 Pin 03
-> Yes
-> No
G552275t18 : CHECK THE FRP SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin D1
-> Yes
component(s): - FRP connector - ECM connector - FRP - ECM
-> No

TO EACH OTHER
between:
Pin 01 Pin 02
-> Yes
-> No


-> Yes
component(s): - ECM
-> No

between:
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-> Yes
component(s): - ECM
-> No

OR THE MODULE
between:
Pin 01 Pin 03
-> Yes
component(s): - ECM
-> No

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G552275t25 : CHECK THE FRP 5 VOLT SUPPLY CIRCUIT FOR HIGH

RESISTANCE
Pin 03 Pin D2
-> Yes
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-> No
G552275t26 : CHECK THE FRP SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
between:
Pin 03 Pin 02
-> Yes
-> No
G552275t28 : CHECK THE FRP SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
Pin 02 Pin E2
-> Yes
-> No

Pin 03 Pin 02
-> Yes
-> No

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-> Yes
component(s): - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

PRESSURE CONTROL VALVE (FPCV)
AND CIRCUIT
G552275t33 : CHECK THE POWER SUPPLY TO THE FPCV
1.
Circuit Pin
Power 01
Signal from ECM 02
2.
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Circuit Pin
Fuel pressure control valve - signal K3
3. Key off. 4. Disconnect the FPCV connector, C43. 5. Key on, engine off. 6. Measure the voltage
between:
-> Yes
-> No
No supply to the FPCV circuit. Check and repair the circuit as necessary. For additional information,

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G552275t36 : CHECK THE FPCV CONTROL CIRCUIT FOR HIGH RESISTANCE
Pin 02 Pin K3
-> Yes
-> No
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Pin 01 Pin 02
-> Yes
component(s): - FPCV connector - FPCV - ECM connector - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

1.
Circuit Pin
2.
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Circuit Pin
Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
Pin M3 Pin L3
-> Yes
-> No

TO EACH OTHER
Pin M3 Pin L3
-> Yes
-> No
Pin 02 Pin M3
Pin 01 Pin L3
-> Yes
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-> No

GROUND
-> Yes
-> No
-> Yes
-> No

POWER
-> Yes
-> No
-> Yes
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-> No

OR THE THE FUEL INJECTOR
Pin M3 Pin L3
-> Yes
-> No
1.
Circuit Pin
2.
Circuit Pin
Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
1. Key off. 2. Connect the fuel injector 2 (INJ2) connector, C46 connected. 3. Disconnect the ECM
connector, C101. 4. Measure the resistance between:
Pin M2 Pin L2
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-> Yes
-> No
G552275t51 : CHECK for short CIRCUIT BETWEEN THE SIGNAL AND

RETURN CIRCUITS
Pin M2 Pin L2
-> Yes
-> No

Pin 02 Pin M2
Pin 01 Pin L2
-> Yes
-> No
REPAIR the high-resistance. For additional information, refer to the wiring diagrams. Clear any DTCs,

GROUND
-> Yes
-> No


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-> Yes
-> No

POWER
-> Yes
-> No

-> Yes
-> No

Pin M2 Pin L2
-> Yes
-> No

1.
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Circuit Pin
2.
Circuit Pin

Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
Pin M4 Pin L4
-> Yes
-> No

TO EACH OTHER
Pin M4 Pin L4

-> Yes
-> No

Pin 02 Pin M4
Pin 01 Pin L4
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-> Yes
-> No

GROUND
-> Yes
-> No

-> Yes
-> No

POWER
-> Yes
-> No


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-> Yes
-> No

Pin M4 Pin L4
-> Yes
-> No

1.
Circuit Pin
2.
Circuit Pin
Fuel injector, cylinder 4 - control L1
Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
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Pin L1 Pin L2
-> Yes
-> No

TO EACH OTHER
Pin L1 Pin L2
-> Yes
-> No

Pin 02 Pin L1
Pin 01 Pin L2
Are the resistances less than 10 ohm?
-> Yes
-> No

GROUND

-> Yes
-> No


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-> Yes
-> No

POWER

-> Yes
component(s): - Fuel injector 4 (INJ1) connector - Fuel Injector 4 (INJ1) - ECM connector - ECM
-> No

-> Yes
-> No

Pin L1 Pin L2

-> Yes
-> No

1.
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Circuit Pin
2.
Circuit Pin

Pin 02 Pin 01
-> Yes
-> No

RESISTANCE
Pin M1 Pin L3
-> Yes
-> No

RETURN CIRCUITS
Pin M1 Pin L3
-> Yes
-> No

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Pin 02 Pin M1
Pin 01 Pin L3
-> Yes
-> No

GROUND

-> Yes
-> No

-> Yes
-> No

POWER

-> Yes
-> No

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-> Yes
-> No


Pin M1 Pin L3
-> Yes
-> No

1.
Circuit Pin
2.
Circuit Pin
Fuel injector, cylinder 6 - ground M3
Pin 02 Pin 01
-> Yes
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-> No

RESISTANCE
Pin M2 Pin M3
-> Yes
-> No
RETURN CIRCUITS
Pin M2 Pin M3
-> Yes
-> No

Pin 02 Pin M2
Pin 01 Pin M3
-> Yes
-> No

GROUND
-> Yes
-> No
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HARNESS OR the Fuel injector
-> Yes
-> No

POWER
-> Yes
-> No

-> Yes
-> No
Pin M2 Pin M3
-> Yes
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-> No
Fuel Diverter Rail
Removal
injury.
and always observe fuel handling precautions. Failure to follow these instructions may result in
personal injury.
WARNING: Do not carry out any repairs to the fuel system with the engine running. The fuel
pressure within the high-pressure system can be as high as 1650 bar. Failure to follow this
these components. Always install blanking caps to any open orifices or lines.
CAUTION: Do not remove the fuel rail pressure sensor from the fuel injection diverter rail.
NOTE:
If a new fuel rail pressure sensor is to be installed, a new fuel injection diverter rail and fuel rail
pressure sensor must be installed as an assembly.

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2 Clean around the low pressure fuel inlet and return lines, high-pressure fuel supply lines and
. surrounding areas.
3 . Disconnect the low-pressure fuel inlet and return lines.
Install suitable blanking caps to the fuel lines and unions.

5 . NOTE:
Detach the high-pressure fuel supply line clamps.
6
. CAUTION: Make sure that the high-pressure fuel supply line remains in contact with
the fuel injection supply manifold and fuel injection diverter rail until both unions have
NOTE:
Loosen the high-pressure fuel supply lines.

7 Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply
. lines, the fuel injection diverter rail and the fuel injection supply manifolds.
8 NOTE:
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.
injection diverter rail and fuel injection supply manifold.
9
the fuel injection pump and fuel injection diverter rail until both unions have been
detached and cleaned. Failure to follow this instruction may result in foreign matter ingress
CAUTION: Make sure the tool used to loosen the high-pressure fuel supply line
unions is used at the top of the unions as this is where there is most material. Failure to
follow this instruction may result in damage to the unions.
Loosen the high-pressure fuel supply line.
10 Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel
. supply lines, the fuel injection diverter rail and the fuel injection pump.
11 Remove and discard the high-pressure fuel supply line.

.
injection diverter rail and fuel injection pump.
12 . Remove the low-pressure fuel line retaining nut.

13 . Disconnect the fuel rail pressure (FRP) sensor electrical connector.
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14 . Disconnect the low-pressure fuel line.
Install suitable blanking caps to the fuel line and union.
15 . Detach the low-pressure fuel line.

16
. CAUTION: Do not remove the fuel rail pressure sensor from the fuel injection
diverter rail.
NOTE:
If a new fuel rail pressure sensor is to be installed, a new fuel injection diverter rail and
fuel rail pressure sensor must be installed as an assembly.
Remove the fuel injection diverter rail.
Installation
1
times and always observe fuel handling precautions. Failure to follow these instructions
malfunction. Failure to follow this instruction may result in damage to the vehicle.
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when working with these components. Always install blanking caps to any open orifices or
lines. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Do not remove the fuel rail pressure sensor from the fuel injection
diverter rail.
NOTE:
If a new fuel rail pressure sensor is to be installed, a new fuel injection diverter rail and
fuel rail pressure sensor must be installed as an assembly. Failure to follow this
Install the fuel injection diverter rail.

Do not fully tighten the fuel injection diverter rail retaining studs at this
stage.
2 . NOTE:
NOTE:
Install new high-pressure fuel supply lines.
Tighten the high-pressure fuel supply line union 1 to diverter rail to 15 Nm.
3 . Tighten the fuel injection diverter rail retaining studs to 23 Nm.
4 . NOTE:

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Attach the high-pressure fuel supply line clamps.
Tighten to 10 Nm.
5 . NOTE:
Attach the low-pressure fuel line.

6 . NOTE:
Connect the low-pressure fuel line.
7 . Connect the FRP sensor electrical connector.
8 . Install the low-pressure fuel line retaining nut.
Tighten to 7 Nm.
9 NOTE:
.
Install a new high-pressure fuel supply line.
Install but do not tighten the high-pressure fuel supply line.

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Tighten the high-pressure fuel supply line in the sequence shown in four
stages:
Tighten the high-pressure fuel supply line union 1 to fuel injection pump to
15 Nm.
Tighten the high-pressure fuel supply line union 1 to fuel injection pump to
30 Nm.
10 . NOTE:
Connect the low-pressure fuel inlet and return lines.
11 . Install the fuel injector sound proofing.

Fuel Injection Pump
Reaction Arm - Fuel Pump Pulley

310-138
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Holder - Fuel Pump Pulley

310-139
Holder - Camshaft Pulley Rear

303-1125
Removal
1
WARNING: Do not carry out any repairs to the fuel system with the engine running.
The fuel pressure within the high-pressure system can be as high as 1650 bar. Failure to
malfunction.

observed when working with these components. Always install blanking caps to any open
orifices or lines.
CAUTION: Do not disassemble or clean inside the fuel pump, even with an ultrasonic
cleaner. Always install a new fuel pump when required.
NOTE:
If the fuel pump has suffered a major mechanical failure, new fuel injectors should also
be installed.

3 . Remove the fuel injection pump belt cover.

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4 . NOTE:
The fuel injection pump belt is not timed to the engine.
Remove and discard the fuel injection pump belt tensioner.
5 NOTE:
.
The fuel injection pump rotates in an anti-clockwise direction when viewed from the
rear of the engine.
Note the direction of rotation of the fuel injection pump belt.

6 . Remove and discard the fuel injection pump belt.
7 . Remove the camshaft rear pulley retaining bolt.
Remove and discard the camshaft rear pulley retaining bolt.

9 . Remove the injection pump pulley retaining nut.
Remove the injection pump pulley retaining nut.

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11 . Detach the exhaust gas recirculation (EGR) coolant outlet tube.

12 . Remove the fuel injection pump belt rear cover.
14 Clean around the low pressure fuel inlet and return lines, high-pressure fuel supply lines and
. surrounding areas.
15 . Disconnect the low pressure fuel inlet and return lines.
Install suitable blanking caps to the fuel lines and unions.

16 . NOTE:
Detach the high pressure fuel supply line clamps.

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17
with the fuel injection supply manifold and fuel injection diverter rail until both unions
NOTE:

Loosen the high pressure fuel supply lines.
. supply lines, the fuel injection diverter rail and the fuel injection supply manifolds.
19 NOTE:
.
Remove and discard the high pressure fuel supply lines.
injection diverter rail and fuel rail.
20
with the fuel injection pump and fuel injection diverter rail until both unions have been
detached and cleaned. Failure to follow this instruction may result in foreign matter
Loosen the high pressure fuel supply line.

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. supply lines, the fuel injection diverter rail and the fuel injection pump.
22 Remove and discard the high pressure fuel supply line.

.
injection diverter rail and fuel injection pump.
23 . Remove the fuel line retaining nut.

24 . Disconnect the fuel rail pressure (FRP) sensor electrical connector.
26 . Detach the fuel line.

27
. CAUTION: Do not remove the fuel rail pressure sensor from the fuel injection
diverter rail.
Remove the fuel injection diverter rail.

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28 . Disconnect the left-hand camshaft cover breather hose.
29 . Disconnect the right-hand camshaft cover breather hose.

30 . Disconnect the left-hand inlet port deactivation vacuum hose.
31 Remove the crankcase vent oil separator.

.
Remove and discard the crankcase vent oil separator and engine block
seals.
32 . Disconnect the fuel injection pump electrical connectors.

33 NOTE:
.
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clockwise.
minutes.
34 . Detach the left-hand glow plug electrical connector.

35 . Detach the right-hand glow plug electrical connector.
36 . Remove the right-hand rear engine lifting bracket.
37 . Reposition the crankcase vent oil seperator pipes.
1) Detach the crankcase vent oil seperator pipes.
2) Reposition the crankcase vent oil seperator pipes.

38 . Remove the fuel injection pump.
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Installation
1
malfunction.

when working with these components. Always install blanking plugs to any open orifices or
lines.
CAUTION: Do not disassemble or clean inside the fuel pump, even with an ultrasonic
cleaner. Always install a new fuel pump when required.
CAUTION: Install new high pressure fuel supply lines. Failure to follow this
Install the fuel injection pump.
Tighten to 23 Nm.
2 . Attach the crankcase vent oil seperator pipes.
1) Reposition the crankcase vent oil seperator pipes.

2) Attach the crankcase vent oil seperator pipes.
Tighten to 10 Nm.
3 . Install the right-hand rear engine lifting bracket.

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Tighten to 10 Nm.
4 NOTE:
.
Make sure glow plug electrical connector is correctly fitted to all glow plugs on the right-
hand bank.
Attach the right-hand glow plug electrical connector.

5 NOTE:
.
Make sure glow plug electrical connector is correctly fitted to all glow plugs on the left-
hand bank.
Attach the left-hand glow plug electrical connector.
6 . NOTE:
Tighten to 25 Nm.
7 . Connect the fuel pump electrical connectors.

8 . Install the oil separator housing.
Install new crankcase vent oil separator and engine block seals.
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9 . Connect the left-hand inlet port deactivation vacuum hose.
10 . Connect the left-hand camshaft cover breather hose.

11 . Connect the right-hand camshaft cover breather hose.
12 Install the fuel injection diverter rail.

.
Do not fully tighten the fuel injection diverter rail retaining bolts at this
stage.
13 NOTE:
.
Install new high pressure fuel supply lines.

Tighten the fuel injection diverter rail retaining bolts to 23 Nm.
stages:
Stage 1: Tighten the high-pressure fuel supply line union 1 to 15 Nm.

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14 . NOTE:
Attach the high pressure fuel supply line clamps.
Tighten to 10 Nm.
15 . Attach the fuel line.
Remove and discard the blanking caps.
17 . Connect the FRP sensor electrical connector.
18 . Attach the fuel line retaining nut.
Tighten to 7 Nm.
19 Install a new high pressure fuel supply line.
.
Install but do not tighten the high pressure fuel supply line.
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stages:
20 . Connect the low pressure fuel inlet and return lines.

21 . Install the fuel injector sound proofing.
22 . Install the fuel injection pump belt rear cover.
Tighten to 7 Nm.
23 . Attach the EGR coolant outlet tube.
Tighten to 10 Nm.
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Tighten to 50 Nm.

27 . Install the new camshaft rear pulley retaining bolt.
Tighten the camshaft rear pulley retaining bolt in two stages:
Tighten to 80 Nm.
Tighten a further 90°.
28 NOTE:
.
The fuel injection pump rotates in an anti-clockwise direction when view from the rear
of the engine.
Note the direction of rotation of the fuel injection pump belt.

29
. CAUTION: Do not install the new fuel injection pump belt to the pulleys with the
fuel injection pump belt tensioner installed. Failure to follow this instruction may result in
damage to the fuel injection pump drive belt.
NOTE:
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Make sure the new fuel injection pump belt is correctly seated on to the fuel injection
pump drive pulleys.
Install a new fuel injection pump belt.
30
. CAUTION: Make sure the fuel injection pump belt tensioner tang is correctly
located to the fuel injection pump cover backplate. Failure to follow this instruction may
result in damage to the components.
Install the new fuel injection pump belt tensioner.
Locate the tang on the new fuel injection pump belt tensioner into the fuel
injection pump cover backplate.
31 NOTE:
.
Do not remove the fuel injection pump belt tensioner locking pin before installing the
new tensioner.
Install the new fuel injection pump belt tensioner retaining bolt.
Tighten to 25 Nm.
32 . Remove and discard the fuel injection pump belt tensioner locking pin.
33 . Install the fuel injection pump belt cover.

35 . Connect the battery.

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36 . Bleed the high-pressure fuel system.

Fuel Injector (18.10.01)
Fuel Injector Remover

303-1127
Removal
injury.
personal injury.
pressure within the high-pressure fuel system can be as high as 1650 bar. Failure to follow this
Failure to follow this instruction may result in serious damage to the vehicle.
www.JagDocs.com
CAUTION: Do not disassemble the fuel injectors or clean the nozzles, even with an
ultrasonic cleaner. Always install new fuel injectors when required.


3 Remove the exhaust gas recirculation (EGR) valve outlet tube.

(17.45.11)

7
. CAUTION: Protect the fuel injector electrical connectors with lint-free material to
prevent contamination from the cleaning fluid. Failure to follow this instruction may result
in serious damage to the vehicle.
Clean the fuel injector, high-pressure fuel supply line and surrounding areas.
8 . NOTE:
9 . NOTE:
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Detach the fuel injection wiring harness.
10 . Clean around the fuel injector, high-pressure fuel supply line and surrounding areas.
11
in serious damage to the vehicle.
NOTE:
Loosen the high-pressure fuel supply line from the fuel injector and fuel rail.
12
supply line, the fuel injector and the fuel rail.
13 NOTE:
.
Remove and discard the high-pressure fuel supply line.
injector and the fuel rail.
14 Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the
. fuel rail.
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15 NOTE:
.
Disconnect the fuel return line from the fuel injector.
Remove and discard the fuel return line retaining clip from the fuel
injector.
Disconnect the fuel return line from the fuel injector.
16 . NOTE:

Remove the fuel injector retaining bolts.
17 . NOTE:
Install the special tool studs.
18
NOTE:

19
follow this instruction may result in damage to the special tool or fuel injector.
NOTE:
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Using the special tool, remove the fuel injector.
Remove the fuel injector.
Remove and discard the fuel injector retaining clamp.
Remove and discard the fuel injector sealing washer.

Installation
injury.
personal injury.
pressure within the high-pressure fuel system can be as high as 1650 bar. Failure to follow this
Failure to follow this instruction may result in serious damage to the vehicle.
CAUTION: Do not disassemble the fuel injectors or clean the nozzles, even with an
ultrasonic cleaner. Always install new fuel injectors when required.
1
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. CAUTION: Do not use tools to install the new fuel return line retaining clip. Failure
to follow this instruction may result in damage to the retaining clip.
NOTE:
Install a new fuel return line retaining clip.
NOTE:
Install a new fuel injector sealing washer.
NOTE:

2 . NOTE:
Install the fuel injector.
Tighten to 10 Nm.
3
. CAUTION: Make sure the fuel return line retaining clip is correctly installed to the
fuel injector before installing the fuel return line.
NOTE:
Visually inspect the fuel return line O-ring for damage.
Apply a light coating of petroleum jelly to the fuel line return line O-ring.

4
supply line as this may damage the ends of the line and allow foreign matter enter the fuel
injection system.
Position the high-pressure fuel supply line as near to the final installation position as possible
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and then remove and discard the blanking plugs from the high-pressure fuel supply line.
5
. CAUTION: Maintain pressure on the high-pressure fuel supply line to keep the olives
in contact with the fuel injectors and the fuel injection supply manifold cones while
installing the unions.
NOTE:
injector end.
NOTE:
Install the new high-pressure fuel supply line.
Tighten the high-pressure fuel supply line union 1 to fuel injector to 15 Nm.
Tighten the high-pressure fuel supply line union 1 to fuel injector to 30 Nm.
6 . NOTE:
Attach the fuel injection wiring harness.
7 . NOTE:

Tighten to 4 Nm.
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11 Install the EGR valve outlet tube.
(17.45.11)


14
. WARNING: Do not carry out any repairs to the fuel system with the engine
NOTE:
The fuel return line must be renewed if any leaks are found from the fuel return line O-
rings.

Fuel Rail
Removal
1
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malfunction.
observed when working with these components. Always install blanking caps to any open
orifices or lines.


3 . NOTE:
Remove the injector sound proofing.
4 . NOTE:
Detach the injector harness from the fuel rail.

5 . Clean around the high-pressure fuel supply line and surrounding areas.
6 . NOTE:
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Remove the high pressure fuel supply line clamp retaining bolt.
7
the fuel rail and fuel injection diverter rail until both unions have been detached and
injection system.
NOTE:
Loosen the high pressure fuel supply line.
8 Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply
. line, the fuel injection diverter rail and the fuel rail.
9 NOTE:
.
Remove and discard the high pressure fuel supply line.
injection diverter rail and fuel rail.
10
. CAUTION: Make sure that the high-pressure fuel supply lines remain in contact
with both the fuel injectors and the fuel rail until all unions have been detached and
injection system.
CAUTION: Do not use any aggressive cleaning fluid or a wire brush to clean the
fluid injector nozzle.
11
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. CAUTION: Make sure that the high-pressure fuel supply lines remain in contact
with both the fuel injectors and the fuel rail until all unions have been detached and
injection system.
CAUTION: Make sure that the fuel injector adaptor unions do not move when
in damage to the fuel injectors or the fuel injector adaptor unions.
NOTE:
Left-hand shown, Right hand similar.
12 NOTE:
.
Left-hand shown, Right hand similar.
injectors and the fuel rail.
13 . NOTE:

Remove the fuel rail.
Installation
1
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malfunction.

when working with these components. Always install blanking caps to any open orifices or
lines.
NOTE:
Install the fuel rail.
Tighten to 24 Nm.
2
injection system.
Position the high-pressure fuel supply lines as near to the final installation position as possible
and then remove and discard the blanking plugs from the high-pressure fuel supply lines and
fuel rail.
3
. CAUTION: Do not allow the unions to hit the olive end of the high-pressure fuel
supply line and allow foreign matter to enter the fuel injection system.
CAUTION: Maintain pressure on the high pressure fuel supply line to keep the olives
in contact with the fuel injectors and the fuel rail cones while installing unions.
NOTE:
Install the new high-pressure fuel supply lines.
Install the new high-pressure fuel supply line, tighten the fuel supply line
1)
unions finger tight.
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Tighten the high-pressure fuel supply lines in the sequence shown in four
stages:

4
injection system.
NOTE:
Install new high-pressure fuel supply line.
Install the new high-pressure fuel supply line, tighten the fuel supply line
1)
unions finger tight.
stages:
5 . NOTE:
Attach the injector harness to the fuel rail.

6 . NOTE:
Install the injector sound proofing.

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Removal

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9 . Detach the exhaust gas recirculation (EGR) valve outlet tube retaining clips.
Discard the retaining clips.
10 . Remove the right-hand EGR valve outlet tube retaining bolt.

11 . Detach the wiring harness from the left-hand EGR valve outlet tube retaining bracket.
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12 . Remove the left-hand EGR valve outlet tube retaining bolt.
13 . NOTE:
NOTE:
Remove the right-hand and left-hand EGR valve outlet tubes.

Discard the gaskets.
16

17

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18
19 . Remove and discard the intake air shutoff throttle seals.

Installation
1 . NOTE:
Engine removed for clarity.
NOTE:
Right-hand shown, left-hand similar
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Swirl Plate Actuator Diaphragm
Removal
NOTE:
Removal steps in this procedure may contain installation details.

2 . Remove the wiring harness cover.
Release the 7 clips.
3 . Remove the wiring harness carrier.
Remove the 4 bolts.

4 . Remove the RH injector sound proofing.

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5 Check the port deactivation hoses are a secure fit onto the stub pipe and for signs of being
. trapped or chaffing.
If the valve does not hold vacuum continue with the replacement of the
diaphragm.
If the valve holds vacuum check the valve on the other side of the engine.
If one side is found not to hold vacuum then both diaphragms are to be
changed.
6 . Disconnect the port deactivation valve vacuum hoses.

7 NOTE:
.
Check the vacuum gauge and any hoses to be used for leaks prior to using on the
vehicle.
NOTE:
Make sure the vacuum gauge hose is a secure fit to the port deactivation diaphragm
caps.
Using a vacuum gauge, check the port deactivation valve diaphragms.

8 NOTE:
.
Some variation in the illustrations may occur, but the essential information is always
correct.
Remove the engine bay brace.

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9 . Release the port deactivation valve connecting rod.
10 NOTE:
.
Cut the retaining clips off the old port deactivation diaphragm caps to aid removal.
NOTE:
Make sure the valve cover is not damaged during removal of the port deactivation
diaphragm cap.
Remove the port deactivation valve cap.
Check the diaphragm for splits or damage.
11 . Remove the port deactivation valve spring.
12 . Remove the port deactivation valve connecting rod and diaphragm.

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Installation
1 . NOTE:
Apply a small amount water to the diaphragm to aid installation.

NOTE:
Make sure the diaphragm is fully seated on the connecting rod.
Install the new port deactivation diaphragm to the new connecting rod.
2
. CAUTION: Make sure that the mating faces are clean and free of foreign material.
CAUTION: Make sure the port deactivation rod is correctly aligned to the port
deactivation valve arm.
NOTE:
Make sue the new port deactivation diaphragm and rod are installed in the correct
orientation to the port deactivation linkage.
Install the port deactivation vale connecting rod and diaphram.

3 . Install the port deactivation valve spring.
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4
. CAUTION: Using a mirror check all clips are fully latched.
CAUTION: Make sure the port deactivation rod is not rotated once the cap has been
installed, if rotation occurs the diaphragm will be damaged.
NOTE:
An audible click is heard when the clips are fully latched.

Install the port deactivation valve cap.
Make sure the cap is correctly aligned within the timing marks.
Secure the clips in the sequence shown.
5 . Attach the port deactivation valve connecting rod.
6 . Repeat the above procedure on the opposite side.

7 NOTE:
.
Check the vacuum gauge and any hoses to be used for leaks prior to using on the
vehicle.
Check the port deactivation valve diaphragms using a vacuum gauge.

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8 NOTE:
.
When the LH hose is re-connected to the valve the right angle bend must be turned
downwards, make sure the hose lies correctly in the gap between the engine cover
support and the valve cover.
Connect the port deactivation valve vacuum hoses.

9 . Position the port deactivation hose as shown in illustration.
10 . Install the RH injector sound proofing.
Secure with the clips.
11 . Install the wiring harness cover.
Secure in the clips.

12 . Install the wiring harness carrier.
Install the bolts. TORQUE: 10 Nm

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14
. CAUTION: Correct installation of the oil filler cap can be obtained by tightening the
cap until an audible click is heard.
Install the engine cover.

303-04D : Fuel Charging and Controls – Turbocharger –
2.7L Diesel
Specifications
Specifications

Oil supply tube union to turbocharger retaining bolt 30 22 –
Oil supply tube to cylinder block retaining bolt 10 – 89
Oil return tube to turbocharger retaining bolts 10 – 89
Oil return tube to cylinder block retaining bolt 10 – 89
Turbocharger to exhaust manifold retaining nuts 23 17 –
Turbocharger support bracket retaining bolts 23 17 –
Turbocharger heatshield retaining bolts 10 – 89
Turbocharger
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1 — Exhaust manifold
2 — Exhaust manifold studs
3 — Turbocharger mounting flange

4 — Turbocharger
5 Turbocharger retaining nuts
6 Exhaust manifold stud (note orientation of stud)
Variable Vane Turbocharger

The engine is fitted with twin variable vane Turbochargers, electronically controlled, one to each
bank. The turbochargers are fixed to the exhaust manifold by a three hole flange. The turbocharger
consists of two elements, a turbine and a compressor both installed on a single shaft.
The turbocharger bearings are supplied with oil from the engine.
The turbine uses the flow of the exhaust gas to drive the compressor. The compressor draws air
through the air cleaner and forces it into the intake manifold.
Principles of Operation - Variable vane turbocharger

The turbocharger is designed to improve engine induction and engine performance. The list below
details the concerns relating to turbocharger performance.
High engine speed produces excessive turbine speed and therefore creates excessive
turbocharger boost pressure.
Low engine speed does not produce sufficient turbine speed and therefore not enough
turbocharger boost pressure is achieved.
The turbocharger does not have a wastegate control valve. Instead, it has variable turbocharger
vanes which are located in the turbocharger turbine housing and these direct the air flow into the
turbocharger turbine. The turbocharger vanes act as the control for the turbocharger boost pressure.
The turbocharger produces its full turbocharger boost pressure over the entire engine speed range,
not just at high engine speed. This is achieved through the adjustment of the vanes and the resulting
change in the flow of the exhaust gas.
The speed of the exhaust gas flow within the turbocharger is increased independent of engine speed
by varying the intake cross section in front of the turbocharger turbine. This is achieved by adjusting
the angle of the vanes controlling the air flow into the turbocharger turbine and this then drives the
turbocharger turbine faster. The higher turbocharger speed produces a high turbocharger boost
pressure at all engine speeds.
The engine control module (ECM) controls the turbocharger vanes by means of an electronic vane
adjustment solenoid attached to the turbocharger.
Regulation at Low Engine Speed
At low engine speeds the ECM operates the vane adjustment solenoid. The vane adjustment solenoid
moves the adjusting ring so that the vanes are set at a shallow angle. The shallow intake cross section
this creates for the stream of exhaust gas allows the turbocharger boost pressure to build up rapidly
and easily at low engine speeds.
Regulation at Moderate Engine Speed

As the engine speed increases and the quantity of exhaust gas increases, the vane adjustment
solenoid moves the adjusting ring so that the vanes are set at a steeper angle. The steeper angle
opens the intake cross section effectively reducing the gas flow, and turbine speed, while
maintaining constant turbocharger boost pressure.
Regulation at Maximum Engine Speed

As the engine speed increases the intake cross section in front of the turbocharger turbine is
continuously enlarged. The turbine speed and hence the quantity of the air supplied to the engine, is
adjusted to suit the engine speed. This means that the turbocharger boost pressure remains
optimized over all engine speeds.
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The maximum position of the turbocharger vanes (maximum opening cross section) is also an
emergency position, in the event of an electrical concern. This lowers the chance of engine damage
due to excessive boost in the event of a turbocharger control concern.
Turbocharger
The turbochargers used on the 2.7L diesel engine are variable geometry units, which means that the
amount of boost generated can be varied according to the engine load, not just the engine speed.
The vane angles are varied by solenoids mounted on the turbochargers.
The solenoid operation is governed by the engine control module in response to engine load and
conditions, ensuring the correct boost pressure for the prevailing conditions.

Turbocharger
Overview
WARNING: The following tests may involve working in close proximity to hot components.
Make sure adequate protection is used. Failure to follow this instruction may result in personal
injury.
WARNING: The turbochargers can continue to rotate after the engine has stopped. Do not
attempt to check the turbochargers until one minute has elapsed since the engine was switched
off. Failure to follow this instruction may result in personal injury.
NOTE:
NOTE:
NOTE:
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Intake air system Circuit(s)
Hose(s)/hose connections Turbocharger actuator(s)
Turbocharger(s) Engine control module (ECM)
General engine condition. Electrical connections and harnesses to the turbocharger(s)
Symptom chart
Check the fuel level and condition,

Low/Contaminated fuel Fuel Charging and Controls Check the air intake
for restriction,
Poor Restricted air intake system Intake Air Distribution and Filtering Check the
performance engine condition, compressions, etc,
General engine condition Engine - 2.7L Diesel Check for DTCs. Refer to the
warranty policy and procedures manual if an
ECM failure
ECM is suspect.
Electrical connections and Check the electrical connections and harnesses
harnesses to the
to the turbocharger(s). Check the air intake for
turbocharger(s)
restriction/leakage (see visual inspection). For air
Restricted air intake system intake checks,
Intake Air Distribution and Filtering For
Charge air cooler turbocharger actuator tests, GO to Pinpoint Test
No boost
restricted/leaking G552276p2.
and GO to Pinpoint Test G552276p3.
Turbocharger actuator For turbocharger mechanical checks, GO to
failure(s)
Turbocharger failure(s) Refer to the warranty policy and procedures
ECM failure
No
For turbocharger mechanical checks, GO to
boost/excessive
Turbocharger failure Pinpoint Test G552276p1.
noise
DTC index
NOTE:
NOTE:

VGT actuator circuit:

high resistance For right hand bank VGT
actuator circuit tests, GO to
Variable geometry VGT actuator circuit:
P004500 turbocharger (VGT) actuator short circuit to
ground Refer to the warranty policy
open circuit (right hand bank)
VGT actuator failure ECM is suspect.
ECM failure
circuit low (right hand bank)
ECM failure
VGT actuator circuit: For right hand bank VGT
short circuit to actuator circuit tests, GO to
Variable geometry
P004800 turbocharger (VGT) actuator
circuit high (right hand bank) VGT actuator failure and procedures manual if an
ECM is suspect.
ECM failure
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high resistance For left hand bank VGT

P004A00 turbocharger (VGT) actuator short circuit to
open circuit (left hand bank)
ECM failure
VGT actuator circuit: For left hand bank VGT
Variable geometry
P004C00 turbocharger (VGT) actuator
circuit low (left hand bank) VGT actuator failure and procedures manual if an
ECM is suspect.
ECM failure

Variable geometry
P004D00 turbocharger (VGT) actuator
circuit high (left hand bank) VGT actuator failure and procedures manual if an
ECM is suspect.
ECM failure
VGT actuator circuit(s): For right hand bank VGT
Variable geometry high resistance, actuator circuit tests, GO to
P132A00 turbocharger (VGT) actuator H short circuit to
bridge fault (right hand bank) ground, short
circuit to power Refer to the warranty policy
and procedure manual if an
Turbocharger vanes ECM is suspect.
stuck/sticking
VGT actuator failure
ECM failure
VGT actuator circuit(s):
high resistance,
short circuit to For right hand bank VGT
Variable geometry ground, short actuator circuit tests, GO to
circuit to power
turbocharger (VGT) actuator Pinpoint Test G552276p2.
P132B00
performance (right hand Turbocharger vanes Refer to the warranty policy
bank) stuck/sticking and procedure manual if an
ECM is suspect.
ECM failure
high resistance,
short circuit to For left hand bank VGT
ground, short actuator circuit tests, GO to
Variable geometry circuit to power
P132D00 turbocharger (VGT) actuator H
Turbocharger vanes Refer to the warranty policy
bridge fault (left hand bank)
stuck/sticking and procedure manual if an
ECM is suspect.
ECM failure
high resistance,
short circuit to For left hand bank VGT
ground, short actuator circuit tests, GO to
Variable geometry circuit to power
P132E00 turbocharger (VGT) actuator
Turbocharger vanes Refer to the warranty policy
performance (left hand bank)
stuck/sticking and procedure manual if an
ECM is suspect.
ECM failure
For left hand bank VGT
Variable geometry VGT actuator circuit(s): actuator circuit tests, GO to
high resistance,
P132F00 short circuit to
voltage plausibility (left hand ground, short Refer to the warranty policy
bank) circuit to power and procedure manual if an
ECM is suspect.
ECM failure
high resistance,
Variable geometry For right hand bank VGT
short circuit to
P138E00 turbocharger (VGT) actuator actuator circuit tests, GO to
ground, short
adaption (right hand bank) circuit to power Pinpoint Test G552276p2.

Air leakage
MAP sensor circuit:

high resistance
Check for air leakage.
MAP sensor circuit:
short circuit to
ground Filtering For MAP sensor tests.
Electronic Engine Controls For
Turbocharger overboost
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MAP sensor circuit: EGR tests.

condition, manifold absolute
P023400 short circuit to Engine Emission Control Check
pressure (MAP) sensor control power for DTCs indicating a
deviation
turbocharger fault. Refer to
MAP sensor failure
the warranty policy and
Exhaust gas procedures manual if an ECM
recirculation (EGR) is suspect.
fault
Turbocharger fault
ECM failure
high resistance

Variable geometry short circuit to actuator circuit tests, GO to
ground
P023600
circuit range/performance VGT actuator circuit: Refer to the warranty policy
(right hand bank) short circuit to and procedures manual if an
ECM failure
P023700 Variable geometry high resistance actuator circuit tests, GO to
turbocharger (VGT) actuator
circuit low (right hand bank) VGT actuator circuit: Refer to the warranty policy
short circuit to and procedures manual if an
ground ECM is suspect.
ECM failure
Variable geometry
circuit high (right hand bank) VGT actuator failure and procedures manual if an
ECM is suspect.
ECM failure
high resistance

Variable geometry short circuit to actuator circuit tests, GO to
ground
P024000
circuit range/performance VGT actuator circuit: Refer to the warranty policy
(left hand bank) short circuit to and procedures manual if an
ECM failure
circuit low (left hand bank)
ECM failure
Variable geometry
circuit high (left hand bank) VGT actuator failure and procedures manual if an
ECM is suspect.
ECM failure
IAT sensor circuit(s):
P226300 Turbocharger boost system For IAT, MAP and MAF sensor
high resistance,
performance, manifold tests.
short circuit to
absolute pressure (MAP) ground, short Electronic Engine Controls For
sensor control deviation circuit to power EGR tests.
Engine Emission Control For
MAP sensor circuit(s): VGT actuator tests. GO to
high resistance,
short circuit to
ground, short and GO to Pinpoint Test
circuit to power G552276p3.
MAF sensor circuit(s): and procedures manual if an
high resistance, ECM is suspect.
short circuit to
ground, short
circuit to power
EGR circuit(s): high

resistance, short
circuit to ground,
short circuit to
power
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Turbocharger vanes
stuck/sticking
ECM failure
MAP sensor circuit:
high resistance
MAP sensor circuit:

short circuit to
For MAP sensor tests.
ground
Electronic Engine Controls For
MAP sensor circuit: EGR tests.
Turbocharger underboost
short circuit to Engine Emission Control Check
condition, manifold absolute
P029900 power for DTCs indicating a
pressure (MAP) sensor control
turbocharger fault. Refer to
deviation MAP sensor failure the warranty policy and
procedures manual if an ECM
Exhaust gas
recirculation (EGR) is suspect.
fault
Turbocharger fault
ECM failure
Pinpoint Tests
CAUTION: Do not insert any tools into the turbocharger body. Failure to follow this
NOTE:
A small amount of oil inside the turbocharger body, visible when the hoses are disconnected, is
normal.
NOTE:
A small amount of play in the turbine shaft is normal. If in any doubt, compare with a known
good unit.
NOTE:
NOTE:
NOTE:
terminals.
THE TURBOCHARGER MECHANICAL
CONDITION
G552276t1 : CHECK FOR EXCESSIVE PLAY IN THE TURBOCHARGER SHAFT
1. Disconnect the intake and outlet hoses from the turbocharger. 2. Check that the turbocharger
rotates freely, and without noise. 3. Grip the ends of the turbine shaft at either side of the
turbocharger and assess the play.
Is the play in the shaft excessive? (Compare the play to a known good unit in the event of
uncertainty).
-> Yes
INSTALL a new turbocharger.
Turbocharger LH
Turbocharger RH CLEAR any DTCs, test the vehicle for normal operation.
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-> No
CHECK for other sources of noise. Refer to the symptom chart for diagnosing the turbocharger
system for the cause of the lack of boost.

THE ROTARY ELECTRONIC
ACTUATOR CIRCUIT A
G552276t2 : CHECK THE ROTARY ELECTRONIC ACTUATOR GROUND
1. Rotary Electronic Actuator connector, C40,
Circuit Pin
(+) pwm motor C40 - 01
(-) pwm motor C40 - 02
Ground C40 - 03
ECM feedback C40 - 04
5volt supply C40 - 05

2. Powertrain Control Module (PCM) connector, C99,
Circuit Pin
(+) pwm motor C99 - J2
(-) pwm motor C99 - K2
Ground C99 - G3
PCM feedback C99 - C4
5volt supply C99 - D1
3. 4. Disconnect the connector, C40. 5. Key on, engine off. 6. Measure the resistance between:
Is the resistance less than 0.5 ohms?
-> Yes
-> No
Repair the high resistance circuit. For additional information, refer to the wiring diagrams. Clear any
G552276t3 : CHECK THE POWER SUPPLY TO THE ROTARY ELECTRONIC

ACTUATOR
Is the voltage between 4.5 volts and 5 volts?

-> Yes
-> No
Repair the power circuit. For additional information, refer to the wiring diagrams. Clear any DTCs,
G552276t4 : CHECK THE ROTARY ELECTRONIC ACTUATOR FEEDBACK

1. 2. Measure the resistance between:

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Is the resistance greater than 10 Kohms (+/-10%) ?
-> Yes
-> No

-> Yes
-> No

1. Disconnect the ECM connector, C99. 2. Measure the resistance between:
Pin 04 Pin C4
-> Yes
-> No

1. 2. Disconnect the ECM connector, C99. 3. Key on, Engine off. 4. Measure the resistance between:
-> Yes
component(s): - ECM
-> No
Repair the short circuit. For additional information, refer to the wiring diagrams. Clear any DTCs, test
1. Key off. 2. Disconnect the ECM connector, C99. 3. Key on, Engine off. 4. Measure the resistance
between:
-> Yes
component(s): - ECM
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-> No
G552276t16 : CHECK THE ROTARY ELECTRONIC ACTUATOR PWM+ CIRCUIT

-> Yes
-> No

-> Yes
-> No

FOR HIGH RESISTANCE
Pin 01 Pin J2
-> Yes
-> No

between:

-> Yes
component(s): - ECM
-> No

between:

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-> Yes
component(s): - ECM
-> No
G552276t21 : CHECK THE ROTARY ELECTRONIC ACTUATOR PWM- CIRCUIT

Pin 02 Pin 03

-> Yes
-> No
G552276t22 : CHECK THE TURBOCHARGER PWM- CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No

FOR HIGH RESISTANCE
Pin 02 Pin K2
-> Yes
component(s): - Connector C40 - ECM connector - Turbocharger 1 (right-hand bank) - ECM
-> No

between:
-> Yes
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component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No
THE ROTARY ELECTRONIC
ACTUATOR CIRCUIT B
G552276t9 : CHECK THE ROTARY ELECTRONIC ACTUATOR GROUND
1. Rotary Electronic Actuator connector, C41
Circuit Pin
(+) pwm motor C41 - 01
(-) pwm motor C41 - 02
Ground C41 - 03
PCM feedback C41 - 04
5volt supply C41 - 05
2. Powertrain Control Module (PCM) connector, C99,
Circuit Pin
(+) pwm motor C99 - J3
(-) pwm motor C99 - K3
Ground C99 - D2
PCM feedback C99 - B4
5volt supply C99 - D1
3. 4. Disconnect the connector, C41. 5. Key on, Engine off. 6. Measure the resistance between:

-> Yes
-> No
G552276t10 : CHECK THE POWER SUPPLY TO THE ROTARY ELECTRONIC

ACTUATOR

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Is the voltage 4.5 volts and 5 volts?
-> Yes
-> No
Repair the power circuit. For additional information, refer to the wiring diagrams. Clear any DTCs,

1. 2. Measure the resistance between:
-> Yes
-> No

-> Yes
-> No

Pin 04 Pin B4
-> Yes
-> No
1. 2. Disconnect the ECM connector, C99. 3. Key on, engine off. 4. Measure the resistance between:
-> Yes
component(s): - ECM
-> No
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between:
-> Yes
component(s): - ECM
-> No

-> Yes
-> No

-> Yes
-> No

FOR HIGH RESISTANCE
Pin 01 Pin J3
-> Yes
-> No

between:

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-> Yes
component(s): - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

-> Yes
-> No

-> Yes
-> No

FOR HIGH RESISTANCE
Pin 02 Pin K3
-> Yes
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component(s): - Connector C41 - ECM connector - Turbocharger 2 (left-hand bank) - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No
between:
-> Yes
component(s): - ECM
-> No
Turbocharger LH
Removal

3 . Remove the turbocharger heatshield.

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4 . Remove the turbocharger support bracket.
5 . Remove the turbocharger outlet pipe retaining bolt.

6 . Disconnect the turbocharger outlet pipe.
7 . Remove the turbocharger outlet pipe from the turbocharger.
8 Detach the crankshaft position (CKP) sensor wiring harness from the oil return tube retaining
. plate.
9 . Detach the turbocharger oil return tube.
Install blanking caps to the exposed ports.
10 . Remove the turbocharger oil return tube from the turbocharger.

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11 . Detach the turbocharger intake tube.

12 . Disconnect the turbocharger solenoid electrical connector.
14 . Disconnect the turbocharger oil supply tube.
Remove and discard the sealing washer.
16 Remove the turbocharger.

.
Remove and discard the turbocharger retaining nuts.
Remove and discard the turbocharger to exhaust manifold retaining

studs.

Installation
1 . Install the turbocharger.
Install new turbocharger to exhaust manifold retaining studs.

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Install new turbocharger retaining nuts.
Tighten to 23 Nm.
3 . Connect the turbocharger oil supply tube.
Install a new sealing washer.
Tighten to 30 Nm.
5 . Connect the turbocharger solenoid electrical connector.
6 . Attach the air cleaner lower outlet tube.
7 . Install the turbocharger oil return tube to the turbocharger.

Tighten to 10 Nm.
8 . Attach the turbocharger oil return tube.

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Tighten to 10 Nm.
9 . Attach the CKP sensor wiring harness to the oil return tube retaining plate.
10 . Install the turbocharger outlet hose to the turbocharger.

11 . Connect the turbocharger outlet pipe.
12 . Install the turbocharger outlet pipe retaining bolt.
13 . Install the turbocharger support bracket.
Tighten to 23 Nm.
14 . Install the turbocharger heatshield.
Tighten to 6 Nm.
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15 . Install the turbocharger heatshield retaining nut.
Tighten to 10 Nm.
16 . Install the left-hand catalytic converter.


Turbocharger RH
Removal

For additional information, refer to Catalytic Converter - 2.7L V6 - TdV6 (17.50.05)
2 . Remove the right-hand engine mount.

For additional information, refer to Engine Mount RH (12.45.03)
4 . Using a suitable piece of string, secure the steering gear.
5 . Remove the starter motor securing bracket.


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8 . Detach the wiring harness from the engine mount retaining bracket.
9 . Remove the engine mount retaining bracket.

10 . Remove the turbocharger heatshield.
11 . Remove the turbocharger support bracket.
12 . Disconnect the oil return tube from the turbocharger.

13 . Remove the oil return tube retaining plate.

14 . Remove the oil return tube.
15 . Disconnect the turbocharger solenoid electrical connector.

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16 . Disconnect the turbocharger oil supply tube.

Remove and discard the sealing washer.
17 . Remove the turbocharger.

Remove and discard the turbocharger retaining nuts.
Remove and discard the turbocharger to exhaust manifold retaining studs.

Installation

Install new turbocharger to exhaust manifold retaining studs.
Install new turbocharger retaining nuts.
Tighten to 23 Nm.
Install a new sealing washer.
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303-05 : Accessory Drive
Specifications
Specifications
lb- lb-
Description Nm
ft in
Accessory drive belt tensioner retaining bolt - Vehicles with 3.0L engine 45 33 -
Accessory drive belt tensioner retaining bolt - Vehicles with 2.7L diesel
47 35 -
engine
Accessory drive belt tensioner retaining bolt - Vehicles with 3.5L or 4.2L
40 30 -
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engine
Accessory drive belt idler pulley retaining bolt - Vehicles with 3.0L, 3.5L or
25 18 -
4.2L engine
Accessory drive belt idler pulley retaining bolt - Vehicles with 2.7L diesel
47 35 -
engine
Fuel injection pump belt rear cover retaining bolts - Vehicles fitted with 2.7L
7 - 62
diesel engine
Camshaft rear pulley retaining bolt - Vehicles fitted with 2.7L diesel engine A - -
Fuel injection pump pulley - Vehicles fitted with 2.7L diesel engine 50 37 -
Fuel injection pump belt tensioner retaining bolt - Vehicles fitted with 2.7L
25 18 -
diesel engine
Supercharger belt tensioner retaining bolt 40 30 -
Supercharger belt idler pulley retaining bolt 25 18 -
A = refer to procedure for correct tightening sequence

Accessory Drive
1 — Accessory drive belt idler pulley
2 — Water pump pulley
4 — Power steering pump pulley
5 — Accessory drive belt tensioner
6 — Air conditioning (A/C) compressor pulley
7 — Crankshaft pulley
8 — Generator pulley
Vehicles with 2.7L diesel engine
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1 Generator pulley
2 Accessory drive belt idler pulley
3 Power steering pump pulley
4 Air conditioning (A/C) compressor pulley
5 Water pump pulley
6 Crankshaft pulley
7 Accessory drive belt tensioner

1 — Water pump pulley
2 — Accessory drive belt tensioner
3 — Power steering pump pulley
4 — Air conditioning (A/C) compressor pulley
7 — Generator pulley
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1 — Supercharger pulley
2 — Supercharger belt idler pulley
4 — Supercharger belt tensioner
Crankshaft Pulley
The combined crankshaft pulley and torsional vibration damper drives a single, six ribbed vee belt.
The belt drives all of the engine-mounted accessories such as the generator, the power assisted
steering pump, the air-conditioning compressor and the coolant water pump.
Air Conditioning Compressor Pulley

This is positioned at the lowest point of the front-end accessory drive on the left-hand side accessory
mounting.
Power Assisted Steering Pump Pulley

The power assisted steering pump pulley is located on the left-hand side, above the air conditioning
compressor.
Generator Pulley
The generator is fitted on the right-hand accessory mounting.
Supercharger Pulley
The supercharger is located between the left-hand and right-hand cylinders and retained at three
mounting points.
Accessory drive belt tensioner and supercharger belt tensioner

The accessory drive belt tensioner and supercharger belt tensioner is calibrated to provide the
correct amount of tension to the belt for a given drive system. Unless a spring within the tensioner
assembly breaks, or some other mechanical part of the tensioner fails, there is no need to check the
tensioner for correct tension.
Accessory drive belt and supercharger belt
Item Description
1 Acceptable drive belt cracking
2 Unacceptable drive belt damage
The accessory drive belt and the supercharger belt should be inspected at every routine service for
excessive wear and damage. A drive belt which displays symptoms of cracking may be perfectly fit for
further service.
Should cracking be detected, serviceability may be assessed using the following guidelines:
Fifteen cracks per rib over a 100 mm length of drive belt is acceptable.
Section(s) of belt missing from any rib is not acceptable and the drive belt must be renewed.
Accessory drive belt tensioner
The accessory drive belt tensioner consists of an idler pulley which is free to rotate on a bearing,
located at the end of a spring-loaded pivot arm.
The pivot arm can be turned counter-clockwise (viewed from the front of the engine) for accessory
drive belt removal and installation.
The accessory drive belt wear indicators are incorporated on the bottom of the accessory drive belt
tensioner. When the indicators are aligned the accessory drive belt requires replacing.
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Accessory Drive - 3.0L/3.5L/4.2L

No data
The 2.7L diesel engine uses two accessory drive systems, the front end accessory drive (FEAD), and
the fuel injection pump drive.
FEAD
The FEAD drives: the coolant pump, the generator, the power assisted steering pump, and the air
conditioning compressor, driven from the crankshaft pulley via a single six-ribbed belt.
Fuel injection pump drive

The fuel injection pump is driven from the exhaust camshaft of the left-hand cylinder bank, by a
single, toothed belt.
The fuel injection pump is NOT timed to the engine.

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2 . Visually inspect for obvious mechanical faults.
FEAD Fuel injection pump belt
Belt condition Security/correct fitment of cover

(cracking/damage/contamination)
Check for debris inside the cover
Belt tension
Belt condition
Function of driven components (siezed, etc) (cracking/damage/contamination)
Pulley alignment Belt tension
Noise definitions
Description of
Definition/Possible cause
noise
Continuous shriek, most noticeable when the engine is accelerated (usually

Squeal
associated with lack of belt tension, contamination or wet slip)
Twittering noise that usually stops at engine speeds above idle. Usually associated
Chirp
with misaligned pulleys
Continuous noise, changing frequency with engine speed, generally associated with
Whine
rotating components (generator, idler, etc)
Rattle Metallic knocking, often a loose component or tensioner fault
Rumble Bearing noise
Symptoms (FEAD)
Symptom Possible cause Action
Belt condition
Belt tension Check the belt condition (see visual inspection). Check the
Noise (see tensioner function. GO to Pinpoint Test G552803p1.
Pulleys
definitions above) misaligned Check the pulley alignment. Check the driven components
for excessive resistance to rotation. Rectify as necessary.
Driven
component
s
Drive belt does not Belt condition Check the belt condition (see visual inspection). Check the
hold tension tensioner function. Rectify as necessary.
Tensioner fault
Symptoms (Fuel injection pump belt)

Check the belt condition (see visual inspection). Check the

belt cover for indications of fouling (this may indicate a
Belt condition pump misalignment),
Fuel Injection Pump The belt tensioner must be renewed
Belt fouling cover if the belt is removed, making a check of the bearing
Noise (see impractical. Remove the belt, check the fuel injection
Tensioner
definitions above) bearing pump pulley for security. Check the fuel injection pump for
failure excessive resistance to rotation (excessive resistance in
the pump will cause the pulley securing nut to loosen as a
Fuel injection design feature). Check for diagnostic trouble codes (DTCs)
pump failure indicating a pump malfunction,
Investigate the cause of the belt breakage/damage (a belt
broken at a 45 degree angle normally indicates a shear, a
Loss of drive (with Belt break straight across the belt normally indicates that the
no drive to the broken/strip belt has been crimped). Check the fuel injection pump for
fuel injection ped teeth excessive resistance to rotation (excessive resistance in
pump, the engine the pump will cause the pulley securing nut to loosen as a
will not run) Drive pulleys design feature). Check for DTCs indicating a pump
loose
malfunction,
Pinpoint tests

ELIMINATE THE FEAD AS THE
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SOURCE OF NOISE
G552803t1 : CHECK FOR THE PRESENCE OF NOISE WITH THE FEAD BELT
DISCONNECTED
1. Remove the ignition key. 2. Disconnect the FEAD belt,
Accessory Drive Belt - 2.7L Diesel (12.10.40) 3. Start the engine and allow to idle. 4. Check for the
presence of the noise.
Is the noise still apparent?
-> Yes
The FEAD is not the cause of the noise. Confirm the symptoms, check for alternative causes.
-> No
Inspect the FEAD belt and driven components. Check the driven components for excessive resistance
to rotation.
Accessory Drive Belt - 3.0L, VIN Range:

G00442->G45703 (12.10.40)
Removal

.
tensioner.
Installation
Accessory Drive Belt - 3.0L, VIN Range:
G45704->G99999 (12.10.40)
Removal


.
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Use a 3/8 inch square drive bar or a 1 inch open ended wrench to
rotate the accessory drive belt tensioner.

5 . Remove the accessory drive belt.

Installation
Accessory Drive Belt - 3.5L/4.2L (12.10.40)
Removal
All vehicles


3 Remove the supercharger belt.
. For additional information, refer to Supercharger Belt - VIN Range: G00442->G45703
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(18.50.08)
All vehicles
.
tensioner.
5 . Remove the accessory drive belt.

1) Remove the accessory drive belt tensioner retaining bolt.
2) Remove the accessory drive belt tensioner.
Installation
Tighten to 40 Nm.
Accessory Drive Belt - 2.7L Diesel
(12.10.40)

303-703
Removal
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2 . Disconnect the top intake tube off the air filter housing.

4 . Reposition the air intake to right-hand turbo charger tube.

.
1)
clockwise.
Installation
Tighten to 8 Nm.
Accessory Drive Belt Idler Pulley - 3.0L,
VIN Range: G00442->G45703 (12.10.43)
Removal
(12.10.40)

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Installation
Tighten to 25 Nm.
Accessory Drive Belt Idler Pulley - 3.0L,
VIN Range: G45704->G99999 (12.10.43)
Removal


.

Installation
Tighten to 25 Nm.
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Accessory Drive Belt Idler Pulley -
3.5L/4.2L, VIN Range: G00442->G45703
(12.10.43)
Removal
All vehicles


(18.50.08)
All vehicles
.
tensioner.

Installation
Tighten to 25 Nm.
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Accessory Drive Belt Idler Pulley -
3.5L/4.2L, VIN Range: G45704->G99999
(12.10.43)
Removal
All vehicles


(18.50.08)
All vehicles
.
Using a 3/8 inch square drive bar, rotate the accessory drive belt tensioner
counter-clockwise.
Detach the accessory drive belt.

5 . NOTE:
Release the secondary air injection (AIR) control valve.
Remove the 2 bolts.

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7
. CAUTION: Care must be taken when disconnecting the AIR control valve to exhaust
manifold tube. Failure to follow these instructions may result in damage to the A/C pipes.
Disconnect the AIR control valve to exhaust manifold tube from the LH exhaust manifold.
All vehicles
Installation
All vehicles
Tighten to 25 Nm.

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Accessory Drive Belt Idler Pulley - 2.7L
Diesel (12.10.43)
Accessory belt detensioner.

303-703
Removal
1 . Disconnect the battery.


.
1)
clockwise.

Installation
Tighten to 47 Nm.
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Accessory Drive Belt Tensioner - 3.0L, VIN
Range: G00442->G45703 (12.10.41)
Removal
(12.10.40)
Installation
Tighten to 45 Nm.
Accessory Drive Belt Tensioner - 3.0L, VIN
Range: G45704->G99999 (12.10.41)
Removal


.
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Installation
Tighten to 45 Nm.
Accessory Drive Belt Tensioner - 3.5L/4.2L
(12.10.41)
Removal


.
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tensioner.

Installation
Tighten to 40 Nm.
Accessory Drive Belt Tensioner - 2.7L Diesel
(12.10.41)
Accessory belt detensioner.

303-703
Removal
1 . Disconnect the battery.
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.
1)
clockwise.

Installation
Tighten to 47 Nm.
Fuel Injection Pump Belt
Removal
2 . Remove the secondary bulkhead centre panel.

3 . Remove the fuel injection pump belt cover.

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4 . Remove and discard the fuel injection pump belt tensioner.
5 . Note the direction of rotation of the fuel injection pump belt.

Installation
1 NOTE:
.
The fuel injection pump rotates in an anti-clockwise direction when viewed from the
rear of the engine.
Note the direction of rotation of the new fuel injection pump belt.
2
. CAUTION: Do not install the fuel injection pump belt to the pulleys with the fuel
injection pump belt tensioner installed. Failure to follow this instruction may result in
damage to the fuel injection pump drive belt.
NOTE:
Make sure the fuel injection pump belt is correctly seated on to the fuel injection pump
drive pulleys.
Install a new fuel injection pump belt.

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3
. CAUTION: Make sure the fuel injection pump belt tensioner is correctly located in to
the fuel injection pump cover backplate. Failure to follow this instruction may result in
damage to the components.
Install the fuel injection pump belt tensioner.
Locate the tang on the new fuel injection pump belt tensioner in to the fuel
injection pump cover backplate.
4 NOTE:
.
Do not remove the fuel injection pump belt tensioner locking pin before installing the
tensioner.
Install the fuel injection pump belt tensioner retaining bolt.
Tighten to 25 Nm.
5 . Remove and discard the fuel injection pump belt tensioner locking pin.
6 . Install the fuel injection pump belt cover.
7 . Install the secondary bulkhead centre panel.

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Fuel Injection Pump Pulley
Reaction arm - fuel pump pulley

303-138
Holder - fuel pump pulley

303-139
Removal
2 . Remove the injection pump pulley retaining nut.
Installation
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Tighten to 50 Nm.
3 . Install a new fuel injection pump belt.

Supercharger Belt - VIN Range: G00442-
>G45703 (18.50.08)
Removal

2) Detach the supercharger belt.

5 . Reposition the supercharger belt tensioner.
Loosen the supercharger belt tensioner retaining bolt.
Reposition the supercharger belt tensioner.

7 . Remove the supercharger belt.

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Installation
Tighten to 40 Nm.
Supercharger Belt - VIN Range: G45704-
>G99999 (18.50.08)
Removal


4 . Remove the supercharger belt.
Installation
Supercharger Belt Idler Pulley - VIN
Range: G04422->G45703 (18.50.09)
Removal

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Installation
Tighten to 40 Nm.
Supercharger Belt Idler Pulley - VIN
Range: G45704->G99999 (18.50.09)
Removal


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4 . Using the special tool, detach the supercharger belt.
5 . Loosen the water pump pulley retaining bolts.

.
tensioner.
8 . Remove the supercharger belt idler pulley and bracket assembly.

Installation
Tighten to 40 Nm.
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Supercharger Belt Tensioner (18.50.24)
Removal

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5 . NOTE:
Remove and discard the oil cooler pipe O-ring seal.
Detach the oil cooler pipe from the oil filter adaptor.
1) Remove the the oil cooler pipe retaining bolt.

2) Detach the oil cooler pipe from the oil filter adaptor.
Installation
1 . NOTE:
Install a new O-ring seal to oil cooler pipe.
Tighten to 40 Nm.
303-06 : Starting System
Specifications
Specifications
lb- lb-
Description Nm
ft in
Starter motor retaining bolts - Vehicles fitted with 3.0L engines 25 18 -
Starter motor retaining bolts - Vehicles fitted with 3.5L or 4.2L engines 45 33 -
Starter motor retaining bolts - Vehicles fitted with 2.7L diesel engines 48 35 -
Battery positive terminal integral connector retaining nut - Vehicles fitted with
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11 9 -
3.0L engines
9 - 80
3.5L or 4.2L engines
11 9 -
2.7L diesel engines
Solenoid terminal integral connector retaining nut 7 - 62
Starting System
The function of the starting system is to crank the engine fast enough to allow the engine to
start. Heavy cables, connectors and switches are used in the system because of the large
currents required.
The starting system consists of a pre-engaged type starter motor, battery, remote control
switch (ignition switch) and relay. When the starter is operated from the ignition switch, the
engagement lever moves the pinion into mesh with the engine ring gear teeth, the electrical
contacts within the solenoid complete the high power circuit and the starter motor operates to
turn the engine.
Vehicles equipped with automatic transmission have a transmission range sensor attached to
the circuit which prevents operation of the starter motor unless NEUTRAL or PARK are
selected.
The sequence of operation is as follows:
Ignition switch in the start position III.
Starter relay activated.
Voltage provided to the starter motor solenoid.
Starter solenoid engages the drive pinion to the flywheel or flexiplate.
Starter solenoid switches the battery current to the starter motor.
System remains engaged until the ignition switch is returned to the run position.
Starting System
Overview

Starting System
Inspection and verification

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Battery charge and condition
Fuses
Wiring harness(es)
Gear selector lever cable adjustment (vehicles with
Damaged, loose or corroded
automatic transmission)
connectors
Starter Motor
Ignition switch
Battery
Starter relay
Transmission control module

(TCM)
Engine control module (ECM)
Symptom chart
Symptom Possible cause(s) Action
Gear selector not in P or N

position (vehicles with
automatic transmission)
Battery Make sure the gear selector is in the P or N

position and correctly adjusted.
Harness/Connectors Selector Lever Cable Adjustment (44.15.07)
The engine does Check the battery condition and state of
Starter motor
not crank (starter charge.
motor does not Starter relay Battery Check the starter motor and harness,
turn) GO to Pinpoint Test G557182p1.
Ignition switch Check the starter relay and circuits. GO to
Transmission control module Check that the engine turns.
(TCM)
Engine siezed
Starter motor fitment Check the starter motor fitment (fasteners
The engine does
tight, starter motor square to engine, etc).
not crank (starter Starter motor
Check the flywheel/drive plate ring gear teeth
motor does turn)
Flywheel/Drive plate ring for damage, foreign objects, etc.
gear
Battery Check the battery condition and state of
charge.
Engine cranks too Harness/Connectors
Battery Check the starter motor and harness,
slowly
Starter motor GO to Pinpoint Test G557182p3.
Check the oil specification.
Oil grade
Starter motor Check the starter motor fitment (fasteners
tight, motor square to engine, etc). Check the
Excessive starter
Flywheel/Drive plate ring starter motor casing condition. Check the
motor noise gear flywheel/drive plate ring gear teeth for
damage, foreign objects, etc.
Starter motor fitment/casing
DTC index
NOTE:
NOTE:


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Starter relay coil to

Starter request circuit - ECM/ignition switch For starter request circuit
P05120C circuit voltage above circuit: short circuit to tests, GO to Pinpoint Test
threshold power G557182p2.
Ignition switch failure

ECM/ignition switch
Starter request circuit - ground For starter request circuit
P05120E circuit voltage below tests, GO to Pinpoint Test
threshold Starter relay coil to G557182p2.
ECM/ignition switch

Starter relay drive circuit:
For starter relay and circuit
P06160E Starter relay circuit low tests, GO to Pinpoint Test
Starter relay drive circuit: high
resistance G557182p2.
Starter relay failure

Starter relay drive circuit: For starter relay and circuit
P061700 Starter relay circuit high short circuit to power tests, GO to Pinpoint Test
G557182p2.
Starter relay drive circuit: For starter relay and circuit
P06170C Starter relay circuit high
Starter relay failure G557182p2.
Pinpoint tests
NOTE:
NOTE:
NOTE:
PINPOINT TEST G557182p1 : BASE

STARTER CIRCUIT TESTS
G557182t1 : CHECK THE SUPPLY VOLTAGE AT THE STARTER MOTOR
1. Key off. 2. Measure the voltage between:
Starter motor Battery
Permanent supply terminal Negative terminal

-> Yes
-> No
REPAIR the battery power supply circuit as necessary. For additional information, refer to the wiring
diagrams. Test the system for normal operation.
G557182t2 : CHECK THE GROUND AT THE STARTER MOTOR

Outer casing Negative terminal

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-> Yes
-> No
REPAIR the ground circuit as necessary. For additional information, refer to the wiring diagrams. Test
G557182t3 : BYPASS THE RELAY START SIGNAL

1. Disconnect the starter solenoid connector:
Vehicle Connector
3.0L/3.5L/4.2L VIN Range: G00442->G45703 EL2
3.0L/3.5L/4.2L VIN Range: G45704->G99999 PI62
2.7L Diesel C60
2. Connect a suitable remote start device between the starter solenoid connection and battery
positive. 3. Operate the remote start device.
Does the engine crank?
-> Yes
CHECK the starter relay circuits. GO to Pinpoint Test G557182p2.
-> No
INSTALL a new starter motor.
Starter Motor - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8 (86.60.01)
Starter Motor - 2.7L V6 - TdV6 (86.60.01) Test the system for normal operation.
PINPOINT TEST G557182p2 : STARTER

RELAY CIRCUIT TESTS
G557182t4 : CHECK THE STARTER RELAY OUTPUT VOLTAGE AT THE
SOLENOID
1. Engine control module connector, PI1 (3.0L/3.5L/4.2L VIN Range: G00442->G45703)
Circuit Pin
Crank request 06
Starter relay - control 41
2. Engine control module connector, EC300 (3.0L/3.5L/4.2L VIN Range: G45704->G99999)
Circuit Pin
Crank request 17
Starter relay - control 51
3. Engine control module connector, EC66 (2.7L Diesel)
Circuit Pin
Crank request F3
Starter relay - control B1
4. Front power distribution box connector, EC04
Circuit Pin
Starter motor solenoid - supply 03
Circuit Pin
Starter motor relay - switched supply 01
Circuit Pin
Starter motor relay - control 08
7. Key off. 8. Disconnect the starter solenoid connector (this is an eyelet):

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Vehicle Connector
3.0L/3.5L/4.2L VIN Range: G00442->G45703 EL2
2.7L Diesel C60
9. Key on, engine cranking. 10. Measure the voltage between:
Connector, component side Battery
EL2
PI62 Negative terminal
C60
-> Yes
RECHECK the starter motor. Possible connection fault between the starter motor solenoid connector
and the solenoid. Rectify as necessary, test the system for normal operation.
-> No
G557182t8 : CHECK THE STARTER RELAY OUTPUT VOLTAGE AT THE FUSE

BOX
1. Key off. 2. Disconnect the front power distribution box connector, EC04. 3. Key on, engine
cranking. 4. Measure the voltage between:
EC04, component side Battery
Is the voltage less than 10 volts?
-> Yes
-> No
REPAIR the solenoid supply circuit as necessary. For additional information, refer to the wiring
G557182t6 : CHECK THE IGNITION SWITCHED SUPPLY TO THE STARTER

RELAY
1. Key off. 2. Disconnect the front power distribution box connector, EC41. 3. Key on, engine
cranking. 4. Measure the voltage between:
-> Yes
-> No
REPAIR the switched supply circuit as necessary. For additional information, refer to the wiring
G557182t9 : CHECK THE STARTER RELAY COIL RESISTANCE
1. .
Coil temperature (degrees C) Coil temperature (degrees F) Coil resistance (ohms)
23 73 70 to 86
85 185 84 to 100
2. Key off. 3. Disconnect the front power distribution box connector, EC28. 4. Measure the resistance
between:
Pin 01 Pin 08
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Is the reading as expected for the current engine temperature? (Refer to the table)
-> Yes
-> No
INSTALL a new front power distribution box (the relay cannot be changed separately). Test the
G557182t5 : CHECK THE CRANK REQUEST SIGNAL TO THE ECM

1. Disconnect the engine control module connector:
Vehicle Connector
3.0L/3.5L/4.2L VIN Range: G45704->G99999 EC300
2.7L Diesel EC66
2. Key on, engine cranking. 3. Measure the voltage between:
ECM Connector Pin, harness side Battery

PI1 06
EC300 17 Negative terminal
EC66 F3
-> Yes
-> No
REPAIR the crank request circuit as necessary. For additional information, refer to the wiring
G557182t7 : CHECK THE STARTER RELAY CONTROL CIRCUIT FOR HIGH

RESISTANCE
ECM Connector Pin, harness side EC28, harness side
PI1 41
EC300 51 Pin 08
EC66 B1
-> Yes
CHECK for DTCs indicating a possible ECM or TCM fault. If no DTCs are set, an intermittent fault may
be present in the wiring harness. Visually check for chaffed wires or other physical damage to the
harness. If no fault is found in the circuit, suspect the following component(s): - Front power
distribution box connector. - Front power distribution box (starter relay). - ECM connector. - ECM.
-> No
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the
ENGINE CRANKS TOO SLOWLY
G557182t11 : CHECK THE VOLT DROP IN THE STARTER POSITIVE CIRCUIT
1. Connect a voltmeter between:
Permanent supply terminal Positive terminal
2. Key on, engine cranking.
Is the voltage greater than 0.5 volts?
-> Yes
CLEAN and tighten all battery cable connections. Test the system for normal operation. Check the
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resistance of the battery cable, replace as necessary.
-> No
G557182t12 : CHECK THE VOLT DROP IN THE STARTER NEGATIVE CIRCUIT

1. Connect a voltmeter between:
Outer casing Negative terminal
2. Key on, engine cranking.
Is the voltage greater than 0.5 volts?
-> Yes
CLEAN and tighten all battery cable connections, starter motor mounting and body to engine ground
strap. Test the system for normal operation. Check the resistance of the ground cables, replace as
necessary.
-> No
INSTALL a new starter motor.
Starter Motor - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8 (86.60.01)
Starter Motor - 2.7L V6 - TdV6 (86.60.01) Test the system for normal operation.
Starter Motor - 4.2L NA V8 - AJV8/4.2L SC

V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 -
AJV8 (86.60.01)
Removal
All vehicles

3 . Disconnect the engine ground cable.
Vehicles fitted with 3.0L engine

4 . Remove the starter motor positive cable cover.

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Vehicles fitted with 3.5L or 4.2L engine

7 . Remove the starter motor positive cable cover.

1) Remove the starter motor retaining bolts.
2) Remove the starter motor.
Installation
Tighten to 25Nm
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Starter Motor - 2.7L V6 - TdV6 (86.60.01)
Removal

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7 . Using a suitable piece of string secure the steering gear.
8 . Remove the generator cooling duct.

9 . Remove the starter motor retaining bracket.
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Installation
Tighten to 48 Nm.
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303-07 : Engine Ignition – 3.0L NA V6 – AJ27
Specifications
Specifications
Item Specification
Firing order 1-4-2-5-3-6
1.3-1.45mm (0.051-
Spark plug gap
0.057in)
Spark plug type AWSF22FS
High temperature nickel anti-seize lubricant F6AZ-9L494-AA
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ESE-M12A4-A
(Spark plug thread)

Spark plugs 15 11 -
Ignition coil-on-plug retaining bolts 6 - 53
Engine Ignition
Component Locations
1 - Ignition coil-on-plug
2 - Ignition coil-on-plug retaining bolt
3 - Spark plug
The right-hand cylinders are numbered 5,3,1 and the left-hand cylinders are numbered 6,4,2 when
viewed from the rear of the engine.
The ignition system consists of an ignition coil located on each individual cylinder and each individual
spark plug. The ignition timing can now be adjusted more rapidly and independently.
The crankshaft position sensor signal is the basis for ignition timing calculations. The alternating
voltage signal from the crankshaft position sensor is converted by the engine control module (ECM).
This digital signal is then used to position the closing time of the primary circuit of the ignition coil.
The effective range for ignition timing control is increased to the fact that there are no rotating parts.
On the basis of engine speed and load inputs, the powertrain control module determines the ignition
timing. This function also takes other inputs into consideration such as engine temperature, throttle
position, knock control, cam position, traction control and electronic transmission control inputs.
This ignition system enables the customer to drive the vehicle home if a coil or coil wiring failure
occurs. In the event of a wiring failure between the powertrain control module and the coil, the coil
will fail instead of the coil fuse blowing, which will allow the remaining coils to continue to function
and the engine to limp home.

>G45703
NOTE:
driver information table for DTCs associated with the display, then to the DTC index table for
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Poly-vee belt Transmission control module
Air intake system
Cooling system
Charging system
Fuel system
NOTE:
NOTE:
NOTE:

Engine cranks, but does Check engine breather system, <<303-08>>
not fire d For ignition system tests, refer to pinpoint
tests in this section. Check fuel pressure.
Ignition system For CKP tests, <<303-14>> Contact dealer
technical support for advice on possible
Fuel system
ECM failure.
Harness
CKP sensor
ECM fault
Purge valve
Fuel pump
Engine coolant For evaporative emissions components,

temperature (ECT) <<303-13>> Check fuel pressure, <<310-
sensor 01>> For ECT sensor tests, <<303-14>> For
Engine cranks and fires, ignition coil circuit tests, GO to Pinpoint
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Spark plugs
but will not start Test G290075p1.
HT short to ground . For ignition coil information,
(tracking) check rubber Ignition Coil-On-Plug LH (18.20.44) and
boots for Ignition Coil-On-Plug RH (18.20.43)
cracks/damage
Ignition coil failure(s)
Harness
content
Battery
For battery information, <<414-01>> For
CKP sensor CKP sensor tests, <<303-14>> For EGR
system information, <<303-08>> Check fuel
Difficult to start cold EGR valve stuck open
pressure. For ECT sensor tests, <<303-14>>
Fuel pump For evaporative emissions components,
<<303-13>>
Engine coolant
temperature (ECT)
sensor
Purge valve
For fuel injectors, <<303-04>> For EFT
Injector leak sensor, IAT sensor and MAF sensor tests,
<<303-14>> For evaporative emissions
Engine fuel temperature
components, <<303-13>> Check fuel
(EFT) sensor pressure. <<310-01>> For ignition coil
circuit tests, GO to Pinpoint Test
IAT sensor G290075p1.
. For ignition coil information,
MAF sensor
Ignition Coil-On-Plug LH (18.20.44) and
Purge valve Ignition Coil-On-Plug RH (18.20.43) For ECT
sensor tests, <<303-14>> For EGR
Fuel pump information, <<303-08>>
Ignition system
ECT sensor

Injector leak
For fuel injectors, <<303-04>> For EFT
EFT sensor
sensor, IAT sensor and MAF sensor tests,
IAT sensor <<303-14>> For evaporative emissions
components, <<303-13>> Check fuel
MAF sensor pressure. <<310-01>> For ignition coil
hot soak (vehicle
Purge valve G290075p1.
has reached operating
temperature) Fuel pump Ignition Coil-On-Plug LH (18.20.44) and
Ignition Coil-On-Plug RH (18.20.43) For ECT
Ignition system
sensor tests, <<303-14>> For EGR
ECT sensor information, <<303-08>>

Breather system
d
For breather system, <<303-08>> For ECM
relay, MAF sensor and ECT sensor tests,
ECM relay
<<303-14>> For ignition coil circuit tests, GO
Harness to Pinpoint Test G290075p1.
MAF sensor Ignition Coil-On-Plug LH (18.20.44) and
start
Ignition Coil-On-Plug RH (18.20.43) For air
ECT sensor filter information, <<303-12>> For fuel line
information, <<310-01>> For FRP sensor
Ignition system
tests, <<303-04>> For intake system
Air filter restricted information, <<303-12>>
Fuel lines
FRP sensor
Air leakage
Fuel pump
Injector leak
Fuel pressure Check fuel pressure, <<310-01>> For FRP

sensor tests, <<303-04>> For fuel line
Fuel lines information, <<310-01>> For intake system,
<<303-12>> For throttle position sensor and
Air leakage throttle motor tests, <<303-14>> For
ignition coil circuit tests, GO to Pinpoint
Throttle sensors Test G290075p1.
Engine hesitates/poor . For ignition coil information,
Throttle motor
acceleration Ignition Coil-On-Plug LH (18.20.44) and
Ignition system Ignition Coil-On-Plug RH (18.20.43) For EGR
system, <<303-08>> Check for DTCs relating
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Exhaust gas recirculation to HO2 sensors. Refer to the DTC index for
pinpoint tests for DTC set. For transmission
HO2 sensors information, <<307-01>> Check accelerator
pedal travel. For APP sensor tests, <<303-
14>>
Restricted pedal travel
(carpet, etc)
APP sensor
Fuel pump Check fuel pressure. For fuel line
information, <<310-01>> For intake system,
Fuel lines
<<303-12>> For MAF sensor tests, <<303-
Air leakage 14>> Check for DTCs relating to HO2
sensors. Refer to the DTC index for pinpoint
MAF sensor tests for DTC set. For ignition coil circuit
Engine backfires
tests, GO to Pinpoint Test G290075p1.
HO2 sensors . For ignition coil information,
Ignition system
Ignition Coil-On-Plug RH (18.20.43) For VCT
Sticking VCT hub information, <<303-01>> For APP sensor
tests, <<303-14>>
APP sensor
Check fuel pressure. For fuel line
Fuel pump information, <<310-01>> For MAF sensor,
Engine surges throttle sensor, and throttle motor relay
Fuel lines
tests, <<303-14>> For ignition coil circuit
MAF sensor . For ignition coil information,
Harness Ignition Coil-On-Plug RH (18.20.43)
Throttle sensors
Throttle motor
Ignition system
KS/circuit malfunction
Fuel pump
Fuel lines pressure. For fuel line information, <<310-
01>> For FRP sensor tests, <<303-04>> For
FRP sensor
MAF sensor and HO2 sensor tests, <<303-
Engine
14>> For intake system, <<303-12>> Check
detonates/knocks MAF sensor
DTCs for VCT range/performance fault. For
HO2 sensors VCT information, <<303-01>> For BARO
sensor, contact dealer technical support for
Air leakage advice on possible ECM failure
Sticking VCT hub

APP sensor malfunction
For APP sensor, throttle position sensor and
Throttle sensors throttle motor relay tests, <<303-14>>
Throttle motor
Throttle sensors
ECT sensor
For APP sensor, throttle position sensor,
MAF sensor
ECT sensor and MAF sensor tests, <<303-
Poor throttle response 14>> For transmission information, <<307-
01>> For intake system, <<303-12>> For
Traction control event breather system information, <<303-08>>
Air leakage
Breather system
d
Warning
light

cylinders fuel cut)
P0121, P0122, P0123, P0222,

P0223

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P1344, P1122, P1123, P1215,

P1216
P0300, P0301, p0302, P0303,

P0308, P1313, P1314
P0327, P0328, P0332, P0333,

P1648
P0351, P0352, P0353, P0354,

P1367, P1368
P0201, P0202, P0203, P0204,

P0205, P0206, P0207, P0208

enabled

enabled

enabled

enabled
Gearbox
performance
Gearbox
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performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
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Gearbox
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performance
Gearbox
performance
performance enabled
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

LIMP-HOME MODE
Throttle motor off
Throttle motor relay off
Throttle motor circuit off
Fuel intervention
Cruise control inhibited
Power limitation
Vehicle speed limited to 120 kph
Reverse throttle progression enabled
Throttle opening limited to maximum 30%

NOTE:
Engine runs normally, up to 3000 rpm
Engine speed restricted to 3000 rpm maximum, by fuel cut-off
HIGH IDLE
Throttle valve kept in fixed position by motor
SAFETY REDUNDANCY
Power limitation
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ECM to ignition coil primary

circuit fault (cylinder
misfire detected DTC also
flagged)
Fuel injector circuit fault(s) tests, GO to Pinpoint
(injector DTCs also flagged) Test G290075p1.
. For fuel system, <<303-
Ignition coil failure
04>> Check spark plug
P0300 Random misfire detected
Spark plug condition/gap. For spark
failure/fouled/incorrect plug test, GO to Pinpoint
gap Test G290075p2.
Cylinder compression low <<303-00>>
Fuel delivery pressure

(low/high)
Fuel injectors
restricted/leaking
Fuel injectors continuously

open
Fuel contamination
Worn camshaft/broken valve

springs
REFER to possible sources for REFER to actions for
P0301 Misfire detected, Cyl 1
P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

circuit open circuit, short
circuit to ground, high
Ignition coil resistance For ignition coil circuit
P0351 primary/secondary circuit tests, GO to Pinpoint
malfunction, cyl 1 Ignition coil ground circuit Test G290075p1.
open circuit, high
resistance

open circuit, high
resistance

open circuit, high
resistance

open circuit, high
resistance
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open circuit, high
resistance

open circuit, high
resistance

P0603 ECM data corrupted support for advice on
ECM
Carry out comprehensive

System checks not complete
P1000 OBD monitors have not completed component monitor
since last memory clear drive cycle. Refer to the
DTC section of JTIS,
accessed by the icon on
the opening page.
System checks complete since

P1111 OBD monitors have completed No action necessary
last memory clear
Misfire rate catalyst damage,

right-hand cylinders. NOTE.
accompanied by a random or
individual cylinder misfire DTC;
P0300 to P0306

left-hand cylinders. NOTE. This
P0300 to P0306
Misfire excess emission. NOTE.

P1316 accompanied by an individual Refer to P0300 possible sources Refer to P0300 Actions
P0306
Ignition monitoring circuit

between splice and ECM
to ground, or short circuit For coil circuit tests, GO
Ignition monitor (right-hand
P1367 to B+ voltage to Pinpoint Test
cylinders)
G290075p1.
Ignition coil group ground
circuit fault
Ignition coil relay failure

to ground, or short circuit For coil circuit tests, GO
Ignition monitor (left-hand
P1368 to B+ voltage to Pinpoint Test
cylinders)
G290075p1.
Ignition coil group ground
circuit fault

Pinpoint Tests

P0300, P0301-0306, P0351-0356; RANDOM
MISFIRE DETECTED, MISFIRE
DETECTED, (CYLINDERS 1-6)
IGNITION COIL PRIMARY CIRCUIT
MALFUNCTION, (CYLINDERS 1-6)
G290075t1 : CHECK COIL FUNCTION BY SUBSTITUTION
1. Swap the suspect coil for a known good unit. 2. CLEAR the DTC. TEST the system for normal
operation.
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Does the same DTC reoccur? The DTC will indicate if the same cylinder is misfiring.
-> Yes
INSTALL a new coil.
Ignition Coil-On-Plug RH (18.20.43) CLEAR the DTC. TEST the system for normal operation.
-> No
G290075t2 : CHECK THE IGNITION COIL SUPPLY VOLTAGE CIRCUIT

1. Disconnect the relevant ignition coil electrical connector(s), (PI02 to PI04, right-hand cylinders,
PI06 to PI08, left-hand cylinders). 2. Turn the ignition switch to the ON position. 3. Make sure the
ignition relay is energized. 4. Measure the voltage between:
Cyl 1 PI02, pin 01 (RW) and GROUND.
Is the voltage less than 10.5 Volts?

-> Yes
REPAIR the relevant ignition coil supply voltage circuit. This circuit includes the ignition relay, and the
front power distribution box (fuse 30). For additional information, refer to the wiring diagrams.
CLEAR the DTCs. TEST the system for normal operation.
-> No
G290075t3 : CHECK THE IGNITION COIL GROUND CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant ignition coil electrical
connector(s), (PI02 to PI04, right-hand cylinders, PI06 to PI08, left-hand cylinders). 3. Measure the
resistance between:
Cyl 1 PI02, pin 03 (B) and GROUND.
-> Yes
DTCs. TEST the system for normal operation.
-> No
G290075t4 : CHECK THE IGNITION COIL SWITCHING CIRCUITS FOR HIGH

RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector PI01. 3.
Disconnect the relevant ignition coil electrical connector(s), (PI02 to PI04, right-hand cylinders, PI06
to PI08, left-hand cylinders). 4. Measure the resistance between:
Cyl 1 PI02, pin 04 (GU) and PI01, pin 87 (GU).
Cyl 2 PI06, pin 04 (GW) and PI01, pin 61 (GW).
Cyl 3 PI03, pin 04 (Y) and PI01, pin 88 (Y).

Cyl 5 PI04, pin 04 (YR) and PI01, pin 89 (GO).
Cyl 6 PI08, pin 4 (GR) and PI01, pin 63 (GR).
-> Yes
-> No
G290075t5 : CHECK THE IGNITION COIL (CYLS 1, 3, 5) MONITOR CIRCUITS

FOR HIGH RESISTANCE
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1. Disconnect the relevant ignition coil electrical connector(s), (PI02 to PI04). 2. Measure the
resistance between:
Cyl 1 PI02, pin 02 (GB) and PI01, pin 131 (GB).
-> Yes
REPAIR the high resistance circuit. This circuit includes the harness splice, PIS09. For additional
information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation.
-> No

FOR SHORT TO B+ VOLTAGE
1. Reconnect the battery negative terminal. 2. Disconnect the relevant ignition coil electrical
connector(s). 3. Measure the voltage between:
Cyl 1 PI02, pin 02 (GB) and GROUND.

-> Yes
REPAIR the short to B+ voltage. For additional information, refer to the wiring diagrams. CLEAR the
-> No

FOR SHORT TO GROUND
1. Disconnect the relevant ignition coil electrical connector(s). 2. Measure the resistance between:
-> Yes
REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. CLEAR the
-> No

FOR HIGH RESISTANCE
resistance between:
Cyl 2 PI06, pin 02 (YB) and PI01, pin 132 (YB).
-> Yes
-> No

FOR SHORT TO B+ VOLTAGE
connector(s), (PI06 to PI08). 3. Measure the voltage between:
Cyl 2 PI06, pin 02 (YB) and GROUND.
-> Yes
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-> No
G290075t10 : CHECK THE IGNITION COIL (CYLS 2, 4, AND 6) MONITOR

CIRCUITS FOR SHORT TO GROUND
resistance between:
-> Yes
-> No
SPARK PLUG RESISTANCE
G290075t11 : CHECK SPARK PLUG RESISTANCE
1. Remove the suspect spark plug(s). 2. Measure the resistance between the spark plug center
electrode tip and the spark plug HT contact.
Is the resistance between 8,000 and 12,000 ohms? (nominal 10,000 ohms)
-> Yes
Check ignition coil and circuits. See possible sources list for misfire.
-> No
INSTALL a new spark plug. CLEAR the DTC. TEST the system for normal operation.
>G99999
Overview

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Fuses
Wiring harness
Engine oil level
Loose or corroded electrical connectors
Cooling system coolant level
Ignition coils
Fuel level
Sensor(s)
Fuel contamination/grade/quality
Transmission control module (TCM)
retrieve the fault codes before proceeding to the DTC Index.
Symptom Chart
Engine breather system Check the engine breather system,

Engine cranks, but does disconnected/restricted Engine Emission Control - VIN Range:
not fire G45704->G99999 For ignition system
Ignition system
tests, refer to pinpoint tests in this
Fuel system section. Check the fuel pressure,
Fuel Tank and Lines - 4.2L NA V8 -
Harness AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8, VIN Range:
Crankshaft position (CKP)
G45704->G99999 For CKP tests,
sensor
Electronic Engine Controls - VIN Range:
ECM fault G45704->G99999 Refer to the warranty
policy and procedures manual if an ECM
is suspect.

valve For purge valve tests,
Fuel pump G45704->G99999 Check the fuel
pressure,
Spark plugs
Engine cranks and fires,
AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
but will not start HT short to ground
(tracking) check rubber AJ27/3.5L NA V8 - AJV8, VIN Range:
boots for G45704->G99999 For spark plug tests,
cracks/damage GO to Pinpoint Test G531326p2.
For ignition coil circuit tests, GO to
Ignition coil failure(s) Pinpoint Test G531326p1.
Harness
Check the anti-freeze content. For
battery information,
Coolant anti-freeze content Battery For CKP sensor tests,
Battery G45704->G99999 For EGR valve tests,
CKP sensor
(EGR) valve stuck open Fuel Tank and Lines - 4.2L NA V8 -
Fuel pump AJ27/3.5L NA V8 - AJV8, VIN Range:
G45704->G99999 For purge valve tests,
G45704->G99999
Injector leak For fuel injectors,

(EFT) sensor Electronic Engine Controls - VIN Range:
Intake air temperature (IAT) Evaporative Emissions - VIN Range:
pressure,
Mass air flow (MAF) sensor Fuel Tank and Lines - 4.2L NA V8 -
Purge valve
Fuel pump G45704->G99999 For ignition coil
Ignition system G531326p1.
For EGR valve tests,
G45704->G99999
For fuel injectors,

Injector leak and MAF sensor tests,
EFT sensor G45704->G99999 For purge valve tests,
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IAT sensor G45704->G99999 Check the fuel
Difficult to start after hot
pressure,
soak (vehicle standing MAF sensor
after engine has reached
Purge valve AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
operating temperature)
G45704->G99999

disconnected/restricted G45704->G99999 For ECM relay and
MAF sensor tests,
ECM relay
Harness G45704->G99999 For ignition coil
Engine stalls soon after circuit tests, GO to Pinpoint Test
start MAF sensor G531326p1.
For air filter information,
Ignition system Intake Air Distribution and Filtering -
VIN Range: G45704->G99999 Check the
Air filter restricted
fuel lines,
Fuel lines
FRP sensor G45704->G99999 For FRP sensor tests,
Air leakage G45704->G99999 For intake system
information,
Fuel pump
Check the fuel pressure, check the fuel
Injector leak lines,
Fuel pressure AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel lines G45704->G99999 For intake system,
Air leakage
VIN Range: G45704->G99999 For TP
Throttle position (TP) sensor and throttle motor tests,
sensors Electronic Engine Controls - VIN Range:
G45704->G99999 For ignition coil
Throttle motor circuit tests, GO to Pinpoint Test
acceleration
G531326p1.
Ignition system For EGR valve tests,
HO2 sensors relating to HO2 sensors. Refer to the
DTC index for pinpoint tests for DTC set.
Transmission malfunction For transmission information,
Check the accelerator pedal travel. For
Restricted pedal travel APP sensor tests,
(carpet, etc) Electronic Engine Controls - VIN Range:
G45704->G99999
Accelerator pedal position
(APP) sensor
Fuel pump Check the fuel pressure, check the fuel
lines,
Fuel lines Fuel Tank and Lines - 4.2L NA V8 -
Air leakage AJ27/3.5L NA V8 - AJV8, VIN Range:
Engine backfires G45704->G99999 For intake system,
MAF sensor
HO2 sensors VIN Range: G45704->G99999 For MAF
sensor tests,
Ignition system Electronic Engine Controls - VIN Range:
Sticking variable camshaft relating to HO2 sensors. Refer to the
timing (VCT) hub DTC index for pinpoint tests for DTC set.
APP sensor Pinpoint Test G531326p1.
For VCT information,
G45704->G99999

lines,
MAF sensor
Engine surges G45704->G99999 For MAF, TP sensor
Harness
and throttle motor tests,
TP sensors Electronic Engine Controls - VIN Range:
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G531326p1.
Ignition system
malfunction Electronic Engine Controls - VIN Range:
Fuel pump pressure, check the fuel lines,
Fuel lines AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
FRP sensor
G45704->G99999 For FRP, MAF and
Engine detonates/knocks HO2 sensor tests,
MAF sensor
HO2 sensors G45704->G99999 For intake system,
DTCs for VCT range/performance fault.
Sticking VCT hub For VCT information,
Engine Refer to the warranty policy and
(internal ECM fault) procedures manual if an ECM is suspect.
APP sensor malfunction For APP, TP sensor and throttle motor

tests,
G45704->G99999
Throttle motor
Poor throttle response APP sensor malfunction For APP, TP, ECT, and MAF sensor tests,
TP sensors G45704->G99999 For transmission
information,
ECT sensor For intake system,
MAF sensor
Transmission malfunction breather system information,
Traction control event G45704->G99999
Air leakage
Breather system
DTC Index
NOTE:
NOTE:

ECM to ignition module/coil

drive circuit: short circuit to
Cylinder 1 ignition coil
For ignition coil tests, GO to
P035100 primary/secondary Ignition module/coil ground
circuit: high resistance Pinpoint Test G531326p1.
circuit
Ignition module/coil supply

circuit: open circuit
(including relay)
drive circuit: short circuit to For ignition coil tests, GO to
P035200 primary/secondary ground, high resistance Pinpoint Test G531326p1.
circuit
Ignition module/coil ground

(including relay)
circuit

(including relay)
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circuit

(including relay)
circuit

(including relay)
circuit

(including relay)
Spark plug For spark plug tests, GO to
P131500 Persistent misfire failure/fouled/incorrect gap Pinpoint Test G531326p2.
For ignition coil circuit tests,
ECM to ignition coil primary GO to Pinpoint Test
circuit fault (cylinder misfire G531326p1.
detected DTC also flagged) Check the fuel pressure,
Fuel Tank and Lines - 4.2L NA
Fuel delivery pressure low V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
(injector DTCs also flagged) NA V8 - AJV8, VIN Range:
G45704->G99999 For injector
Ignition coil failure circuit tests,
Fuel Charging and Controls -
Cylinder compression low VIN Range: G45704->G99999
Check the cylinder
compressions,
Engine - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 -
AJV8
Ignition monitoring circuit to

ECM: open circuit, short
Ignition amplifier circuit to ground, short
group A circuit to power
G531326p1.
Ignition module/coils right hand
bank ground circuit fault
Ignition amplifier circuit to ground, short
group B circuit to power
G531326p1.
Ignition module/coils left hand
Pinpoint Tests
NOTE:
NOTE:
PINPOINT TEST G531326p1 : IGNITION

COIL CIRCUITS
1. Disconnect the relevant ignition coil electrical connector:
Ignition coil connector
Cylinder 1, PI02
Cylinder 2, PI06
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Cylinder 3, PI03
Cylinder 4, PI07
Cylinder 5, PI04
Cylinder 6, PI08
2. Key on, engine off. 3. Make sure the ignition relay is energized. 4. Measure the voltage between:
Ignition coil connector, harness side Battery
-> Yes
REPAIR the relevant ignition coil supply circuit. This circuit includes fuse 15 of the front power
distribution box and the ignition relay. For additional information, refer to the wiring diagrams.
CLEAR the DTCs and test the system for normal operation.
-> No
G531326t4 : CHECK THE IGNITION COIL SWITCHING CIRCUITS FOR SHORT
CIRCUIT TO GROUND
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531326t5 : CHECK THE IGNITION COIL MONITOR CIRCUITS FOR SHORT

CIRCUIT TO GROUND

-> Yes
-> No

CIRCUIT TO POWER
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-> Yes
-> No
G531326t3 : CHECK THE IGNITION COIL GROUND CIRCUIT FOR HIGH

RESISTANCE
Cylinder 1 ignition coil connector, harness side Battery
PI02, pin 03 Negative terminal

-> Yes
DTCs and test the system for normal operation.
-> No

RESISTANCE
Cylinder 1 ignition coil connector, harness side ECM connector PI300, harness side
PI02, pin 04 Pin 61

PI06, pin 04 Pin 60
PI03, pin 04 Pin 59
PI07, pin 04 Pin 58

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PI04, pin 04 Pin 57
PI08, pin 04 Pin 56
-> Yes
-> No
G531326t14 : CHECK THE IGNITION COIL MONITOR CIRCUITS FOR HIGH

RESISTANCE
PI02, pin 02 Pin 62
PI06, pin 02 Pin 64
PI03, pin 02 Pin 64
PI07, pin 02 Pin 62
PI04, pin 02 Pin 64
PI08, pin 02 Pin 62
-> Yes
-> No
INSTALL a new ignition coil to the relevant cylinder.
Ignition Coil-On-Plug LH (18.20.44) or
Ignition Coil-On-Plug RH (18.20.43) Clear the DTC and test the system for normal operation. Refer to
the warranty policy and procedures manual if an ECM is suspect.
1. Remove the suspect spark plug(s). 2. Measure the resistance between:
Spark plug Spark plug
Center electrode tip HT contact
-> Yes
CHECK the ignition coil and circuits. GO to Pinpoint Test G531326p1.
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-> No
INSTALL a new spark plug. CLEAR the DTC and test the system for normal operation.

Removal
1 . Disconnect the ignition coil-on-plug electrical connector.
2 . Remove the ignition coil-on-plug.
Installation
Tighten to 6 Nm.
Ignition Coil-On-Plug RH (18.20.43)
Removal

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Installation
Tighten to 6 Nm.
303-07B : Engine Ignition – 4.2L NA V8 – AJV8/4.2L SC
V8 – AJV8/3.5L NA V8 – AJV8
Specifications
Specifications
Item Specification
Firing order 1-5-4-2-6-3-7-8
Spark plug type - Vehicles with supercharger NGK-IFR-5N10
Spark plug type - Vehicles without supercharger NGK-IFR-5N10

Spark plugs 27 18 -
Ignition coil-on-plug retaining bolts 5 - 44
Engine Ignition
Component Locations

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1 - Ignition coil-on-plug
2 - Ignition coil-on-plug retaining bolt
3 - Spark plug
The right-hand cylinders are numbered 7, 5, 3, 1 and the left-hand cylinders are numbered 8, 6, 4, 2
when viewed from the rear of the engine.
An ignition coil is located on each individual spark plug allowing the ignition timing to be adjusted
independently.
The crankshaft position (CKP) sensor signal is the basis for ignition timing calculations. The
alternating voltage signal from the CKP sensor is converted to a digital signal by the engine control
module (ECM). This digital signal is then used to position the closing time of the primary circuit of the
ignition coil. The effective range for ignition timing control is increased to the fact that there are no
rotating parts.
On the basis of engine speed and load inputs, the ECM determines the ignition timing. This function
also takes other inputs into consideration such as engine temperature, throttle position, knock
control, camshaft position, traction control and electronic transmission control inputs.
This ignition system enables the customer to drive the vehicle home if an ignition coil or ignition coil
wiring failure occurs. In the event of a wiring failure between the ECM and the ignition coil, the
ignition coil will fail instead of the ignition coil fuse blowing, which will allow the remaining ignition
coils to continue to function and the engine to limp home.

>G45703
NOTE:
Driver Information table for DTCs associated with the display, then to the DTC index table for

Air intake system
Cooling system
Charging system
Fuel system
NOTE:
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NOTE:
NOTE:

Engine cranks, but does Check engine breather system, <<303-08>>
not fire d For ignition system circuit tests, GO to
Ignition system . Check fuel pressure, <<310-01>> For CKP
tests, <<303-14>> Contact dealer technical
Fuel system
support for advice on possible ECM failure.
Harness
CKP sensor
ECM fault
Purge valve
Fuel pump
Engine coolant
temperature (ECT)
sensor
For evaporative emissions components,
Spark plugs <<303-13>> Check fuel pressure, <<310-
Engine cranks and fires, 01>> For ECT sensor tests, <<303-14>> For
but will not start Check for water ingress ignition system circuit tests, GO to Pinpoint
into spark plug wells Test G290076p1.
.
HT short to ground
(tracking) check rubber
boots for
cracks/damage
Harness
content
Battery
For battery information, <<414-01>> For
CKP sensor CKP sensor tests, <<303-14>> For EGR
system information, <<303-08>> Check fuel
Difficult to start cold EGR valve stuck open
pressure. For ECT sensor tests, <<303-14>>
Fuel pump For evaporative emissions components,
<<303-13>>
Engine coolant
temperature (ECT)
sensor
Purge valve
Injector leak
IAT sensor
For fuel injectors, <<303-04>> For fuel
MAF sensor temperature sensor, IAT sensor and MAF
Purge valve
Difficult to start hot emissions components, <<303-13>> Check
Fuel pump fuel pressure. For ignition system circuit
Ignition system . For ECT sensor tests, <<303-14>>
Engine coolant
temperature (ECT)
sensor

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Injector leak
IAT sensor
For fuel injectors, <<303-04>> For fuel
MAF sensor temperature sensor, IAT sensor and MAF
hot soak (vehicle
Purge valve emissions components, <<303-13>> Check
fuel pressure. For ignition system circuit
has reached operating Fuel pump tests, GO to Pinpoint Test G290076p1.
temperature)
. For ECT sensor tests, <<303-14>> For EGR
Ignition system
Engine coolant
temperature (ECT)
sensor

Breather system
disconnected/restricte For breather system, <<303-08>> For ECM
d relay, MAF sensor and ECT sensor tests,
<<303-14>> For ignition system circuit tests,
ECM relay
Engine stalls soon after GO to Pinpoint Test G290076p1.
start Harness . For air filter information, <<303-12>> For
fuel line information, <<310-01>> For fuel
MAF sensor pressure sensor tests, <<303-04>> For
intake system information, <<303-12>>
Engine coolant
temperature (ECT)
sensor
Ignition system
Fuel lines
Fuel pressure sensor
Air leakage
Fuel pump
Injector leak
Fuel pressure
Fuel lines Check fuel pressure, <<310-01>> For fuel

pressure sensor tests, <<303-04>> For fuel
Air leakage line information, <<310-01>> For intake
system, <<303-12>> For throttle position
Throttle sensors sensor and throttle motor tests, <<303-
Engine hesitates/poor 14>> For ignition system circuit tests, GO to
Throttle motor
acceleration Pinpoint Test G290076p1.
Ignition system . For exhaust gas recirculation, <<303-08>>
Check for DTCs relating to HO2 sensors. For
Exhaust gas recirculation transmission information, <<307-01>>
Check accelerator pedal travel. For APP
HO2 sensors sensor tests, <<303-14>>

(carpet, etc)
APP sensor
Fuel pump
Fuel lines information, <<310-01>> For intake system,
<<303-12>> For MAF sensor tests, <<303-
Air leakage
14>> Check for DTCs relating to HO2
Engine backfires
MAF sensor sensors. For ignition system circuit tests, GO
HO2 sensors . For VCT information, <<303-01>> For APP
Ignition system
Sticking VCT hub
APP sensor
Fuel pump
Fuel lines
MAF sensor information, <<310-01>> For MAF sensor,
throttle sensor, and throttle motor relay
Engine surges
Harness tests, <<303-14>> For ignition system circuit
Throttle sensors .
Throttle motor
Ignition system
Fuel pump
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Fuel lines pressure. For fuel line information, <<310-
01>> For fuel pressure sensor tests, <<303-
Fuel pressure sensor
04>> For MAF sensor and HO2 sensor tests,
Engine
<<303-14>> For intake system, <<303-12>>
Check DTCs for VCT range/performance
HO2 sensors fault. For VCT information, <<303-01>> For
BARO sensor, contact dealer technical
Air leakage support for advice on possible ECM failure
Sticking VCT hub

For APP sensor, throttle position sensor and
Throttle sensors throttle motor relay tests, <<303-14>>
Throttle motor
Throttle sensors For APP sensor, throttle position sensor,

ECT sensor and MAF sensor tests, <<303-
Poor throttle response Engine coolant 14>> For transmission information, <<307-
temperature (ECT) 01>> For intake system, <<303-12>> For
sensor breather system information, <<303-08>>
MAF sensor
Traction control event
Air leakage
Breather system
d

Warning
light

cylinders fuel cut)
P0121, P0122, P0123, P0222,

P0223
P1344, P1122, P1123, P1215,

P1216
Amber Restricted Performance Engine speed limited P0300, P0301, p0302, P0303,
P0304, P0305, P0306, P0307,
P0308, P1313, P1314
P0327, P0328, P0332, P0333,

P1648
P0351, P0352, P0353, P0354,

P1367, P1368
P0201, P0202, P0203, P0204,

P0205, P0206, P0207, P0208

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enabled

enabled

enabled

enabled
Gearbox
performance

fault/Restricted
performance
Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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fault/Restricted
performance
Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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fault/Restricted
performance
Gearbox
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Gearbox
performance
Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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Gearbox
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fault/Restricted
performance
Gearbox
performance
Gearbox
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performance enabled
Gearbox
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Gearbox
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LIMP-HOME MODE
Throttle motor off
Fuel intervention
Power limitation
Cruise Control Inhibited
NOTE:
HIGH IDLE
Cruise control Inhibited
SAFETY REDUNDANCY
Power limitation
Cruise control Inhibited

ECM to ignition coil primary For ignition coil circuit

circuit fault (cylinder tests, GO to Pinpoint
misfire detected DTC also Test G290076p1.
P0300 Random misfire detected flagged)
. For fuel system, <<303-
04>> Check spark plug
(injector DTCs also flagged) condition/gap, For spark
plug test, GO to Pinpoint
Ignition coil failure Test G290076p2.
. For engine information,
Spark plug <<303-00>>
failure/fouled/incorrect
gap
Cylinder compression low

(low/high)
Fuel injectors
restricted/leaking

open
Fuel contamination

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springs
P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300

P0300 P0300
P0351 Ignition coil primary/secondary REFER to possible sources for REFER to actions for
circuit malfunction, cyl 1 P0300 P0300
Ignition coil primary/secondary REFER to possible sources for REFER to actions for
P0352
P0353
P0354
P0355
P0356
P0357
P0358

P0603 ECM data corrupted support for advice on
ECM
Carry out
comprehensive
component monitor
System checks not complete
P1000 OBD monitors have not completed drive cycle. Refer to the
since last memory clear
DTC section of JTIS,
accessed by the icon on
the opening page.
System checks complete since

P1111 OBD monitors have completed No action necessary
last memory clear

right-hand cylinders. NOTE.
P0300, P0301 to P0304
left-hand cylinders. NOTE. This
P0300 to P0308
Misfire excess emission. NOTE.

P1316 accompanied by an individual Refer to P0300 possible sources Refer to P0300 Actions
P0308

open circuit, short circuit For coil circuit tests, GO
to ground, or short circuit
Ignition monitor (right-hand to Pinpoint Test
P1367 to B+ voltage
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cylinders) G290076p1.
Ignition coil group ground .
circuit fault

open circuit, short circuit For coil circuit tests, GO
to ground, or short circuit
Ignition monitor (left-hand to Pinpoint Test
P1368 to B+ voltage
cylinders) G290076p1.
Ignition coil group ground .
circuit fault
Pinpoint Tests

P0300, P0301-0308, P0351-0358; RANDOM
MISFIRE DETECTED, MISFIRE
DETECTED, (CYLINDERS 1-8)
IGNITION COIL PRIMARY CIRCUIT
MALFUNCTION, (CYLINDERS 1-8)
G290076t1 : CHECK COIL FUNCTION BY SUBSTITUTION
1. Swap the suspect coil for a known good unit. 2. CLEAR the DTC. TEST the system for normal
operation.
Does the same DTC reoccur? The DTC will indicate if the same cylinder is misfiring.
-> Yes
INSTALL a new coil.
Ignition Coil-On-Plug (18.20.40) CLEAR the DTC. TEST the system for normal operation.
-> No

1. Disconnect the relevant ignition coil electrical connector(s), (PI02 to PI09). 2. Turn the ignition
switch to the ON position. 3. Make sure the ignition relay is energised. 4. Measure the voltage
between:
-> Yes
REPAIR the relevant ignition coil supply voltage circuit. This circuit includes the ignition relay, and the
front power distribution box (fuse 1). For additional information, refer to the wiring diagrams. CLEAR
the DTCs. TEST the system for normal operation.
-> No
G290076t3 : CHECK THE IGNITION COIL GROUND CIRCUIT

1. Turn the ignition switch to the OFF position. 2. Disconnect the relevant ignition coil electrical
connector(s), (PI02 to PI09). 3. Measure the resistance between:

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-> Yes
-> No

RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ECM electrical connector, PI01. 3.
Disconnect the relevant ignition coil electrical connector(s), (PI02 to PI09). 4. Measure the resistance
between:
Cyl 1 PI02, pin 04 (GU) and PI01, pin 87 (GU).
Cyl 3 PI03, pin 04 (Y) and PI01, pin 88 (Y).
Cyl 5 PI04, pin 04 (YR) and PI01, pin 89 (YR).

Cyl 8 PI09, pin 04 (YR) and PI01, pin 64 (YR).
-> Yes
-> No
G290076t5 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR

CIRCUITS FOR HIGH RESISTANCE
resistance between:
-> Yes
-> No

CIRCUITS FOR SHORT TO B+ VOLTAGE

-> Yes
-> No

resistance between:
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-> Yes
-> No

CIRCUITS FOR HIGH RESISTANCE
resistance between:

-> Yes
-> No

CIRCUITS FOR SHORT TO B+ VOLTAGE
-> Yes
-> No

resistance between:

-> Yes
-> No

1. Remove the suspect spark plug(s). 2. Measure the resistance between the spark plug center
electrode tip and the spark plug HT contact.
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-> Yes
-> No
INSTALL a new spark plug. CLEAR the DTC. TEST the system for normal operation.
>G99999
Overview

Fuses
Wiring harness
Engine oil level
Loose or corroded electrical connectors
Ignition coils
Fuel level
Sensor(s)
Symptom Chart
Engine breather system Check the engine breather system,

Engine cranks, but does disconnected/restricted Engine Emission Control - VIN Range:
not fire G45704->G99999 For ignition system
Ignition system
tests, refer to pinpoint tests in this
Fuel system section. Check the fuel pressure,
Harness AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
G45704->G99999 For CKP tests,
sensor
ECM fault G45704->G99999 Refer to the warranty
policy and procedures manual if an ECM
is suspect.

valve For purge valve tests,
Fuel pump G45704->G99999 Check the fuel
pressure,
Spark plugs
but will not start HT short to ground
(tracking) check rubber AJ27/3.5L NA V8 - AJV8, VIN Range:
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boots for G45704->G99999 For spark plug tests,

cracks/damage GO to Pinpoint Test G531328p2.
Ignition coil failure(s) Pinpoint Test G531328p1.
Harness
Check the anti-freeze content. For
battery information,
Coolant anti-freeze content Battery For CKP sensor tests,
Battery G45704->G99999 For EGR valve tests,
CKP sensor
(EGR) valve stuck open Fuel Tank and Lines - 4.2L NA V8 -
Fuel pump AJ27/3.5L NA V8 - AJV8, VIN Range:
G45704->G99999
Injector leak For fuel injectors,

(EFT) sensor Electronic Engine Controls - VIN Range:
Intake air temperature (IAT) Evaporative Emissions - VIN Range:
pressure,
Mass air flow (MAF) sensor Fuel Tank and Lines - 4.2L NA V8 -
Purge valve
G45704->G99999
For fuel injectors,

Injector leak and MAF sensor tests,
EFT sensor G45704->G99999 For purge valve tests,
IAT sensor G45704->G99999 Check the fuel
Difficult to start after hot
pressure,
soak (vehicle standing MAF sensor
after engine has reached
Purge valve AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
operating temperature)
G45704->G99999

disconnected/restricted G45704->G99999 For ECM relay and
MAF sensor tests,
ECM relay
Harness G45704->G99999 For ignition coil
Engine stalls soon after circuit tests, GO to Pinpoint Test
start MAF sensor G531328p1.
For air filter information,
Ignition system Intake Air Distribution and Filtering -
VIN Range: G00442->G45703 Check the
fuel lines,
Fuel lines
FRP sensor G45704->G99999 For FRP sensor tests,
Air leakage G45704->G99999 For intake system
information,
Fuel pump
Check the fuel pressure, check the fuel
Injector leak lines,
Fuel pressure AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
Fuel lines G45704->G99999 For intake system,
Air leakage
VIN Range: G00442->G45703 For TP
Throttle position (TP) sensor and throttle motor tests,
sensors Electronic Engine Controls - VIN Range:
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acceleration
G531328p1.
Ignition system For EGR valve tests,
HO2 sensors relating to HO2 sensors. Refer to the
DTC index for pinpoint tests for DTC set.
Transmission malfunction For transmission information,
Check the accelerator pedal travel. For
Restricted pedal travel APP sensor tests,
(carpet, etc) Electronic Engine Controls - VIN Range:
G45704->G99999
(APP) sensor
lines,
Air leakage AJ27/3.5L NA V8 - AJV8, VIN Range:
Engine backfires G45704->G99999 For intake system,
MAF sensor
HO2 sensors VIN Range: G00442->G45703 For MAF
sensor tests,
Ignition system Electronic Engine Controls - VIN Range:
Sticking variable camshaft relating to HO2 sensors. Refer to the
timing (VCT) hub DTC index for pinpoint tests for DTC set.
APP sensor Pinpoint Test G531328p1.
For VCT information,
G45704->G99999

lines,
MAF sensor
Engine surges G45704->G99999 For MAF, TP sensor
Harness
and throttle motor tests,
G531328p1.
Ignition system
malfunction Electronic Engine Controls - VIN Range:
Fuel pump pressure, check the fuel lines,
Fuel lines AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
FRP sensor
G45704->G99999 For FRP, MAF and
Engine detonates/knocks HO2 sensor tests,
MAF sensor
HO2 sensors G45704->G99999 For intake system,
DTCs for VCT range/performance fault.
Sticking VCT hub For VCT information,
Engine Refer to the warranty policy and
(internal ECM fault) procedures manual if an ECM is suspect.
APP sensor malfunction For APP, TP sensor and throttle motor

tests,
G45704->G99999
Throttle motor
Poor throttle response APP sensor malfunction For APP, TP, ECT and MAF sensor tests,
TP sensors G45704->G99999 For transmission
information,
ECT sensor For intake system,
MAF sensor
Transmission malfunction breather system information,
Traction control event G45704->G99999
Air leakage
Breather system

NOTE:
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NOTE:


circuit

(including relay)
drive circuit: short circuit to For ignition coil tests, GO to
P035200 primary/secondary ground, high resistance Pinpoint Test G531328p1.
circuit

(including relay)
circuit

(including relay)
circuit

(including relay)
circuit

(including relay)
circuit

(including relay)
Cylinder 7 ignition coil ECM to ignition module/coil
P035700 primary/secondary drive circuit: short circuit to
ground, high resistance Pinpoint Test G531328p1.
circuit

(including relay)
circuit

(including relay)
For spark plug tests, GO to
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GO to Pinpoint Test
Spark plug G531328p1.
failure/fouled/incorrect gap
Check the fuel pressure,
Ignition coil failure Fuel Tank and Lines - 4.2L NA
V8 - AJV8/4.2L SC V8 -
ECM to ignition coil primary AJV8/3.0L NA V6 - AJ27/3.5L
circuit fault (cylinder misfire NA V8 - AJV8, VIN Range:
P131500 Persistent misfire
detected DTC also flagged) G45704->G99999 For injector
circuit tests,
Fuel delivery pressure low Fuel Charging and Controls -
(injector DTCs also flagged) Check the cylinder
compressions,
Cylinder compression low Engine - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 -
AJV8

Ignition amplifier circuit to ground, short For ignition coil tests, GO to
P136700 circuit to power
group A Pinpoint Test G531328p1.
Ignition module/coils right hand

Ignition amplifier Ignition monitoring circuit to For ignition coil tests, GO to
P136800
group B ECM: open circuit, short Pinpoint Test G531328p1.
circuit to ground, short
circuit to power
Ignition module/coils left hand

Pinpoint Tests
NOTE:
NOTE:
PINPOINT TEST G531328p1 : IGNITION

COIL CIRCUITS
1. Disconnect the relevant ignition coil electrical connector:
Ignition coil connector
Cylinder 1, PI02
Cylinder 2, PI06
Cylinder 3, PI03
Cylinder 4, PI07
Cylinder 5, PI04
Cylinder 6, PI08
Cylinder 7, PI05
Cylinder 8, PI09
2. Key on, engine off. 3. Make sure the ignition relay is energized. 4. Measure the voltage between:
-> Yes
REPAIR the relevant ignition coil supply circuit. This circuit includes fuse 30 of the front power
distribution box and the ignition relay. For additional information, refer to the wiring diagrams.
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CLEAR the DTCs and test the system for normal operation.
-> No

CIRCUIT TO GROUND
-> Yes
-> No
CIRCUIT TO POWER
-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No
G531328t3 : CHECK THE IGNITION COIL GROUND CIRCUIT FOR HIGH

RESISTANCE
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-> Yes
-> No

RESISTANCE
PI02, pin 04 Pin 61
PI06, pin 04 Pin 60
PI03, pin 04 Pin 59
PI07, pin 04 Pin 58
PI04, pin 04 Pin 57
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PI08, pin 04 Pin 56
PI05, pin 04 Pin 55
PI09, pin 04 Pin 54
-> Yes
-> No
G531328t7 : CHECK THE IGNITION COIL MONITOR CIRCUITS FOR HIGH

RESISTANCE
PI02, pin 02 Pin 62
PI06, pin 02 Pin 64
PI03, pin 02 Pin 64
PI07, pin 02 Pin 62
PI04, pin 02 Pin 64
PI08, pin 02 Pin 62
PI05, pin 02 Pin 62
PI09, pin 02 Pin 64

-> Yes
-> No
INSTALL a new ignition coil to the relevant cylinder.
Ignition Coil-On-Plug (18.20.40) Clear the DTC and test the system for normal operation. Refer to the
warranty policy and procedures manual if an ECM is suspect.

1. Remove the suspect spark plug(s). 2. Measure the resistance between:
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Spark plug Spark plug
Center electrode tip HT contact
-> Yes
-> No
INSTALL a new spark plug. CLEAR the DTC and test the system for normal operation.
Ignition Coil-On-Plug (18.20.40)

Removal
1 . Remove the oil level indicator.
2 . NOTE:

Installation
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303-07C : Glow Plug System
Specifications
Specifications
Glow plug 10 - 89
Glow Plug System

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1 Glow plug module
2 Pre-heat warning light
3 Glow plug
4 Glow plug harness
5 Glow plug fuse
The fundamental purpose of the glow plugs is to improve the cold start capability, cold start
emissions and customer perception of the vehicle, such as short glow plug times and
minimum cranking times, as well as low combustion noise at low ambient temperatures.
The maximum current when switched on will be approximately 18 Amps per glow plug at 40°
C (104° F) with a 12 Volt supply.
The glow plug control module (GPCM) is located in the engine bay on the right-hand side. It
acts as a switch for the current to the glow plugs and is controlled via the engine control
module (ECM). Above a given coolant temperature, glow plugs will not be switched on
before, during or after starting. Within a certain coolant temperature range, the glow plugs
will be active before cranking to increase combustion chamber temperature, during cranking
to assist engine starting, and after the engine has started in order to reduce the emissions of
white and possibility black smoke from the tail pipe immediately following a cold start.
The ECM is connected to the GPCM via a reference control line and a diagnostic line. The
former will be pulled down by the ECM causing the GPCM to switch on and to remain
switched on while the reference voltage is low. The ECM will store the error information
generated by the GPCM in the case of glow plug failure.
Glow Plug System

Overview

Glow Plug System

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2 . Visually inspect for obvious signs of electrical damage.
Electrical
Glow plug lamp
Fuses (100 Amp midifuse and fuse 9 of the front power distribution box)
Glow plug control module (GPCM)
Engine management control relay
Wiring harness(es)
Electrical connector(s)
Glow plug(s)
and test the system for normal operation before proceeding to the next step.
Symptom chart
Check the glow plug harnesses at the glow plugs and at

Poor starting Glow plugs the connection to the main harness. For additional
inoperative/ineffici
(extreme information, refer to the wiring diagrams. Check for
ent
weather DTCs indicating a control module or circuit fault. The
conditions) Fuel temperature too fuel system recycles fuel until operating temperature is
low reached to reduce this possibility.

the connection to the main harness. For additional
High cold-
information, refer to the wiring diagrams. Check for
engine After-glow phase
inoperative DTCs indicating a control module or circuit fault. After-
emissions
glow is designed to function at engine temperatures
below 50° C (122° F), and below 2500 rpm.

High cold- the connection to the main harness. For additional
engine noise, information, refer to the wiring diagrams. Check for
After-glow phase
vibration or inoperative DTCs indicating a control module or circuit fault. After-
harshness glow is designed to function at engine temperatures
below 50° C (122° F), and below 2500 rpm.
DTC index
NOTE:
NOTE:

DTC Description Possible source Action
Glow plug control The GPCM is driven, but the For GPCM circuit tests, GO to
P038000
module (GPCM) glow plugs are not Pinpoint Test G552799p2.
powered
Glow plug control The GPCM is not driven, but For GPCM circuit tests, GO to
P038200
module (GPCM) the glow plugs are Pinpoint Test G552799p2.
powered
Glow plug control For GPCM control circuit tests,
P038300 module (GPCM) circuit GPCM control circuit: short GO to Pinpoint Test
low circuit to ground G552799p1.

P038400 module (GPCM) circuit GPCM control circuit: short GO to Pinpoint Test
high circuit to power G552799p1.

P067000 module (GPCM) circuit GPCM control circuit: high GO to Pinpoint Test
open resistance G552799p1.
Pinpoint Tests
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NOTE:
NOTE:
NOTE:
terminals.
PINPOINT TEST G552799p1 : GLOW
PLUG CONTROL MODULE (GPCM)
CONTROL CIRCUIT
G552799t1 : CHECK THE GPCM CONTROL CIRCUIT FOR SHORT CIRCUIT TO
GROUND
1.
Circuit Pin
Ground 01
Control from ECM 02
Power supply from FPDB 03
Logic monitor 05
2.
Circuit Pin
Glow plug control module signal G3
Logic monitor E3
3. Key off. 4. Disconnect the GPCM electrical connector, EC69. 5. Measure the resistance between:
E69, harness side Battery
-> Yes
-> No
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G552799t2 : CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR

THE MODULE
-> Yes
-> No
G552799t3 : CHECK THE GPCM CONTROL CIRCUIT FOR SHORT CIRCUIT TO

POWER

-> Yes
-> No

THE module
-> Yes
-> No
G552799t5 : CHECK THE GPCM CONTROL CIRCUIT FOR HIGH RESISTANCE

EC69, harness side C100, harness side
Pin 02 Pin G3

-> Yes
physical damage to the harness. Refer to the warranty policy and procedures manual if a module is
suspect.
-> No
REPAIR the high resistance circuit. This circuit includes connector, PI41. For additional information,
refer to the wiring diagrams. Clear the DTC, test the system for normal operation.
PINPOINT TEST G552799p2 : GLOW

PLUG CONTROL MODULE (GPCM)
OUTPUT
G552799t6 : CHECK THE PERMANENT POWER SUPPLY TO THE GPCM
1.
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Circuit Pin
Ground 01
Control from ECM 02
Power supply from FPDB 03
Logic monitor 05
2.
Circuit Pin
Cylinder 1 output Pin 01
3.
Circuit Pin
Cylinder 1 01
Cylinder 2 02
Cylinder 3 03
4.
Circuit Pin
Cylinder 4 01
Cylinder 5 02
Cylinder 6 03
5. Disconnect the glow plug module connector, EC73 (this is an eyelet). 6. Measure the voltage
between:

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-> Yes
-> No
REPAIR the permanent power supply circuit. This circuit includes the 100A midi fuse. For additional
G552799t7 : CHECK THE IGNITION POWER SUPPLY TO THE GPCM

1. Disconnect the glow plug module connector, EC69. 2. Key on, engine off.
Make sure the EMS relay is energized 3. Measure the voltage between:
-> Yes
-> No
REPAIR the ignition power supply circuit. This circuit includes fuse 9 of the front power distribution
box. For additional information, refer to the wiring diagrams. Clear any DTCs, test the system for
normal operation.
G552799t8 : CHECK THE GROUND TO THE GPCM

-> Yes
-> No
G552799t9 : CHECK THE GLOW PLUG OUTPUT CIRCUITS FOR SHORT

CIRCUIT TO GROUND
1. Key off. 2. Disconnect the glow plug module connector, EC74 3. Disconnect the glow plug
connectors, EC76 and EC77. 4. Measure the resistance between:
Pin 01
Pin 03
Pin 04
Pin 06
-> Yes
-> No
G552799t10 : CHECK THE GLOW PLUG OUTPUT CIRCUITS FOR SHORT

CIRCUIT TO POWER
Pin 01
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Pin 03
Pin 04
Pin 06
-> Yes
-> No
G552799t11 : CHECK THE GLOW PLUG OUTPUT CIRCUITS FOR HIGH
RESISTANCE
Pin 01 Pin 01
Pin 02 Pin 02
Pin 03 Pin 03
Pin 04 Pin 01
Pin 05 Pin 02
Pin 06 Pin 03
-> Yes
If DTCs P0380 or P0382 are logged and the tests above have not identified a circuit fault, a control
module may be at fault.
-> No
DTC, test the system for normal operation.
Glow Plugs
Removal
1 . Remove the intake air shutoff throttle.
For additional information, refer to Intake Air Shutoff Throttle
2 . Remove the crankcase vent oil separator.

For additional information, refer to Crankcase Vent Oil Separator
3 NOTE:
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.
clockwise.
minutes.
4 . Detach the right-hand glow plug electrical connector.

5 . Detach the left-hand glow plug electrical connector.
6 . Remove the right-hand bank glow plugs.
7 . Remove the left-hand bank glow plugs.

Installation
1 NOTE:
.
Make sure glow plug electrical connector is correctly fitted to all glow plugs on the left-
hand bank.
Tighten to 10 Nm.
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2 NOTE:
.
Make sure glow plug electrical connector is correctly fitted to all glow plugs on the right-
hand bank.
Tighten to 10 Nm.
3 . NOTE:
Tighten to 25 Nm.
303-08A : Engine Emission Control – 4.2L NA V8 –
AJV8/4.2L SC V8 – AJV8/3.0L NA V6 – AJ27/3.5L NA V8
– AJV8
Specifications
Specifications

Exhaust gas recirculation (EGR) valve to intake manifold retaining bolts 10 7 -
EGR valve tube to EGR valve retaining bolts 21 15 -
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Exhaust manifold to EGR valve tube retaining nuts 21 15 -

Specifications
lb- lb-
Description Nm
ft in
Exhaust gas recirculation (EGR) valve to intake manifold retaining bolts -
10 7 -
EGR valve tube to EGR valve retaining bolts - Vehicles with 3.5L or 4.2L
21 15 -
engine
Exhaust manifold to EGR valve tube retaining nuts - Vehicles with 3.5L or
21 15 -
4.2L engine
Secondary air injection (AIR) control valve to exhaust manifold tube retaining
35 26 -
nuts
AIR control valve to exhaust manifold tube to exhaust manifold adaptor 35 26 -
Exhaust manifold blanking plug - Vehicles without AIR 35 26 -
AIR control valve bracket retaining bolt - Vehicles with 3.0L engine 8 - 71
AIR control valve bracket retaining nut - Vehicles with 3.0L engine 8 - 71
AIR control valve retaining bolts - Vehicles with 3.5L or 4.2L engine 25 18 -
AIR pump retaining nuts 20 15 -
AIR vacuum reservoir retaining nut 5 - 44
AIR vacuum reservoir retaining bolt 5 - 44

G00442->G45703
Positive Crankcase Ventilation System
Vehicles fitted with 3.5L or 4.2L engine

On vehicles fitted with a 3.5L or 4.2L engine the positive crankcase ventilation (PCV) system consists
of a PCV valve, and two PCV hoses. The PCV valve is mounted on the right-hand valve cover and a
hose is connected between PCV valve and the throttle body elbow. The PCV valve regulates the
amount of ventilation air and crankcase gas supplied to the intake manifold and also prevents
backfiring into the crankcase. The left-hand valve cover PCV hose is connected to the air cleaner
outlet pipe.
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Vehicles fitted with 3.0L engine

On vehicles fitted with 3.0L engine the PCV system consists of two hoses, connected between the
left-hand valve cover and the intake manifold and the right-hand valve cover and the air cleaner
outlet pipe.
The PCV system recycles crankcase gases back through the engine where they mix with incoming
air/fuel charge.
The positive crankcase ventilation system helps to reduce hydrocarbon emissions from the engine.
Exhaust Gas Recirculation System
Exhaust Gas Recirculation (EGR) Valve

Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
The exhaust gas recirculation (EGR) system is fitted on all vehicles fitted with a 3.5L or 4.2L engine. It
comprises of an EGR valve and exhaust manifold to EGR valve tube. The EGR system allows a
measured quantity of exhaust gas to be directed back to the intake manifold. The exhaust gas is
introduced to the incoming charge in the intake manifold, where it mixes with the air/fuel mixture
and lowers the peak gas temperature, reducing nitrogen oxide (NOX) exhaust emissions. The gas is
drawn through the exhaust manifold to EGR valve tube from the exhaust to the inlet manifold via the
EGR valve. The EGR valve is electrically operated and is controlled via an input from the engine
control module (ECM).
On vehicles without supercharger the EGR valve is mounted on the intake manifold. On vehicles with
supercharger the EGR valve is mounted on the throttle body elbow.
The ECM can monitor the operation of the EGR system by receiving inputs from the manifold
absolute pressure (MAP) sensor. The MAP sensor monitors the EGR flow by the change in intake
manifold pressure when the EGR valve is operated. If at any time the input signal to the ECM exceeds
pre-defined thresholds due to low pressure reading for a calibrated period of time, a diagnostic
trouble code (DTC) is recorded.
On vehicles without supercharger the MAP sensor is mounted on the rear of intake manifold. On
vehicles with supercharger the MAP sensor is mounted on the rear of the throttle body elbow.
<<303-14B>>
G45704->G99999
Positive Crankcase Ventilation (PCV) System
The PCV system recycles crankcase gases back through the engine where they mix with incoming
air/fuel charge and help to reduce hydrocarbon emissions.

The PCV system consists of two hoses, connected between the left-hand valve cover and the intake
manifold and the right-hand valve cover and the air cleaner outlet pipe.

The PCV system consists of a valve, and two hoses. The PCV valve is mounted on the right-hand valve
cover and a hose is connected between PCV valve and the throttle body elbow. The left-hand valve
cover PCV hose is connected to the air cleaner outlet pipe.
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The PCV valve regulates the amount of ventilation air and crankcase gas supplied to the intake
manifold and also prevents backfiring into the crankcase.
Exhaust Gas Recirculation (EGR) System - Vehicles with 3.5L or 4.2L engine
EGR Valve
EGR Valve Tube
The EGR system comprises of an EGR valve and exhaust manifold to EGR valve tube. The EGR system
allows a measured quantity of exhaust gas to be directed back to the intake manifold. The exhaust
gas is introduced to the incoming charge air in the intake manifold, where it mixes with the air/fuel
mixture and lowers the peak gas temperature, reducing nitrogen oxide (NOx) exhaust emissions. The
gas is drawn through the exhaust manifold to EGR valve tube from the exhaust to the inlet manifold
through the EGR valve. The EGR valve is electrically operated and is controlled through an input from
the engine control module (ECM).
On vehicles without a supercharger the EGR valve is mounted on the intake manifold. On vehicles
with a supercharger the EGR valve is mounted on the throttle body elbow.
The ECM monitors the operation of the EGR system from inputs from the manifold absolute pressure
(MAP) sensor and can detect high or low flow through the valve as a result of changes to the
pressure readings.
High or low flow outside the expected range results in the setting of a diagnostic trouble code (DTC).
On vehicles without a supercharger the MAP sensor is mounted on the rear of intake manifold. On
vehicles with a supercharger the MAP sensor is mounted on the rear of the throttle body elbow. For
additional information, refer to Electronic Engine Controls (303-14B)
Secondary Air Injection (AIR) System

To assist in the reduction of exhaust emissions to meet European Union (EU) Stage 4 and Federal
Petrol Emission standards, AIR is fitted to the vehicle.
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1 AIR vacuum reservoir
2 AIR switching valve
3 Exhaust manifolds
4 AIR pump
5 AIR control valve
The AIR pump is used to provide a supply of air into the exhaust manifolds during the cold start
period of the engine. The AIR cycle lasts for up to 65 seconds. The hot unburnt fuel particles leaving
the combustion chamber mix with the air injected into the exhaust manifolds and immediately
combust.
This subsequent combustion of the unburnt and partially burnt 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 AIR 'afterburning' reduces the time delay before the catalysts reach an efficient
operating temperature.
The AIR system comprises the following components:
AIR pump
AIR switching valve
AIR control valve
AIR vacuum reservoir
AIR pump relay
AIR pressure sensor (North American specification vehicles only)

AIR Pump
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The AIR 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 AIR pump operation. The AIR pump is
powered from the vehicle battery by a dedicated relay and supplies approximately 10 to 15 kg/hr (22
to 33 lb/hr) of air when the engine is at idle speed and the ambient temperature is below 20°C
(68°F).
Air is drawn into the AIR pump through vents in its front cover and is then passed through a foam
filter. The air is delivered to the exhaust manifold on each side of the engine through a combination
of plastic pipes and stainless steel tubes.
One second after the AIR pump is energised, the ECM switches on the AIR switching valve, which
opens to allow vacuum from the AIR vacuum reservoir to be applied to the vacuum operated AIR
control valve. When the vacuum is applied to the AIR control valve, it opens to allow the air from the
AIR pump through to the exhaust manifolds.
When the ECM switches off the AIR switching valve, the vacuum supply to the AIR control valve is
cut-off and the valve closes to prevent further air being injected into the exhaust manifolds. With an
approximate five second delay after as the AIR switching valve is closed, the ECM removes power
from the AIR pump relay, and this in turn stops the AIR pump from operating.
AIR Switching Valve
The ECM switches on the AIR switching valve with a one second delay after initiating AIR pump
operation. When the AIR switching valve is open, a steady vacuum supply is allowed through to open
the vacuum operated AIR control valve. When the ECM switches off the AIR switching valve, the
valve closes and immediately shuts off the vacuum supply to the AIR control valve. The pump
continues to operate for a further five seconds for system diagnostic purposes.
When the AIR switching valve is switched off, the vacuum supply line opens to atmosphere, and this
causes the AIR switching valve to close automatically to prevent any further injection of air.
AIR Control Valve
The injected air from the AIR pump is controlled by the AIR control valve. This allows the correct
amount of air to be injected directly into the exhaust manifolds. The AIR control valve prevents
exhaust gasses from blowing back into the AIR pump.
The AIR control valve is assisted in operation by a vacuum source from the AIR vacuum reservoir
located in the right-hand side of the engine bay. This assistance allows the actuation of the AIR
control valve independently from the intake manifold vacuum levels available.
When the pressure in the exhaust system is higher than in the AIR system, the AIR control valve
closes the circuit, and this protects the AIR system from exhaust gasses blowing back into the AIR
system.
Vacuum to the AIR switching valve is provided from the intake manifold vacuum by the AIR vacuum
reservoir. A small bore vacuum hose provides the vacuum route between the AIR vacuum reservoir
and AIR switching valve. A further small bore vacuum hose is used to connect the AIR switching valve
to the AIR control valve.
AIR Vacuum Reservoir

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The AIR vacuum reservoir is located on the right-hand side of the engine bay.
The AIR vacuum reservoir is included in the vacuum supply line between the intake manifold and the
AIR switching valve.
The AIR vacuum reservoir contains a one-way valve to stop vacuum leaking back towards the intake
manifold side. The AIR vacuum reservoir holds a constant vacuum so that the AIR control valve opens
as soon as the AIR switching valve is switched on.
AIR Pump Relay

The AIR pump relay is located on the AIR pump mounting bracket. The ECM is used to control the
operation of the AIR pump by the AIR pump relay.
The AIR system receives its voltage supply through the AIR pump relay. The ECM monitors the state
of the relay for correct operation as part of its system diagnostic.
AIR Pressure Sensor - North American specification vehicles only

The AIR system is monitored by measuring the system pressure by using the AIR pressure sensor at
several instances during its cycle of operation.
The AIR system pressure is measured before operation of the AIR pump. The AIR pump is then
switched on and with a one second delay, the AIR switching valve is opened. After a stabilizing
period, the system pressure is measured again, this time by taking the average of a one second
duration of readings, and normalising for variations in battery voltage and atmospheric pressure. If
the system pressure measured at this time has not risen enough with respect to the initial AIR
pressure reading then a failure will be flagged.
A second pressure measurement is made after the requirement for AIR into the exhaust system has
expired, but continuing on from the same period of AIR pump operation, i.e. the pump is left
running, against a closed AIR switching valve. Again this pressure measurement is the average of a
one second duration of readings normalised for variations in battery voltage and atmospheric
pressure. If the system pressure measured at this time has not risen enough or has risen too much
with respect to the system pressure during normal operation of AIR then a failure will be flagged.
A final pressure reading is taken after the AIR system has been switched off to ensure the system
shuts down.

G00442->G45703
4 . If the concern is not visually evident, refer to the Symptom Chart.
Diagnostic Trouble Code (DTC) P0400 indicates exhaust gas recirculation (EGR) system flow
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malfunction.
Possible Source(s):
Exhaust manifold to EGR valve pipe tube blocked.

Exhaust manifold to EGR valve pipe tube cracked.
EGR valve stuck closed.
EGR valve stuck open.
EGR valve loose.
Fuse 37 in the front power distribution box (FPDB).
Relay 5 in the FPDB
Electrical harness.
Action(s) to take:
GO to Pinpoint Test A.
Diagnostic Trouble Code (DTC) P0405 indicates exhaust gas recirculation (EGR) valve malfunction,
short to battery/12volts (V).
Possible Source(s):
Electrical harness.
Electrical connector(s).
Engine control module (ECM).
EGR valve.
Action(s) to take:
GO to Pinpoint Test B.
Diagnostic Trouble Code (DTC) P0406 indicates exhaust gas recirculation (EGR) valve malfunction,
short to ground/open circuit.
Possible Source(s):
Electrical harness.
Electrical connector(s).
ECM.
EGR valve.
Action(s) to take:
GO to Pinpoint Test C.
PINPOINT TEST G187746p1 : Diagnostic

Trouble Code (DTC) P0400 indicates
exhaust gas recirculation (EGR) system
flow malfunction.
G187746t24 : CHECK EGR VALVE FOR CORRECT FITMENT TO INTAKE
MANIFOLD
1. Check the EGR valve retaining bolts for correct torque.
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Was the EGR valve fitted correctly?
-> Yes
-> No
G187746t1 : CHECK EXHAUST GAS RECIRCULATION (EGR) VALVE TO

MANIFOLD/INTAKE ELBOW GASKET FOR CORRECT SEAL
1. Visually inspect the gasket for external damage.
Is the gasket damaged?
-> Yes
INSTALL a new gasket, make sure valve is seated correctly and retaining bolts installed to the correct
torque.
Exhaust Gas Recirculation (EGR) Valve (17.45.01) CLEAR DTC. To validate fix drive vehicle between 30
mph (48 kph) and 40 mph (64 kph). Allow vehicle to idle for 2 minutes.
-> No
G187746t2 : CHECK FOR EXHAUST MANIFOLD TO EGR VALVE TUBE FOR

DAMAGE or BLOCKAGES
1. Visually inspect the exhaust manifold to EGR valve tube.
Is the tube damaged or blocked?
-> Yes
If the tube is damaged INSTALL a new tube.
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube (17.45.11) CLEAR the DTC. To
validate fix drive vehicle between 30 mph (48 kph) and 40 mph (64 kph). Allow vehicle to idle for 2
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minutes. If the tube is blocked, unblock the tube. CLEAR DTC. TEST the system for normal operation.
-> No
G187746t3 : CHECK FOR POWER SUPPLY TO EGR VALVE

1. Disconnect EGR valve electrical connector PI 15 2. TURN ignition switch to the ON position 3.
MEASURE the voltage at PI 15 pin 2 (GU)
Is the voltage less than 10 volts
-> Yes
-> No
G187746t4 : CHECK FUSE 37 IN THE FRONT POWER DISTRIBUTION BOX

(FPDB)
1. Check the fuse.
Is the fuse ok?
-> Yes
-> No
G187746t5 : CHECK HARNESS BETWEEN FPDB AND EGR FOR SHORT TO

GROUND
1. Disconnect the EGR valve electrical connector PI 15. 2. CHECK the resistance between PI 15 pin 2
(GU) and ground.
Is the resistance less than 10,000 Ohms?
-> Yes
REPAIR the circuit between the EGR valve and FPDB. INSTALL a new fuse. CLEAR DTC. To validate fix
drive vehicle between 30 mph (48 kph) and 40 mph (64 kph). Allow vehicle to idle for 2 minutes.
-> No
INSTALL a new fuse. CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40 mph
(64 kph). Allow vehicle to idle for 2 minutes.
G187746t6 : CHECK FOR BATTERY VOLTAGE AT FPDB

1. CHECK for voltage at FPDB electrical connector FH 32 pin 43 (GU).
-> Yes
REPAIR the circuit between FPDB electrical connector FH 32 pin 43 (GU) and FPDB relay 5.
-> No
REPAIR the circuit between FPDB electrical connector FH 32 pin 43 (GU) and EGR valve electrical
connector PI 15 pin 2 (GU). CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
mph (64 kph). Allow vehicle to idle for 2 minutes.
G187746t19 : CHECK FOR POWER SUPPLY TO EGR VALVE

1. Disconnect EGR valve electrical connector PI 15 2. MEASURE the voltage at PI 15 pin 5 (GU)
-> Yes
REPAIR the circuit between PI 15 pin 5 (GU) and splice PIS 15. CLEAR DTC. TEST the system for normal
operation.
-> No
INSTALL a new EGR valve. CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
exhaust gas recirculation (EGR) valve
malfunction, short to battery/12volts
G187746t7 : CHECK FOR A SHORT TO BATTERY VOLTAGE
1. Disconnect the EGR valve electrical connectror PI 15. 2. TURN ignition switch to the ON position. 3.
Measure the voltage at PI 15 pin 4 (YU).
Is the voltage more than 1 volt?
-> Yes
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-> No
G187746t8 : CHECK FOR A SHORT TO BATTERY VOLTAGE IN ECM

1. Disconnect ECM electrical connector PI 1. 2. Measure the voltage at PI 15 pin 4 (YU).
-> Yes
REPAIR circuit between the PI 1 pin 57 (YU) and the EGR valve electrical connector PI 15 pin 4 (YU).
CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40 mph (64 kph). Allow vehicle
to idle for 2 minutes.
-> No
INSTALL a new ECM. <<303-14B>>CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph)
and 40 mph (64 kph). Allow vehicle to idle for 2 minutes.

1. Measure the voltage at PI 15 pin 1 (YG).
-> Yes
-> No

1. Disconnect ECM electrical connector PI 1. 2. Measure the voltage at PI 15 pin 1 (YG).
-> Yes
REPAIR circuit between the PI 1 pin 58 (YG) and the EGR valve electrical connector PI 15 pin 1 (YG).
-> No

1. Measure the voltage at PI 15 pin 6 (YR).
Is the voltage more than 1 Volt?
-> Yes
-> No

1. Disconnect ECM electrical connector PI 1. 2. Measure the voltage at PI 15 pin 6 (YR).
-> Yes
REPAIR circuit between the PI 1 pin 59 (YR) and the EGR valve electrical connector PI 15 pin 6 (YR).
-> No

1. Measure the voltage at PI 15 pin 3 (YU).
Is the voltage more than 1 Volt?
-> Yes
-> No
INSTALL a new EGR valve. CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40

1. Disconnect ECM electrical connector PI 1. 2. Measure the voltage at PI 15 pin 3 (YU).
-> Yes
REPAIR circuit between the PI 1 pin 60 (YU) and the EGR valve electrical connector PI 15 pin 3 (YU).
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-> No

exhaust gas recirculation (EGR) valve
malfunction, short to ground/open circuit.
G187746t13 : CHECK FOR A SHORT TO GROUND
1. Disconnect the EGR valve electrical connectror PI 15. 2. Disconnect the engine control module
(ECM) electrical connectror PI 1. 3. Measure the resistance between the EGR valve electrical
connector PI 15 pin 4 (YU) and GROUND.
-> Yes
REPAIR the circuit between EGR valve electrical connector PI 15 pin 4 (YU) and ECM electrical
connector PI 1 pin 57 (YU). CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
-> No
G187746t14 : CHECK FOR AN OPEN CIRCUIT

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 4 (YU) and ECM
electrical connector PI 1 pin 57 (YU).
Is the resistance more than 5.0 ohms?
-> Yes
connector PI 1 pin 57 (YU). CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
-> No

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 1 (YG) and GROUND.
-> Yes
REPAIR the circuit between EGR valve electrical connector PI 15 pin 1 (YG) and ECM electrical
connector PI 1 pin 58 (YG). CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
-> No

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 1 (YG) and ECM
electrical connector PI 1 pin 58 (YG).
Is the resistance more than 5.0 Ohms?
-> Yes
REPAIR the circuit between EGR valve electrical connector PI 15 pin 1 (YG) and ECM electrical
connector PI 1 pin 58 (YG). CLEAR DTC. To validate fix drive vehicle between 30 mph (48 kph) and 40
-> No
1. Measure the resistance between the EGR valve electrical connector PI 15 pin 6 (YR) and GROUND.
-> Yes
REPAIR the circuit between EGR valve electrical connector PI 15 pin 6 (YR) and ECM electrical
connector PI 1 pin 59 (YR). CLEAR DTC. TEST the system for normal operation.
-> No

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 6 (YR) and ECM
electrical connector PI 1 pin 59 (YR).

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-> Yes
REPAIR the circuit between EGR valve electrical connector PI 15 pin 6 (YR) and ECM electrical
connector PI 1 pin 59 (YR). CLEAR DTC. TEST the system for normal operation.
-> No

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 3 (YU) and GROUND.
-> Yes
connector PI 1 pin 60 (YU). CLEAR DTC. TEST the system for normal operation.
-> No

1. Measure the resistance between the EGR valve electrical connector PI 15 pin 3 (Yu) and ECM
electrical connector PI 1 pin 60 (YU).

-> Yes
connector PI 1 pin 60 (YU). CLEAR DTC. TEST the system for normal operation.
-> No
INSTALL a new EGR valve. CLEAR DTC. TEST the system for normal operation. If DTC is repeated
INSTALL a new ECM. CLEAR DTC. TEST the system for normal operation.
G45704->G99999
Overview
will be the change to 7-digit diagnostic trouble codes (DTCs) from the familiar 5-digit, and the
introduction of secondary air injection.
For additional information on the operation of the emission control systems.



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Fuses
Wiring harness
Engine breather hoses Loose or corroded electrical

connectors
Cyclone separator
Sensor(s)
Exhaust gas recirculation (EGR) pipes (check for
cracks) Stepper motor(s)
EGR valve Secondary air injection pump
Secondary air injection valve
Symptom Chart
Symptom
Symptom (specific) Possible source Action
(general)
Check the engine breather
Engine cranks, but
Non-Start Engine breather system system hoses, separator, etc.
does not fire disconnected/restricted Rectify as necessary.
Check the EGR valve,

Difficult to Exhaust Gas Recirculation
Difficult to start cold Exhaust gas recirculation
start (EGR) valve stuck open (EGR) Valve (17.45.01) Check
the pipework.

Engine stalls soon
Breather system system hoses, separator, etc.
after start disconnected/restricted Rectify as necessary.
Engine stalls
Check the EGR valve.
Engine stops/stalls Exhaust Gas Recirculation
(EGR) Valve (17.45.01)

Rough
Poor idle quality Exhaust Gas Recirculation
running EGR valve stuck open
(EGR) Valve (17.45.01)
Engine Check the EGR valve.

hesitates/poor Exhaust Gas Recirculation
acceleration (EGR) Valve (17.45.01)
Poor
driveability
Poor throttle
Breather system system hoses, separator, etc.
response disconnected/restricted Rectify as necessary.

Exhaust Gas Recirculation
Fuel EGR valve stuck open (EGR) Valve (17.45.01) For EGR
consumption
valve circuit tests. GO to
Excessive: EGR system not operating
Black smoke Pinpoint Test G528708p1.
Crankcase ventilation Check the engine breather
Emissions system restricted system hoses, separator, etc.
Rectify as necessary.
Inspect the EGR pipes, paying

Loud 'ticking' noise particular attention to the
Noisy
with engine running EGR pipes cracked ribbed sections. Replace as
necessary.
Oil leakage Engine oil leaks Crankcase ventilation Check the engine breather
system restricted system hoses, separator, etc.
Rectify as necessary.
DTC index
NOTE:
NOTE:
For a full list of DTCs.

Electronic Engine Controls - VIN Range: G45704->G99999 or
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EGR valve incorrectly fitted or

loose Check the fitment of the
EGR valve.
EGR valve stuck closed,
P040100 EGR flow insufficient Exhaust Gas Recirculation
blocked
(EGR) Valve (17.45.01)
EGR pipe blocked Check the EGR pipework.
EGR valve mechanical failure

For secondary air
Secondary air injection Secondary air valve control injection valve circuit
P041300
valve circuit circuit: short circuit to tests, GO to Pinpoint
power Test G528708p4.
Secondary air valve control For secondary air

Secondary air injection injection valve circuit
P041400 ground
valve circuit tests, GO to Pinpoint
Secondary air valve control Test G528708p4.
EGR valve power supply
circuit: short circuit to For EGR stepper circuit
Exhaust gas recirculation
P048900 ground tests, GO to Pinpoint
(EGR) control circuit low
Test G528708p1.
For EGR stepper circuit
P049000 EGR valve to ECM drive circuit: tests, GO to Pinpoint
(EGR) control circuit high short circuit to power Test G528708p1.
Check the secondary air

Secondary air injection injection system
Secondary air injection pump/valve/pipework pipework, etc. For pump
system air flow/pressure leaks tests. GO to Pinpoint
P243100
sensor circuit Test G528708p2.
range/performance Secondary air injection pump For valve tests. GO to
Pinpoint Test
G528708p4.
Secondary air injection

manifold pressure (MAP)
sensor circuit: short circuit For secondary air
to ground injection MAP sensor
P243200 system air flow/pressure
sensor circuit low Secondary air injection Test G528708p3.
manifold pressure (MAP)
sensor circuit: high
resistance
For secondary air
Secondary air injection Secondary air injection
injection MAP sensor
P243300 system air flow/pressure manifold pressure (MAP)
sensor circuit high sensor circuit: short circuit tests, GO to Pinpoint
For secondary air

Secondary air injection Secondary air injection pump injection pump circuit
P244400
system pump stuck ON control circuit: short circuit tests, GO to Pinpoint
to ground Test G528708p2.
For secondary air

Secondary air injection Secondary air injection pump injection pump circuit
P244500
system pump stuck OFF control circuit: short circuit tests, GO to Pinpoint
Pinpoint tests
NOTE:
NOTE:

THE EGR STEPPER SUPPLY AND
CONTROL CIRCUITS
G528708t1 : CHECK THE EGR STEPPER SUPPLY VOLTAGE CIRCUITS
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1. Key off. 2. Disconnect the EGR stepper electrical connector, PI15. 3. Key on, ignition off.
Make sure the EMS relay is energized. 4. Measure the voltage between:
EGR stepper connector, PI15 Battery
Pin 02
Negative terminal
Pin 05
-> Yes
REPAIR the relevant EGR stepper supply voltage circuit. This circuit includes the front power
distribution box (fuse 14) and the EMS control relay. For additional information, refer to the wiring
diagrams. CLEAR the DTCs and test the system for normal operation.
-> No
G528708t2 : CHECK THE EGR STEPPER CONTROL CIRCUITS FOR SHORT

CIRCUIT TO GROUND
Pin 04
Pin 01
Negative terminal
Pin 06
Pin 03
-> Yes
-> No
G528708t3 : CHECK THE EGR STEPPER CONTROL CIRCUITS FOR SHORT

CIRCUIT TO POWER
Pin 04
Pin 01
Positive terminal
Pin 06
Pin 03
-> Yes
-> No
G528708t4 : CHECK THE EGR STEPPER CONTROL CIRCUITS FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, EC300. 3. Measure the resistance between:
EGR stepper connector, PI15 ECM connector, EC300
Pin 04 Pin 53
Pin 01 Pin 52
Pin 06 Pin 51
Pin 03 Pin 50
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-> Yes
-> No
INSTALL a new EGR valve.
Exhaust Gas Recirculation (EGR) Valve (17.45.01) CLEAR the DTC and test the system for normal
operation. Refer to the warranty policy and procedures manual if an ECM is suspect.

THE SECONDARY AIR INJECTION
PUMP CIRCUITS
G528708t5 : CHECK THE SECONDARY AIR INJECTION PUMP RELAY SUPPLY
VOLTAGES
1. Key off. 2. Remove the secondary air injection pump relay. 3. Measure the voltage between:
Secondary air injection relay base Battery

Pin 03
-> Yes
REPAIR the circuit between the relay base and battery. This circuit includes in-line (fuse 2) and the
mega fuses. For additional information, refer to the wiring diagrams. CLEAR the DTC and test the
-> No
G528708t10 : CHECK THE SECONDARY AIR INJECTION RELAY TO PUMP

SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Disconnect the secondary air injection pump electrical connector, EC93. 2. Measure the resistance
between:
-> Yes
-> No

SUPPLY CIRCUIT FOR SHORT CIRCUIT TO POWER

-> Yes
-> No
G528708t6 : CHECK THE SECONDARY AIR INJECTION PUMP SIGNAL CIRCUIT


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-> Yes
-> No

-> Yes
-> No

SUPPLY CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the secondary air pump connector, EC93. 2. Measure the resistance between:
Secondary air injection relay base Secondary air pump connector, EC93
Pin 05 Pin 02
-> Yes
-> No
G528708t13 : CHECK THE SECONDARY AIR INJECTION PUMP GROUND

Secondary air pump connector, EC93 Battery
-> Yes
-> No
FOR HIGH RESISTANCE
Secondary air injection relay base ECM connector, EC300
Pin 02 Pin 50
-> Yes
-> No
INSTALL a new secondary air injection pump relay. CLEAR the DTC and test the system for normal
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operation.
PINPOINT TEST G528708p3 : (V8 N/A

FEDERAL SPECIFICATION ONLY)
CHECK THE SECONDARY AIR
INJECTION MAP SENSOR CIRCUITS
G528708t9 : CHECK THE SECONDARY AIR INJECTION MAP SENSOR SUPPLY
1. Key off. 2. Disconnect the secondary air injection MAP sensor electrical connector, EC120. 3.
Secondary air injection MAP sensor connector, EC120 Battery
-> Yes
-> No

-> Yes
-> No
G528708t15 : CHECK THE SECONDARY AIR INJECTION MAP SENSOR SIGNAL

-> Yes
-> No

-> Yes
-> No

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Secondary air injection MAP sensor connector, EC120 ECM connector, EC300
Pin 01 Pin 19
-> Yes
-> No

Pin 02 Pin 13
-> Yes
-> No
G528708t19 : CHECK THE SECONDARY AIR INJECTION MAP SENSOR

Pin 03 Pin 07
-> Yes
-> No
INSTALL a new secondary air injection MAP sensor. CLEAR the DTC and test the system for normal
operation.

THE SECONDARY AIR INJECTION
VALVE CIRCUITS
G528708t20 : CHECK THE SECONDARY AIR INJECTION VALVE SUPPLY
VOLTAGE
1. Key off. 2. Disconnect the secondary air injection valve electrical connector, PI90. 3. Key on, engine
off. 4. Measure the voltage between:
Secondary air injection valve connector, PI90 Battery

-> Yes
REPAIR the supply circuit between the secondary air injection valve and battery. This circuit includes
fuse 27 of the front power distribution box and the mega fuse. For additional information, refer to
the wiring diagrams. CLEAR the DTC and test the system for normal operation.
-> No
G528708t21 : CHECK THE SECONDARY AIR INJECTION VALVE CONTROL


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-> Yes
-> No

-> Yes
-> No

Secondary air injection valve connector, PI90 ECM connector, EC300
Pin 01 Pin 55
-> Yes
-> No
INSTALL a new secondary air injection valve.
Secondary Air Injection (AIR) Control Valve - 3.0L NA V6 - AJ27
Secondary Air Injection (AIR) Control Valve - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8
Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 - AJV8 CLEAR the DTC and test the system for
normal operation.

(17.45.01)
Removal
Left-hand drive vehicles with Supercharger
2 . Remove the cabin air filter housing retaining nut.

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4 . Remove the engine compartment panel.

. For additional information, refer to Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G00442-
>G45703 (19.70.04)
For additional information, refer to Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G45704-
>G99999 (19.70.04)
7 . NOTE:
Disconnect the coolant hoses.

8 . Remove the exhaust manifold to EGR valve tube retaining nuts.
9 . Remove the EGR valve and the exhaust manifold to EGR valve tube.
Remove and discard the exhaust manifold to EGR valve tube gasket.
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Remove and discard the EGR valve to air intake elbow gasket.
10 Remove the EGR valve.

.
Remove and discard the EGR valve to exhaust manifold to EGR valve tube
gasket.
11 . NOTE:
Disconnect the EGR valve coolant hoses.
1) Disconnect the EGR valve electrical connector.
2) Disconnect the EGR valve coolant hoses.
12 . Remove the retaining bolts.

13 Remove the EGR valve.
.
Remove and discard the EGR valve to exhaust manifold to EGR valve tube
gasket.
Remove and discard the EGR valve to intake manifold gasket.

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Installation
1 . Install the EGR valve.
Install a new EGR valve to exhaust manifold to EGR valve tube gasket.
Tighten to 21 Nm.
Install a new exhaust manifold to EGR valve tube gasket.
Install a new EGR valve to air intake elbow gasket.

Tighten to 10 Nm.
4 . NOTE:
5 . Connect the EGR valve electrical connector.

>G45703 (19.70.04)
For additional information, refer to Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G45704-
>G99999 (19.70.04)
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Install a new EGR valve to exhaust manifold to EGR valve tube gasket.
Install a new EGR valve to intake manifold gasket.
Tighten to 10 Nm.
9 . NOTE:
Connect the EGR valve electrical connector.
1) Connect the EGR valve coolant hoses.
2) Connect the EGR valve electrical connector.
Left-hand drive vehicles with Supercharger

10 . Install the engine compartment panel.
12 . Install the cabin air filter housing retaining nut.

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13 . Install the cabin air filter.

All vehicles
14 . Check and top up the coolant expansion tank.
15 NOTE:
.

Test
Exhaust Manifold to Exhaust Gas
Recirculation (EGR) Valve Tube (17.45.11)
Removal
1 Remove the exhaust gas recirculation (EGR) valve.
. For additional information, refer to Exhaust Manifold to Exhaust Gas Recirculation (EGR)
Valve Tube (17.45.11)

3 . Remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube.
Installation
For additional information, refer to Exhaust Gas Recirculation (EGR) Valve (17.45.01)
2 . Install the exhaust manifold to exhaust gas recirculation (EGR) valve tube.
Tighten to 21 Nm.
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3 . Install the intake manifold.

Secondary Air Injection (AIR) Control
Valve - 3.0L NA V6 - AJ27
Removal
1 Remove the secondary air injection (AIR) control valve to exhaust manifold right-hand tube.
. For additional information, refer to Secondary Air Injection (AIR) Control Valve to Exhaust
Manifold Tube RH - 3.0L NA V6 - AJ27
2 . Disconnect the AIR switching valve electrical connector.
3 . Disconnect the AIR switching valve vacuum hoses.
4 . Detach the AIR wiring harness.

5 . Disconnect the AIR control valve vacuum hose.
6 . NOTE:
Note the position of the timing marks on the AIR control valve and the AIR supply hose.
Disconnect the AIR supply hose.

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7 . Remove the AIR control valve and bracket assembly.
Installation
Tighten to 8 Nm.
Valve - 4.2L NA V8 - AJV8/3.5L NA V8 -
AJV8
Removal

3 . Disconnect the secondary air injection (AIR) control valve vacuum hose.
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5 . Reposition the AIR control valve downwards.
Remove the AIR control valve retaining bolts.

7 . Remove the AIR control valve.
Disconnect the AIR control valve supply hose.
Installation
Tighten to 25 Nm.
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3 NOTE:
.
If required, carry out a short drive cycle.

For additional information, refer to Powertrain Control Module (PCM) Short Drive Cycle Self-
Test
Valve - 4.2L SC V8 - AJV8
Removal
2 . Remove the radiator grille opening panel.


4 . Remove the air cleaner intake duct.
6 . Disconnect the AIR control valve vacuum hose.

7 . Release the hose from the cooling fan motor and shroud.
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8 . Disconnect the AIR control valve air supply hose.
1) Release the hose from the cooling fan motor and shroud.
2) Disconnect the AIR control valve air supply hose.
9 . Remove the AIR control valve.

Installation
1 . Install the AIR control valve.
Tighten to 25 Nm.
2 . Connect the AIR control valve air supply hose.
1) Connect the AIR control valve air supply hose.
2) Secure the hose to the cooling fan motor and shroud.

3 . Secure the hose to the cooling fan motor and shroud.
4 . Connect the AIR control valve vacuum hose.

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Tighten to 35 Nm.
6 . Install the air cleaner intake duct.

8 . Install the radiator grille opening panel.


10 NOTE:
.

Test
Valve to Exhaust Manifold Tube LH - 3.0L
NA V6 - AJ27
Removal
2 NOTE:
.
Note the position of the timing mark on the secondary air injection (AIR) control valve to
exhaust manifold left-hand tube. The timing mark indicates the correct end of the AIR
control valve to exhaust manifold left-hand tube that should be connected to the AIR
control valve to exhaust manifold right-hand tube.
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Disconnect the secondary air injection (AIR) control valve to exhaust manifold left-hand tube.
3 Remove the AIR control valve to exhaust manifold left-hand tube from the left-hand exhaust
. manifold.
Installation
Tighten to 35 Nm.
2 NOTE:
.
Make sure that the timing mark on the AIR control valve to exhaust manifold left-hand
tube is correctly aligned.
Tighten to 35 Nm.
Valve to Exhaust Manifold Tube RH - 3.0L
NA V6 - AJ27
Removal

3 Disconnect the secondary air injection (AIR) control valve to exhaust manifold right-hand tube
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. from the right-hand exhaust manifold.
4 . Disconnect the AIR control valve to exhaust manifold left-hand tube.
5 . Disconnect the AIR control valve to exhaust manifold right-hand tube.

6 . Remove the AIR control valve to exhaust manifold right-hand tube.
Installation
Tighten to 8 Nm.
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Valve to Exhaust Manifold Tube - 4.2L NA
V8 - AJV8/3.5L NA V8 - AJV8, 4.2L
Removal
All vehicles
3 . Remove the right-hand exhaust manifold heat shield upper retaining bolts.

5 Disconnect the secondary air injection (AIR) control valve to exhaust manifold tube from the
. left-hand exhaust manifold.
6 . Remove the steering gear coupling upper pinch bolt
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7 . Remove the steering gear coupling.
Remove the steering gear coupling lower pinch bolt.
All vehicles
8 . Remove the right-hand heated oxygen sensor (HO2S).
For additional information, refer to Heated Oxygen Sensor (HO2S)
9 . Remove the right-hand exhaust manifold heat shield.

10 Disconnect the AIR control valve to exhaust manifold tube from the right-hand exhaust
. manifold.
13 . NOTE:
Disconnect the AIR control valve to exhaust manifold tube.

14 . NOTE:
Remove the AIR control valve to exhaust manifold tube.

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Installation
All vehicles
1 . NOTE:
Tighten to 35 Nm.

All vehicles
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Valve to Exhaust Manifold Tube - 4.2L SC
V8 - AJV8, 4.2L
Removal
3 Disconnect the secondary air injection (AIR) control valve to exhaust manifold tube from the
. left-hand exhaust manifold.

7 Disconnect the AIR control valve to exhaust manifold tube from the right-hand exhaust
. manifold.
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8 . Remove the AIR control valve to exhaust manifold tube.
Installation
Tighten to 35 Nm.
Secondary Air Injection (AIR) Pump
Removal
1 Remove the front bumper cover.
. For additional information, refer to Front Bumper Cover - VIN Range: G00442->H18679
(76.22.78)
2 . Disconnect the secondary air pump relay electrical connector.

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3 . Disconnect the secondary air pump electrical connector.
4 . Disconnect the secondary air pump hose.

5 . Remove the secondary air pump.
Installation
Tighten to 20 Nm.
2 NOTE:
.

Test
303-08B : Engine Emission Control – 2.7L V6 – TdV6
Specifications
Specifications

Exhaust gas recirculation (EGR) valve to cylinder head retaining bolts 10 – 89
EGR valve to EGR cooler retaining bolts 10 – 89
EGR valve tube to exhaust manifold retaining bolts 10 – 89
EGR valve cooler mounting bracket retaining bolt 10 – 89
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EGR valve outlet tube to EGR valve retaining bolts 10 – 89

EGR valve outlet tube to timing cover retaining bolt 5 – 44
Fuel filter mounting bracket retaining 10 mm bolt 25 18 –
Fuel filter mounting bracket retaining 6 mm bolt 10 – 89

Crankcase Ventilation
The crankcase ventilation system on the 2.7L Diesel ensures that all gases emitted from the
crankcase during engine running are separated from any oil particles.
1 Left-hand breather tube
2 Crankcase vent oil seperator
3 Right-hand breather tube

4 Crankcase oil return tube
5 Crankcase oil return valve
6 Oil return tube
Crankcase ventilation is by a cyclone seperator. The oil seperator is constructed from a plastic
composite material. The oil seperator is located between the ‘V’ at the back of the engine block by
means of three seals. The oil seperator contains a diaphragm and spring which opens under intake
vacuum.
The ventilation systems first chamber is a horizontal void cavity fed by eight points. Once primary
separation is complete, the partially cleaned vapor is sucked through a cyclone where the process
further reduces the oil content. Prior to the vapor entering the air supply at the compressor, a
diaphragm pressure balance valve operates to minimize the crankcase pressure variations caused by
engine air demand and service condition.
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Due to the shape and design of the cyclone unit, the oil and vapor are seperated more effectively.
Vapor is directed into the inlet system and the heavier oil drains back into the engine.
Exhaust Emission Control

The exhaust of a diesel engine contains the following pollutants:
Carbon Monoxide (CO)
Hydrocarbons (HC)
Particulates
Oxides of Nitrogen (NOx)
These pollutants are primarily produced as a result of incomplete combustion of the fuel.
The particulates in the exhaust gases consist of pure carbon and various compounds such as metal
oxide and sulphur.
Exhaust Gas Re-Circulation
1 Exhaust gas recirculation (EGR) valve
2 EGR cooler
3 Gasket
The exhaust gas re-circulation (EGR) system is fitted to the engine in order to reduce the amount of
nitrogen oxide (NOx). This is done by reducing the temperature of the combustion process by
introducing some waste exhaust gases into the inlet manifold. The effect of this is that there is a
depletion of oxygen which reduces the temperature of the combustion process and in turn reduces
the amount of NOx produced.
The engine control module (ECM) will determine the amount of EGR operation depending on the
engine rpm, intake air temperature, coolant temperature and fuel flow rate. The amount of exhaust
gas being recirculated is measured by a combination of position sensing of the valves and a mass air
flow (MAF) sensor.
The EGR valves are operated through their full range at each engine start-up. This is to clear any
carbon deposits that may have built up whilst the engine was running.
The EGR system is continually monitored for faults. Depending on how the system fails, the ECM will
dictate whether the malfunction indication light (MIL) is on or off. In the event of a failure of the EGR
system, the ECM will use substitute values and the EGR function will become inoperative.
The EGR cooler is connected to the vehicle cooling system via hoses and is there to cool the exhaust
gases being recirculated.
The EGR valve and cooler are supplied as separate components. The EGR valve itself should not be
disassembled.
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Exhaust gas recirculation (EGR)

The EGR system recycles exhaust gases back through the combustion process to reduce NOx
emissions.
By introducing this gas into the air intake, oxygen content and combustion temperatures are
reduced, which reduces the NOx emissions.
High EGR flow is necessary during cruising and mid-range acceleration, when combustion
temperatures are typically very high, while lower EGR flow is needed during low speed and light load
conditions.
No EGR flow should occur during conditions when it could adversely affect engine operating
efficiency or vehicle driveability, such as engine warm-up, idle, etc.
The EGR function of the 2.7 L engine is managed by the engine control module (ECM), which controls
the operation of stepper motors, allowing precise control of the EGR valve actuators.
The ECM determines the optimum EGR flow using inputs from sensors in the engine management
system, including the mass air flow meters, coolant temperature sensor, and intake air temperature
sensor.
Positive crankcase ventilation

The crankcase ventilation system uses the depression created in the air intake to draw vapors from
the crankcase through the engine where they are burnt with the fuel/air charge.
By doing this, any build-up of pressure inside the crankcase is avoided, reducing blow-by and
potential oil leakage problems, while still reducing emissions into the atmosphere.
The 2.7 L engine crankcase ventilation is through a cyclone separator mounted in the engine 'V'.
The separator consists of a diaphragm and spring inside the casing which respond to crankcase
pressure variations and separate the oil from the vapor, allowing the oil back into the engine while
the vapor is directed to the intake system.
Overview

Electrical connections to the stepper motor(s)
Stepper motor(s)
Harnesses
Engine breather hoses
Mass air flow (MAF) sensors
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Cyclone separator
Manifold absolute pressure (MAP) sensor
EGR Pipes (check for cracks)
Intake air temperature (IAT) sensor
Intake air shutoff throttle
Symptom chart
EGR valve stuck Inspect the system (see visual inspection). Check for
Difficult to start
open DTCs.
Poor idle quality
open DTCs.
Lack of power when EGR valve stuck Inspect the system (see visual inspection). Check for
accelerating open DTCs.
Engine stops/stalls EGR valve stuck Inspect the system (see visual inspection). Check for
open DTCs.
Excessive fuel EGR valve stuck Inspect the system (see visual inspection). Check for
consumption open DTCs.
Excessive black smoke
open DTCs.
EGR system not Inspect the system (see visual inspection). Check for
Excessive emissions
operating DTCs.
Loud 'ticking' noise Closely inspect the pipes for cracks (particularly at the
EGR pipes cracked
with engine running corrugated sections).
Crankcase Inspect the hoses. Check each hose for

Excessive blow-by ventilation system restriction/blockage by gently blowing through. Check
restricted for blockage of the separator.
Crankcase Inspect the hoses. Check each hose for

Engine oil leaks ventilation system restriction/blockage by gently blowing through. Check
restricted for blockage of the separator.
DTC index
NOTE:
NOTE:

EGR valve Check pipework for restriction.

incorrectly Check the mechanical function
P040100 fitted or loose
insufficient flow detected of the throttle valve. For EGR
actuator and circuit tests, GO to
EGR pipe blocked
EGR valve stuck and GO to Pinpoint Test
closed, blocked G552800p4.
For MAF sensor circuit tests,
EGR valve failure Electronic Engine Controls
MAF sensor fault
EGR valve
Check pipework for restriction.
incorrectly
fitted or loose Check the mechanical function
of the throttle valve. For EGR
EGR pipe blocked actuator and circuit tests, GO to
P040200 Pinpoint Test G552800p2.
excessive flow detected EGR valve stuck and GO to Pinpoint Test
closed, blocked G552800p4.
EGR valve failure
MAF sensor fault
EGR valve circuit(s):
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high resistance
EGR valve circuit(s): For EGR actuator and circuit

short circuit to tests, GO to Pinpoint Test
Exhaust gas recirculation (EGR) ground
G552800p2.
P040300 valve H-bridges (right hand
bank) EGR valve circuit(s): Refer to the warranty policy and
short circuit to procedure manual if an ECM is
power suspect.
EGR valve failure
ECM failure
IAT sensor fault
MAP sensor fault
MAF sensor fault

For IAT, MAP and MAF sensor
Exhaust gas recirculation (EGR) EGR valve stuck circuit tests,
closed, blocked
control circuit Electronic Engine Controls For
P040400
range/performance (right hand EGR valve circuit(s): right hand bank EGR valve and
bank) high resistance circuit tests, GO to Pinpoint
Test G552800p2.
short circuit to
ground

short circuit to
power
EGR valve failure

high resistance
Exhaust gas recirculation (EGR) For EGR sensor and circuit tests,
P040500 valve circuit low (right hand EGR valve circuit(s): GO to Pinpoint Test
bank) short circuit to G552800p2.
ground
EGR valve failure

Exhaust gas recirculation (EGR) For EGR sensor and circuit tests,
short circuit to
P040600 valve circuit high (right hand GO to Pinpoint Test
power
bank) G552800p2.
EGR valve failure
Intake air shutoff
throttle
circuit(s): high
resistance
Exhaust gas recirculation (EGR) - For intake air shutoff throttle
Intake air shutoff
P040700 intake air shutoff throttle circuit and circuit tests, GO to Pinpoint
throttle
low circuit(s): short Test G552800p1.
circuit to
ground
Intake air shutoff

throttle failure
Intake air shutoff
throttle
Exhaust gas recirculation (EGR) - For intake air shutoff throttle
circuit(s): short
P040800 intake air shutoff throttle circuit and circuit tests, GO to Pinpoint
circuit to power
high Test G552800p1.
Intake air shutoff
throttle failure
high resistance
EGR valve circuit(s): For EGR sensor and circuit tests,

short circuit to GO to Pinpoint Test
Exhaust gas recirculation (EGR) ground G552800p4.
P048700
valve H-bridges (left hand bank) Refer to the warranty policy and
EGR valve circuit(s): procedure manual if an ECM is
short circuit to
suspect.
power
EGR valve failure

ECM failure
EGR valve
stuck/sticking

high resistance

short circuit to
ground

short circuit to
power For intake air shutoff throttle
and circuit tests, GO to Pinpoint
Intake air shut off
throttle Test G552800p1.
Exhaust gas recirculation (EGR) - stuck/sticking For EGR actuator and circuit
intake air shutoff throttle
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P133400 Intake air shut off G552800p2.

minimum/maximum stop throttle and GO to Pinpoint Test
performance circuit(s): high G552800p4.
resistance
Intake air shut off procedure manual if an ECM is
throttle suspect.
circuit(s): short
circuit to
ground
Intake air shut off

throttle
circuit(s): short
circuit to power
Intake air shut off

throttle failure
ECM failure
high resistance
For EGR actuator and circuit
P140A00 EGR valve circuit(s): tests, GO to Pinpoint Test
valve circuit low (left hand bank) short circuit to G552800p4.
ground
EGR valve failure

P140B00 Exhaust gas recirculation (EGR) EGR valve circuit(s): For EGR actuator and circuit
valve circuit high (left hand short circuit to tests, GO to Pinpoint Test
bank) power G552800p4.
EGR valve failure

Intake air shutoff
throttle
circuit(s): high
resistance
Intake air shutoff

throttle For intake air shutoff throttle
circuit(s): short and circuit tests, GO to Pinpoint
Exhaust gas recirculation (EGR) - circuit to
Test G552800p1.
P140C00 intake air shutoff throttle H ground
bridges
Intake air shutoff procedure manual if an ECM is
throttle suspect.
circuit(s): short
circuit to power
Intake air shutoff

throttle failure
ECM failure
IAT sensor fault
MAP sensor fault
MAF sensor fault
EGR valve stuck

closed, blocked For IAT, MAP and MAF sensor
Exhaust gas recirculation (EGR) circuit tests,
control circuit EGR valve circuit(s): Electronic Engine Controls For
P140D00
range/performance (left hand high resistance EGR actuator and circuit tests,
bank) GO to Pinpoint Test
EGR valve circuit(s): G552800p4.
short circuit to
ground

short circuit to
power
EGR valve failure

P140E00 valve circuit adaption (left hand G552800p4.
bank) EGR valve circuit(s): Refer to the warranty policy and
ground suspect.

short circuit to
power
EGR valve failure
ECM failure
high resistance

G552800p2.
P141A00 valve circuit intermittent/erratic
(right hand bank) EGR valve circuit(s): Refer to the warranty policy and
power suspect.
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EGR valve failure
ECM failure
Intake air shutoff
throttle
circuit(s): high
resistance
Intake air shutoff

throttle For intake air shutoff throttle
circuit(s): short and circuit tests, GO to Pinpoint
Exhaust gas recirculation (EGR) - circuit to
Test G552800p1.
P141B00 intake air shutoff throttle circuit ground
intermittent/erratic
throttle suspect.
circuit(s): short
circuit to power
Intake air shutoff

throttle failure
ECM failure
high resistance For EGR actuator and circuit
Exhaust gas recirculation (EGR) tests, GO to Pinpoint Test
P141C00 valve circuit intermittent/erratic
EGR valve circuit(s): G552800p4.
(left hand bank) short circuit to Refer to the warranty policy and
ground procedure manual if an ECM is
EGR valve circuit(s): suspect.
short circuit to
power
EGR valve failure
ECM failure
high resistance

G552800p2.
P141D00 valve circuit adaption (right
hand bank) EGR valve circuit(s): Refer to the warranty policy and
power suspect.
EGR valve failure
ECM failure
EGR valve
stuck/sticking

high resistance

short circuit to
ground For intake air shutoff throttle
EGR valve circuit(s): Test G552800p1.
short circuit to For EGR actuator and circuit
Exhaust gas recirculation (EGR) - power
P214100 G552800p2.
control deviation below Intake air shutoff
throttle and GO to Pinpoint Test
minimum threshold
stuck/sticking G552800p4.
throttle suspect.
circuit(s): high
resistance
Intake air shutoff

throttle
circuit(s): short
circuit to
ground
Intake air shutoff
throttle
circuit(s): short
circuit to power
Intake air shutoff

throttle failure
ECM failure
EGR valve
stuck/sticking

high resistance

short circuit to
ground
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short circuit to
power For intake air shutoff throttle
Intake air shutoff
throttle Test G552800p1.
Exhaust gas recirculation (EGR) - stuck/sticking For EGR actuator and circuit
P214200 Intake air shutoff G552800p2.
control deviation above throttle and GO to Pinpoint Test
maximum threshold circuit(s): high G552800p4.
resistance
throttle suspect.
circuit(s): short
circuit to
ground
Intake air shutoff

throttle
circuit(s): short
circuit to power
Intake air shutoff

throttle failure
ECM failure
Pinpoint Tests
NOTE:
NOTE:
NOTE:
terminals.
PINPOINT TEST G552800p1 : INTAKE

AIR SHUTOFF THROTTLE ACTUATOR
G552800t1 : CHECK THE INTAKE AIR SHUTOFF THROTTLE SENSOR RETURN
CIRCUIT
1.
Circuit Pin
Signal from ECM 02
Ground from ECM 01
Power from ECM 06
2.
Circuit Pin
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Intake air throttle - signal E1
Intake air throttle - ground F2
Intake air throttle - power F1
3. Key off. 4. Disconnect the intake air throttle connector, C39. 5. Key on, engine off. 6. Measure the
resistance between:
-> Yes
-> No
G552800t2 : CHECK THE POWER SUPPLY TO THE INTAKE AIR SHUTOFF
THROTTLE
-> Yes
-> No
G552800t3 : CHECK THE INTAKE AIR SHUTOFF THROTTLE SIGNAL CIRCUIT

-> Yes
-> No


-> Yes
-> No

FOR SHORT CIRCUIT TO SENSOR POWER
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Pin 02 Pin 06
-> Yes
-> No

FOR HIGH RESISTANCE
Pin 02 Pin E1

-> Yes
component(s): - Intake air shutoff throttle connector - ECM connector - Intake air shutoff throttle -
ECM
-> No
G552800t7 : CHECK THE SIGNAL AND RETURN CIRCUITS FOR SHORT

Pin 02 Pin 01
-> Yes
-> No

THE MODULE
between:
Pin 02 Pin 01
-> Yes
component(s): - ECM
-> No

between:

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-> Yes
component(s): - ECM
-> No

OR THE MODULE
between:
Pin 02 Pin 06
-> Yes
component(s): - ECM
-> No
G552800t11 : CHECK THE SUPPLY CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No
G552800t12 : CHECK THE SUPPLY CIRCUIT FOR SHORT CIRCUIT TO POWER

-> Yes
-> No
G552800t13 : CHECK THE INTAKE AIR SHUTOFF THROTTLE SUPPLY

Pin 06 Pin F1
-> Yes
-> No
REPAIR the high resistance. For additional information, refer to the wiring diagrams. Clear any DTCs,
G552800t14 : CHECK THE INTAKE AIR SHUTOFF THROTTLE RETURN

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-> Yes
-> No

1. Key off. 2. Disconnec the ECM connector, C100. 3. Key on, engine off. 4. Measure the resistance
between:
Pin 06 Pin 01
-> Yes
-> No
G552800t16 : CHECK THE INTAKE AIR SHUTOFF THROTTLE RETURN

Pin 01 Pin F2
-> Yes
-> No

1. Key off. 2. Disconnec the ECM connector, C100. 3. Key on, engine off. 4. Measure the resistance
between:
Pin 06 Pin 01

-> Yes
-> No


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-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

HAND BANK EGR ACTUATOR
G552800t55 : CHECK THE RIGHT HAND BANK EGR ACTUATOR RETURN
CIRCUIT
1.
Circuit Pin
Signal from ECM 02
Ground from ECM 04
Power from ECM 03
2.
Circuit Pin
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EGR actuator - signal A3
EGR actuator - ground H2
EGR actuator - power H1
3. Key off. 4. Disconnect the EGR actuator connector, C70. 5. Key on, engine off. 6. Measure the
resistance between:
-> Yes
-> No
G552800t51 : CHECK THE POWER SUPPLY TO THE EGR ACTUATOR
-> Yes
-> No
G552800t21 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR A SHORT

CIRCUIT TO GROUND
resistance between:
-> Yes
-> No
G552800t22 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR A SHORT

CIRCUIT TO POWER

-> Yes
-> No
G552800t23 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
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Pin 02 Pin A3
-> Yes
component(s): - ETV connector - ECM connector - ETV - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

GROUND

-> Yes
-> No


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-> Yes
-> No
G552800t53 : CHECK THE SUPPLY CIRCUIT FOR HIGH RESISTANCE

Pin 03 Pin H1
-> Yes
-> No
between:
Pin 04 Pin 03
-> Yes
-> No

-> Yes
component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No
G552800t54 : CHECK THE EGR ACTUATOR RETURN CIRCUIT FOR SHORT

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CIRCUIT TO POWER
-> Yes
-> No

between:
Pin 04 Pin 03
-> Yes
-> No
G552800t59 : CHECK THE EGR ACTUATOR RETURN CIRCUIT FOR HIGH

RESISTANCE
Pin 04 Pin H2
-> Yes
-> No

between:

-> Yes
component(s): - ECM
-> No

HAND BANK EGR ACTUATOR
G552800t26 : CHECK THE LEFT HAND BANK EGR ACTUATOR RETURN
CIRCUIT
1.
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Circuit Pin
Signal from ECM 02
Ground from ECM 04
Power from ECM 03
2.
Circuit Pin
EGR actuator - signal A2
EGR actuator - ground K1
EGR actuator - power J1
resistance between:
-> Yes
-> No
G552800t27 : CHECK THE POWER SUPPLY TO THE EGR ACTUATOR

-> Yes
-> No
G552800t28 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR SHORT
CIRCUIT TO GROUND
resistance between:
-> Yes
-> No
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G552800t29 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G552800t30 : CHECK THE EGR ACTUATOR SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Pin 02 Pin A2
-> Yes
component(s): - ETV connector - ECM connector - ETV - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No

GROUND
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-> Yes
-> No


-> Yes
-> No
G552800t35 : CHECK THE SUPPLY CIRCUIT FOR HIGH RESISTANCE

Pin 03 Pin J1
-> Yes
-> No
G552800t36 : CHECK THE SUPPLY AND SIGNAL CIRCUITS FOR SHORT

between:
Pin 04 Pin 03
-> Yes
-> No

-> Yes
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component(s): - ECM
-> No

between:
-> Yes
component(s): - ECM
-> No
G552800t39 : CHECK THE EGR ACTUATOR RETURN CIRCUIT FOR SHORT
CIRCUIT TO POWER
-> Yes
-> No

between:
Pin 04 Pin 03
-> Yes
-> No
G552800t41 : CHECK THE EGR ACTUATOR RETURN CIRCUIT FOR HIGH

RESISTANCE
Pin 04 Pin K1
-> Yes
-> No

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between:
-> Yes
component(s): - ECM
-> No
Crankcase Vent Oil Separator

Removal

5 . Reposition the engine harness from the casing.

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All vehicles
7 . Disconnect the left-hand port deactivation vacuum hose.
8 . Detach the crankcase vent oil separator breather hoses.

9 NOTE:
.
clockwise.
minutes.
All vehicles
10 . NOTE:
Remove and discard the seals.
Remove the crankcase vent oil separator.

Installation
All vehicles
1
. CAUTION: Make sure the crankcase vent oil seperator is correctly located on the
alignment dowel before fully seating. Failure to follow this instruction may result in
damage to the component.
Install the crankcase vent oil separator.
Install new seals.

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2 . NOTE:
Install the oil filter element housing.
Tighten to 25 Nm.
All vehicles
3 . Attach the crankcase vent oil separator breather hoses.
4 . Connect the left-hand port deactivation vacuum hose.

Tighten to 4 Nm.
6 . Reposition the engine harness into the casing.

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LH
Removal
1

when working with these components. Always install blanking plugs to any open orifices or
lines. Failure to follow this procedure may result in damage to the vehicle.
Drain the cooling system.


(17.45.11)

4 . Disconnect the EGR valve electrical connector.
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5 . NOTE:
Fit suitable blanking caps to fuel filter unions, fuel supply lines and fuel return lines.
Detach the fuel filter supply and return lines.
6 . Loosen the fuel filter securing bolt.

7 . Remove the fuel filter from the retaining bracket.
8 . Remove the fuel filter retaining bracket.
9 . Detach the EGR valve coolant outlet hose.

10 . Disconnect the EGR valve coolant outlet hose.
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11 . NOTE:
Discard the EGR valve inlet tube securing clip.
Remove the EGR valve inlet tube securing clip.
12 . Detach the vent hose.

13 . Detach the coolant inlet hose from the timing cover.
14 . Disconnect the coolant inlet hose.
15 . Remove the EGR valve and cooler assembly securing bolts.

16 . Reposition the EGR valve and cooler assembly.
17 . Remove the EGR valve and cooler assembly.

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18 . Remove the EGR valve.
Installation
1 . NOTE:

Tighten to 10 Nm.
4 . Tighten the fuel filter retaining bracket.

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6 . Fill and bleed the cooling system.

Outlet Tube (17.45.11)
Removal
4 . NOTE:
Detach the exhaust gas recirculation (EGR) valve outlet tube.

5 . NOTE:
Detach the wiring harness.

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6 . NOTE:
Detach the EGR valve outlet tube.
7 . NOTE:
Remove the EGR valve outlet tube.
Discard the gasket.

Installation
1 . NOTE:
Loosley install the EGR valve outlet tube.
Do not fully close the retaining clip at this stage.
2 . NOTE:
Install the EGR valve outlet tube retaining bolts.
Install a new gasket
Do not fully tighten the retaining bolts at this stage.

3 . NOTE:
Attach the EGR valve outlet tube.
Do not fully tighten the retaining bolt at this stage.

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4 . NOTE:
Fully close the EGR valve outlet tube retaining clip.

5 . NOTE:
Tighten to 10 Nm.
6 . NOTE:
Tighten to 5 Nm.


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RH
Removal

(17.45.11)
4 . Disconnect the EGR valve electrical connector.

6 . Disconnect the diesel particulate filter differential pressure sensor electrical connector.
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7 Detach the diesel particulate filter differential pressure sensor and glow plug module securing
. bracket.
8
Detach the diesel particulate filter differential pressure sensor high pressure and low pressure
hoses.
9 . Disconnect the glow plug module electrical connectors.
10 Remove the diesel particulate filter differential pressure sensor and glow plug module
. securing bracket.
Remove the glow plug module positive cable retaining nut.
11 . Detach the diesel particulate filter differential pressure sensor high and low pressure pipes.

12 . Remove the EGR valve coolant outlet hose.
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13 . NOTE:
Discard the EGR valve inlet tube securing clip.
Remove the EGR valve inlet tube securing clip.
14 . Detach the EGR cooler outlet pipe from the timing cover.
Loosen the timing belt cover securing bolt.

15 . Detach the vent hose.
16 . Disconnect the coolant inlet hose.
17 . Detach the coolant inlet hose from the timing cover.

18 . Remove the EGR valve and cooler assembly securing bolts.
19 . Reposition the EGR valve and cooler assembly.

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20 . Remove the EGR valve and cooler assembly.
21 . Remove the EGR valve.

Installation
Tighten to 10 Nm.
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6
Tighten to 25 Nm.
7 . Fill and bleed the cooling system.

303-12A : Intake Air Distribution and Filtering – 3.0L
NA V6 - AJ27
Specifications
Specifications

Air cleaner 8 — 71

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1 — Air cleaner outlet pipe
2 — Mass air flow (MAF) sensor
3 — Air cleaner cover
4 — Air cleaner element
5 — Air cleaner
6 — Air cleaner intake pipe
Intake Air Distribution and Filtering - VIN

Range: G00442->G45703

Mechanical
Air cleaner intake pipe
Air cleaner outlet pipe
Air cleaner element
Diagnostic System.
Range: G45704->G99999
2 . Visually inspect for obvious signs of damage.
Mass air flow (MAF) sensor
Hoses and ducts (damage/connections) Manifold absolute pressure (MAP) sensor
Air cleaner element (contaminated/blocked) Throttle body
Restricted air intake Harness (security/damage)

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Seals and gaskets Connections (security/damage)
Intake manifold tuning (IMT) valves
retrieve the fault codes before proceeding to the DTC index chart.
Symptom chart
Clear the restriction,

Vehicle does not Restricted/blocked air intake
Air Cleaner (19.10.05) Replace the
start/hard starting/poor
Restricted/blocked air cleaner air cleaner element as necessary,
performance
element Air Cleaner Element (19.10.08)
Intake pipe
disconnected/damaged after Check the intake system and hoses
Excessive intake noise the air cleaner for correct installation/damage,
Air cleaner assembly incorrectly
assembled/damaged
DTC index
NOTE:
NOTE:

Blocked air cleaner
Air intake leak

Check the air cleaner and
Engine breather leak intake ducts, etc, check the
engine breather system.
Mass air flow (MAF) sensor Engine Emission Control -
to ECM sensing circuit:
Mass or volume air flow A VIN Range: G45704-
P010100 high resistance,
circuit range/performance intermittent short >G99999 For MAF and
circuit to ground throttle tests.
MAF sensor supply circuit: VIN Range: G45704-
high resistance >G99999
Throttle adaption fault

(check throttle position
voltage at Ignition ON)
Intake manifold air leak
(loose or missing
component) Check the air intake manifold
and intake system. For MAF,
Manifold absolute pressure MAP sensor to ECM
MAP and throttle tests.
P010600 (MAP)/BARO sensor circuit(s) fault
range/performance
Throttle adaption fault VIN Range: G45704-
(check throttle position >G99999
voltage at Ignition ON)
MAP sensor failure

P017100 System too lean (right hand Air intake leak between Check the air intake system
MAF sensor and for leaks, etc. Check the fuel
bank) cylinder head filter and lines.
Fuel filter/system V8 - AJV8/4.2L SC V8 -
restriction AJV8/3.0L NA V6 - AJ27/3.5L
NA V8 - AJV8, VIN Range:
G45704->G99999 For
MAF sensor fault (low injector tests.
intake air flow) Fuel Charging and Controls -
VIN Range: G45704-
Exhaust leak (before >G99999 For MAF sensor
catalyst) tests.
VIN Range: G45704-
>G99999 For exhaust
system tests.
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Restricted air cleaner
intake system. For fuel
Leaking fuel injector(s)
Oil contaminated with fuel Check the oil condition, if
System too rich (right hand (too many cold starts contamination is present,
P017200
bank) with vehicle renew the engine oil and
subsequently not filter. For MAF sensor circuit
getting hot enough for tests.
long enough)
MAF sensor fault (high VIN Range: G45704-
intake air flow) >G99999
Check the intake system.

Air intake leak between Check the fuel pressure,
MAF sensor and check the fuel lines.
cylinder head
Fuel filter/system V8 - AJV8/4.2L SC V8 -
restriction AJV8/3.0L NA V6 - AJ27/3.5L
System too lean (left hand NA V8 - AJV8, VIN Range:
P017400
bank) Fuel injector restriction G45704->G99999 For fuel
injector information.
MAF sensor fault (low Fuel Injectors (18.10.02) For
intake air flow) MAF sensor circuit tests.
Exhaust leak (before
catalyst) VIN Range: G45704-
>G99999 Check the exhaust
condition and security.

Restricted air cleaner
intake system. For fuel
injector information.
Oil contaminated with fuel Check the oil condition, if
System too rich (left hand (too many cold starts contamination is present,
P017500
bank) with vehicle renew the engine oil and
subsequently not filter. For MAF sensor circuit
getting hot enough for tests.
long enough)
MAF sensor fault (high VIN Range: G45704-
intake air flow) >G99999

intake system. Check the
Air intake restriction
accessory drive belt and
Idle air control system RPM
P050600 components.
lower than expected Accessory drive overload
(defective/seized Accessory Drive Belt - 3.0L
component) NA V6 - AJ27, VIN Range:
G00442->G45703 (12.10.40)

intake system. Check the
Idle control system RPM Air intake restriction
accessory drive belt and
lower than expected cold
P050624 components.
start emission strategy ISC Accessory drive overload
(defective/seized Accessory Drive Belt - 3.0L
system lower than expected
component) NA V6 - AJ27, VIN Range:
G00442->G45703 (12.10.40)
Intake air leak between

MAF sensor and Check the intake system.
throttle Check the engine breather
Idle air control system RPM system,
P050700
higher than expected Intake air leak between Engine Emission Control -
throttle and engine VIN Range: G45704-
>G99999
Engine crankcase breather
leak
Idle control system RPM Intake air leak between Check the intake system.
P050723 higher than expected cold MAF sensor and
throttle
start emission strategy ISC system,
system higher than Intake air leak between Engine Emission Control -
expected throttle and engine VIN Range: G45704-
>G99999
Engine crankcase breather
leak
IMT circuit(s): short circuit
Intake manifold tuning (IMT)
to ground Electronic Engine Controls -
P066100 valve control circuit low -
VIN Range: G45704-
right hand IMT circuit(s): high >G99999
resistance

P066200 valve control circuit high - IMT circuit(s): short circuit
to power VIN Range: G45704-
right hand
>G99999
IMT circuit(s): short circuit

to ground Electronic Engine Controls -
P066400 valve control circuit low -
VIN Range: G45704-
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left hand IMT circuit(s): high >G99999

resistance

P066500 valve control circuit high - IMT circuit(s): short circuit
to power VIN Range: G45704-
left hand
>G99999
1 . Confirm the DTC and follow the action instruction from the index.

Removal
1 . Remove the radiator grill opening panel. <<501-02>>

3 . Disconnect the mass air flow (MAF) sensor electrical connector.
4 . Disconnect the extra air flap actuator electrical connector.
5 . Remove the air cleaner retaining bolt.

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Installation
1 NOTE:
.
When installing the air cleaner, make sure the locating pegs fit securely in the grommets
located in the inner wing.
Tighten to 8Nm.
Removal
2 . Disconnect the mass air flow sensor (MAF) electrical connector.
3 . Remove the air cleaner cover.
4 . Remove the air cleaner element.

Installation
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Removal
1 . Disconnect the engine breather hose.
Installation
303-12B : Intake Air Ditribution and Filtering – 4.2L NA
V8 – AJV8/4.2L SC V8 – AJV8/3.5L NA V8 – AJV8
Specifications
Specifications

Air cleaner retaining bolt 8 - 71
Supercharger outlet pipe retaining nuts 9 - 80
Supercharger outlet pipe retaining bolts 9 - 80
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Supercharger retaining bolts 24 18 -

Air intake elbow retaining bolts 24 18 -
Air intake elbow lower bracket retaining bolts 20 15 -
Exhaust gas recirculation (EGR) valve retaining bolts 10 7 -
Exhaust manifold to EGR valve tube retaining bolts 21 15 -
Exhaust manifold to EGR valve tube retaining nuts 21 15 -
Thermostat housing retaining bolts 10 7 -
Throttle body intake hose retaining clip 5 - 45
5 — Air cleaner

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1 — Throttle body intake pipe
2 — Additional air inlet actuator

1 — Charge air cooler
2 — Supercharger outlet pipe
3 — Throttle body elbow
4 — Charge air cooler
5 — Supercharger
Intake air distribution and filtering for vehicles with supercharger

Air is supplied to the supercharger via the air cleaner, air cleaner outlet pipe, throttle body intake
pipe, throttle body and throttle body elbow. The supercharger delivers pressurized air to two
separate charge air cooler units, each unit being mounted on the cylinder bank it supplies.
Pressurized cooled air is fed from the charge air coolers directly into each inlet port. The air cleaner
outlet pipe differs from the normally aspirated by having tuned resonators to reduce inlet noise
levels. An intake air temperature sensor is fitted at the outlet of the bank 1 charge air cooler. The
sensor provides an input to the engine control module (ECM). <<303-14B>> The intake elbow directs
the metered airflow from the throttle body outlet (underside of the throttle body) into the intake of
the supercharger. The supercharger by-pass valve assembly is part of the intake elbow. The 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.
Supercharger
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.
Charge Air Cooler

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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. <<303-03B>>

Range: G00442->G45703

Mechanical
Air cleaner intake pipe
Air cleaner outlet pipe
Air cleaner element
Throttle body intake pipe
Throttle body gasket
Throttle body
Supercharger outlet pipe to charge air cooler duct(s)
Supercharger outlet pipe gasket
Supercharger outlet pipe
Air intake elbow
Air intake elbow gasket
Air intake elbow retaining bolt seal(s)
Supercharger
Charge air cooler gasket(s)
Charge air cooler(s)
Diagnostic System.
Range: G45704->G99999
Overview
will be the change to 7-digit diagnostic trouble codes (DTCs) from the familiar 5-digit, plus the
addition of secondary air injection and changes to evaporative emissions and exhaust gas
recirculation to comply with stage four emissions requirements.
For more information on these systems,


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2 . Visually inspect for obvious signs of damage.
Hoses and ducts (damage/connections)
Air cleaner element (contaminated/blocked)
Restricted air intake Mass air flow (MAF) sensor
Supercharger Manifold absolute pressure (MAP) sensor
Supercharger drive belt Throttle body
Charge air coolers (damage/connection) Harness (security/damage)
Supercharger outlet pipes and gaskets Connections (security/damage)
Supercharger air intake elbow/hoses
Seals and gaskets
Symptom chart (vehicles without supercharger)

Vehicle does not Restricted/blocked air intake
Air Cleaner (19.10.05) Replace the
start/hard starting/poor
Restricted/blocked air cleaner air cleaner element as necessary,
performance
element Air Cleaner Element (19.10.08)
Intake pipe
disconnected/damaged after Check the intake system and hoses
Excessive intake noise the air cleaner for correct installation/damage,
Air cleaner assembly incorrectly
assembled/damaged
Supercharger drive
belt
broken/slipping
Check the supercharger and drive belt (see visual inspection).
Supercharger fault
For supercharger air intake elbow tests, GO to Pinpoint Test
Lack of
G532443p1.
boost supercharger air
intake elbow Check the charge air coolers and pipework (see visual
fault inspection).
Major air leakage

(after the
supercharger)
Supercharger drive
belt slipping Check the supercharger and drive belt (see visual inspection).
Remove the supercharger drive belt and recheck for noise. Turn
Noise Supercharger fault the supercharger by hand and check for excessive resistance.
Check the supercharger pulley for excessive play. Check the
Major air leakage charge air coolers and pipework (see visual inspection).
(after the
supercharger)
DTC index
NOTE:
NOTE:
For a full list of DTCs.

Blocked air cleaner
Air intake leak

Engine breather leak Air Cleaner (19.10.05) Replace the air
cleaner element as necessary,
MAF sensor to ECM
MAF circuit Air Cleaner Element (19.10.08) Inspect
P010100 sensing circuit:
range/performance the engine breather system,
high resistance,
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intermittent For MAF sensor tests,

short circuit to Electronic Engine Controls - VIN Range:
ground G45704->G99999
MAF sensor supply

circuit: high
resistance
Check the intake system and hoses for
correct installation/damage,
Air Cleaner (19.10.05) Replace the air
Intake manifold air
leak (loose or cleaner element as necessary,
missing Air Cleaner Element (19.10.08) Check
MAP/Barometric
component) the intake manifold for correct
P010600 pressure circuit
installation/damage,
range/performance MAP sensor to ECM Intake Manifold - VIN Range: G45704-
circuit(s) fault
>G99999 (30.15.01) For MAP sensor
tests,
MAP sensor failure
G45704->G99999 .
Air intake leak Check the intake system and hoses for
between MAF correct installation/damage,
sensor and Air Cleaner (19.10.05) Check the fuel
System too lean (right cylinder head pressure, check the fuel lines,
P017100
hand bank) Fuel Tank and Lines - 4.2L NA V8 -
Fuel filter/system
restriction AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
MAF sensor fault G45704->G99999 Check the exhaust
(low intake air system (before catalyst) for condition
flow) and security,

catalyst)
System too rich (right
P017200 Air Cleaner Element (19.10.08) For MAF
hand bank) MAF sensor fault
(high intake air sensor tests,
flow) Electronic Engine Controls - VIN Range:
G45704->G99999 .
Air intake leak Check the intake system and hoses for
between MAF
correct installation/damage,
sensor and
cylinder head Air Cleaner (19.10.05) Check the fuel
pressure, check the fuel lines,
Fuel filter/system Fuel Tank and Lines - 4.2L NA V8 -
System too lean (left
P017400 restriction AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
hand bank)
MAF sensor fault G45704->G99999 Check the exhaust
(low intake air
system (before catalyst) for condition
flow)
and security,
catalyst)
System too rich (left
P017500 Air Cleaner Element (19.10.08) For MAF
hand bank) MAF sensor fault
(high intake air sensor tests,
flow) Electronic Engine Controls - VIN Range:
G45704->G99999 .

Restricted air cleaner Air Cleaner (19.10.05) Replace the air
Idle air control system element cleaner element as necessary,
P050600 RPM lower than Air Cleaner Element (19.10.08) For MAF
expected MAF sensor fault sensor tests,
(high intake air Electronic Engine Controls - VIN Range:
flow)
G45704->G99999 .
Idle air control system Check the intake system and hoses for
Intake air leak
P050700 RPM higher than correct installation/damage,
between MAF
expected sensor and Air Cleaner (19.10.05) Inspect the
throttle engine breather system,
Intake air leak

between throttle
and engine
Engine crankcase
breather leak
Pinpoint tests
NOTE:

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THE SUPERCHARGER AIR INTAKE

ELBOW
G532443t1 : CHECK THE AIR INTAKE ELBOW VACUUM LINE
1. Check the vacuum connection to the supercharger air intake elbow at both ends. 2. Check the
vacuum line to the supercharger air intake elbow along its length.
Is the vacuum line connected and in good condition?
-> Yes
-> No
CONNECT or replace the vacuum line as necessary. Test the system for normal operation.
G532443t2 : CHECK THE OPERATION OF THE AIR INTAKE ELBOW

ACTUATOR LINKAGE
1. Disconnect the vacuum line from the actuator diaphragm. 2. Connect a suitable hand vacuum
pump to the actuator diaphragm. 3. Apply a vacuum to the actuator diaphragm. 4. Observe the
actuator linkage operation.
Does the actuator linkage operate?
-> Yes
-> No
INSTALL a new supercharger air intake elbow. Test the system for normal operation.
G532443t3 : CHECK THE OPERATION OF THE AIR INTAKE ELBOW

BUTTERFLY
1. Remove the air cleaner outlet pipe,
Air Cleaner Outlet Pipe (19.10.31) 2. Remove the supercharger outlet pipe,
Supercharger Outlet Pipe (18.50.16) 3. Apply a vacuum to the actuator diaphragm. 4. Observe the
butterfly operation.
Does the butterfly operate?
-> Yes
Check for another cause of the malfunction.
-> No
INSTALL a new supercharger air intake elbow. Test the system for normal operation.

Removal
1 . Remove the radiator grill opening panel. <<501-02>>

3 . Disconnect the mass air flow (MAF) sensor electrical connector.

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4 . Disconnect the extra air flap actuator electrical connector.
5 . Remove the air cleaner retaining bolt.

Installation
1 NOTE:
.
When installing the air cleaner, make sure the locating pegs fit securely in the grommets
located in the inner wing.
Tighten to 8Nm.
Removal
2 . Disconnect the mass air flow sensor (MAF) electrical connector.

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Installation
Cleaner Outlet Pipe (19.10.31)
Removal
3 . Disconnect the engine breather hose.

Installation
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Charge Air Cooler
Removal
2.
CAUTION: Make sure no foreign matter enters the cylinder head ports.
Remove the charge air cooler.
Remove and discard the charge air cooler gasket.
Installation
Install a new charge air cooler gasket.
Tighten to 13 Nm.

Supercharger - VIN Range: G00442-
>G45703 (18.50.15)
Installation
Tighten to 24 Nm.
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2 . Connect the manifold absolute pressure (MAP) sensor.
Install new retaining bolt seals.
Tighten to 24 Nm.
4 . Install the air intake elbow retaining bracket lower retaining bolts.
Tighten to 20 Nm.
Tighten to 10 Nm.
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8 . NOTE:
Remove the sealing caps from the coolant ports.

11 . Connect the charge air cooler coolant pipes.
12 . NOTE:
Install new O-ring seals to the thermostat housing.
Install the thermostat housing.
Tighten to 10 Nm.
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20 . Connect the thermostat housing hoses.
Tighten to 8 Nm.
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23 . Install new seals to the supercharger outlet pipe retaining bolts.
24 .
Install the supercharger outlet pipe.

25 . NOTE:
26 . Install the throttle body. <<303-04B>>
Reposition the hose retaining clip.

28 . Attach the supercharger belt.
Attach the supercharger belt.

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30 . Carry out the cooling system filling and bleeding procedure. <<303-03>>
Supercharger - VIN Range: G45704-
>G99999 (18.50.15)
Installation
Tighten to 21 Nm.
2 . Connect the MAP sensor.
Install new retaining bolt seals.
Tighten to 21 Nm.
4 . Install the air intake elbow retaining bracket lower retaining bolts.
Tighten to 18 Nm.
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Tighten to 10 Nm.
7 . Install the exhaust manifold to EGR valve tube retaining nuts.
Tighten to 21 Nm.
8 . NOTE:
9 . Connect the EGR valve electrical connector.

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11 . Connect the charge air cooler coolant hoses.
12 . Install the coolant assembly.
Connect the coolant hose.

13 . Attach the coolant assembly.
Tighten to 10 Nm.

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Tighten to 8 Nm.

23 .
Install the supercharger outlet pipe.
1) Tighten the supercharger outlet pipe retaining bolts to 10 Nm.
2) Tighten the charge air cooler ducts retaining bolts to 9 Nm.

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24 . NOTE:

>G99999 (19.70.04)
27 . Attach the supercharger belt.

29 . Install the coolant expansion tank.


31 . Carry out the cooling system filling and bleeding procedure.

Supercharger Outlet Pipe (18.50.16)
Installation
1 . Install new supercharger outlet pipe to charge air cooler ducts.
Tighten to 8 Nm.
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4 . Install the supercharger outlet pipe.
Tighten to 9 Nm.
5 . NOTE:

7 . Install the throttle body intake pipe.
Tighten to 5 Nm.

11 . Check and top up the coolant expansion tank.

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303-12C : Intake Air Distribution and Filtering – 2.7L V6
– TdV6
Specifications
Specifications

Air cleaner retaining bolt 8 - 71

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4 — Air cleaner base
NOTE:
The air cleaner outlet pipe and air cleaner cover are only supplied as an assembly and
must not be disassembled.
The primary functional requirements of the air induction system is to:
deliver clean filtered air to the engine with minimum pressure loss.
to reduce the engine intake and structure related noises to within legal & vehicle
requirements.
manage the induction of water, sand or snow to prevent adverse effect on vehicle
operation.
minimize air temperature rise over ambient air temperature at the throttle body/turbo in
high ambient conditions.
purge the hot air from the intake system quickly whilst the engine is hot, and after a period
of rest. This is to maximize engine drive away performance.

Overview


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2 . Visually inspect for obvious signs of mechanical and electrical damage.
Hoses and ducts (damage/connections)
Air cleaner element (contaminated/blocked) Mass air flow (MAF) sensor(s)
Restricted air intake Intake air shutoff throttle
Vacuum hoses Harness (security/damage)
Pipework to turbochargers Connections (security/damage)
Turbocharger(s) Port de-activation system
Charge air coolers (contaminated/blocked)
Symptom chart
Restricted/blocked air intake cleaner element as necessary,
Vehicle does not Air Cleaner Element (19.10.08) Check the
Restricted/blocked air
start/hard turbochargers,
cleaner element
starting/poor Turbocharger Check the intake air shutoff
performance Turbocharger fault throttle function (make sure the intake air
shutoff throttle returns to the open
Intake air shutoff throttle position),
Check the joint between the air cleaner

Compressed intake air leak outlet pipe and the intake air shutoff
after the turbocharger throttle. Check the joints between the intake
air shutoff throttle and the intake manifolds,
Air intake pipe
Excessive intake Intake Air Shutoff Throttle Check the charge
disconnected/damaged
noise after the air cleaner air cooler seals,
Charge Air Cooler Check the air intake
Air cleaner assembly system and hoses for correct
incorrectly installation/damage,
assembled/damaged Air Cleaner (19.10.05)
Excessive For control valve tests, GO to Pinpoint Test

Port de-activation camshaft
combustion noise cover control valves G552277p1.
DTC index
NOTE:
NOTE:

P009700 Air charge temperature Air charge temperature For air charge temperature
sensor circuit: low sensor tests,
sensor circuit input Electronic Engine Controls
For air charge temperature

Air charge temperature Air charge temperature
P009800 sensor tests,
sensor circuit sensor circuit: high
input Electronic Engine Controls
For air charge temperature

Air charge temperature Air charge temperature
P009900 sensor tests,
sensor circuit sensor circuit:
intermittent/erratic Electronic Engine Controls
MAF sensor circuit: high

resistance
MAF sensor circuit: short For MAF sensor tests,

Mass air flow (MAF) sensor circuit to ground Electronic Engine Controls
P010000 range/performance (right Refer to the warranty policy and
hand bank) MAF sensor circuit: short procedures manual if an ECM is
circuit to power suspect.
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MAF sensor failure
ECM failure
resistance
For MAF sensor tests,
MAF sensor circuit: short Electronic Engine Controls For
circuit to ground EGR system tests,
Engine Emission Control Check
MAF sensor failure
for evidence of air leakage (see
Mass air flow (MAF) too
P010200 visual inspection). Check for
low on right hand bank Exhaust gas recirculation
(EGR) valve stuck turbocharger codes. For
open/closed turbocharger tests,
Turbocharger Refer to the
Air leakage warranty policy and procedures
Turbocharger fault
ECM failure
MAF sensor circuit: short
circuit to power
MAF sensor failure Check for evidence of air
Mass air flow (MAF) too leakage (see visual inspection).
P010300
high on right hand bank Air leakage Check for turbocharger codes.
For turbocharger tests,
Turbocharger fault Turbocharger Refer to the
warranty policy and procedures
ECM failure

resistance

P010400 circuit intermittent/erratic Refer to the warranty policy and
(right hand bank) MAF sensor circuit: short procedures manual if an ECM is
MAF sensor failure
ECM failure
resistance

P010A00 range/performance (left Refer to the warranty policy and
MAF sensor failure
ECM failure
resistance
MAF sensor circuit: short Electronic Engine Controls For
circuit to ground EGR system tests,
Engine Emission Control Check
MAF sensor failure
for evidence of air leakage (see
P010C00 visual inspection). Check for
low on left hand bank Exhaust gas recirculation
(EGR) valve stuck turbocharger codes. For
open/closed turbocharger tests,
Air leakage warranty policy and procedures
Turbocharger fault
ECM failure

Mass air flow (MAF) too circuit to power Electronic Engine Controls
P010D00 Check for evidence of air
high on left hand bank
MAF sensor failure leakage (see visual inspection).
Check for turbocharger codes.
Air leakage For turbocharger tests,
Turbocharger fault warranty policy and procedures
ECM failure
resistance

P010E00 intermittent/erratic (left Refer to the warranty policy and
MAF sensor failure
ECM failure
MAF sensor(s) circuit:
high resistance
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short circuit to
ground

short circuit to
power
MAF sensor failure Electronic Engine Controls
Check for turbocharger codes.
Mass air flow (MAF) sensor Turbocharger actuator(s)
P010F00 For turbocharger tests,
correlation circuit: high
resistance Turbocharger Refer to the
warranty policy and procedures
Turbocharger actuator(s) manual if an ECM is suspect.
circuit: short circuit
to ground
Turbocharger actuator(s)
to power
Turbocharger actuator
failure
ECM failure
Intake air temperature For IAT1 sensor tests,
P011200 IAT1 sensor circuit: low
(IAT) 1 sensor circuit input Electronic Engine Controls
P011300 IAT1 sensor circuit: high
(IAT) 1 sensor circuit input Electronic Engine Controls

P011400 IAT1 sensor circuit:
(IAT) 1 sensor circuit intermittent/erratic Electronic Engine Controls
For port de-activation solenoid

Port de-activation solenoid Port de-activation
P200800 circuit tests, GO to Pinpoint
circuit solenoid circuit: high
resistance Test G552277p2.
Port de-activation For port de-activation solenoid

Port de-activation solenoid
P200900 solenoid circuit: circuit tests, GO to Pinpoint
circuit short circuit to Test G552277p2.
ground
Port de-activation For port de-activation solenoid
P201000 solenoid circuit: circuit tests, GO to Pinpoint
circuit short circuit to Test G552277p2.
battery
Pinpoint tests
NOTE:
NOTE:
NOTE:
terminals.
THE OPERATION OF THE PORT DE-
ACTIVATION CAMSHAFT COVER
CONTROL VALVE(S)
G552277t1 : CHECK THE VACUUM LINES TO THE CONTROL VALVES
1. Check the vacuum lines for connection, security and condition.
Are the vacuum lines connected, secure and in good condition?
-> Yes
-> No
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RECTIFY or replace as necessary. Test the system for normal operation.
G552277t2 : CHECK THE FUNCTION OF THE CONTROL VALVES

1. Disconnect the vacuum line to the suspect control valve actuator. 2. Connect a suitable hand
vacuum pump to the control valve actuator. 3. Apply a vacuum to the actuator. 4. Observe the
actuator linkage operation.
Does the actuator linkage operate?
-> Yes
CHECK for DTCs indicating an intake air shutoff throttle fault.
-> No
INSTALL a new camshaft cover. Test the system for normal operation.
PINPOINT TEST G552277p2 : PORT DE-

ACTIVATION SOLENOID AND CIRCUIT
G552277t3 : CHECK FOR POWER TO THE PORT DE-ACTIVATION SOLENOID
1. Port de-activation solenoid connector, C36
Circuit Pin
Power 01
Signal from ECM 02
2. Engine control module (ECM) connector, C100
Circuit Pin
Port de-activation solenoid - signal K4
3. Key off. 4. Disconnect the port de-activation solenoid connector, C36. 5. Key on, engine off. 6.
-> Yes
-> No
G552277t4 : CHECK THE PORT DE-ACTIVATION SOLENOID SIGNAL CIRCUIT

-> Yes
-> No

-> Yes
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-> No

FOR HIGH RESISTANCE
Pin 02 Pin K4
-> Yes
-> No

Pin 01 Pin 02
-> Yes
component(s): - Port de-activation solenoid connector - Port de-activation solenoid - ECM connector
- ECM
-> No
INSTALL a new port de-activation solenoid. Clear any DTCs, test the system for normal operation.

between:
-> Yes
component(s): - ECM
-> No

between:

-> Yes
component(s): - ECM
-> No
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Remover/Install, Cooling Hose Clamp

303-397
Removal
1 . Remove the radiator grille opening panel.
For additional information, refer to Radiator Grille Opening Panel (76.10.06)
2 . Detach the mass air flow (MAF) sensor wiring harness.
3 . Disconnect the MAF sensors electrical connectors.
4 . Using the special tool, detach the MAF sensor outlet pipes.
1) Detach the upper MAF sensor outlet pipe.
2) Detach the lower MAF sensor outlet pipe.
5 . Disconnect the port deactivation vacuum hose.

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Remove the air cleaner retaining bolt.

Installation
Tighten to 8 Nm.
Removal

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Installation
Charge Air Cooler
1 The charge air cooler is removed as part of the radiator assembly and can be serviced
. separately.
303-13 : Evaorative Emissions
Specifications
Specifications

Evaporative emission canister carrier bolts 7 — 62
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G00442->G45703
1 — Evaporative emission canister vent solenoid
2 — Fuel tank pressure sensor
3 — Evaporative emission canister
4 — Evaporative emission canister purge valve

5 — Evaporative emission canister purge valve resonator.
The evaporative emission fuel vapor management system consists of an evaporative emission
canister, evaporative emission canister purge valve and an evaporative emission canister purge valve
resonator. A combination of plastic pipes and rubber hoses connect the evaporative emission
canister to the fuel tank and the evaporative emission canister purge valve to the intake manifold.
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Onboard refuel vapour recovery (ORVR).

The vehicle is fitted with an onboard refuel vapour recovery (ORVR) type fuel tank. During refuelling
all vapour is collected in the evaporative emission canister as well as in normal vehicle operations.
On Federal (USA) specification vehicles the fuel vapor management system uses a canister vent
solenoid and a fuel tank pressure sensor which are used during the engine management system on
board diagnostic routines.
When the evaporative emission canister purge valve is closed, the fuel tank is vented into the
evaporative emission canister through the fuel tank roll-over valve. The evaporative emission
canister absorbs the fuel vapor and prevents the release of hydrocarbons into the atmosphere.
When the vapor evaporative emission canister purge valve is opened, the canister is exposed to the
intake manifold vacuum and the fuel vapor deposits are drawn into the manifold where they mix
with the incoming air/fuel charge.
The evaporative emission fuel vapor management system is controlled by the engine control module
according to calibrated data tables.
G45704->G99999
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1 — Evaporative emission canister purge valve
2 — Evaporative emission canister
The evaporative emission fuel vapor management system consists of an evaporative emission
canister and an evaporative emission canister purge valve. A combination of plastic pipes and rubber
hoses connect the evaporative emission canister to the fuel tank and the evaporative emission
canister purge valve to the intake manifold.
Onboard refuel vapor recovery (ORVR).
The vehicle is fitted with an onboard refuel vapor recovery (ORVR) type fuel tank. During refuelling all
vapor is collected in the evaporative emission canister as well as in normal vehicle operations.
When the evaporative emission canister purge valve is closed, the fuel tank is vented into the
evaporative emission canister through the fuel tank roll-over valve. The evaporative emission
canister absorbs the fuel vapor and prevents the release of hydrocarbons into the atmosphere.
When the vapor evaporative emission canister purge valve is opened, the canister is exposed to the
intake manifold vacuum and the fuel vapor deposits are drawn into the manifold where they mix
with the incoming air/fuel charge.
The evaporative emission fuel vapor management system is controlled by the engine control module
(ECM) according to calibrated data tables.

G00442->G45703
Preliminary Inspection
1 . Visually inspect for obvious signs of mechanical or electrical damage, blown fuses, etc.
3 . If the concern is not visually evident, verify the symptom and proceed with diagnosis, using the
Jaguar approved diagnostic system, where available.
4 . Where K-Line or Vacutec equipment is available, it should be used as an aid to diagnosis. The
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equipment must be capable of testing to the 0.020 thou standard.
Diagnostic Drive Cycles

Following the setting of a DTC, the appropriate repairs must be carried out, and the normal operation
of the system checked. This will be done by performing a series of drive cycles which will enable the
vehicle to operate the evaporative emissions system as a function check. The following drive cycles
cover the use of the Jaguar approved diagnostic system, a scan tool, and a test with no additional
equipment, where possible.
Flow check monitor drive cycle conditions (non-Federal)

NOTE:
These conditions must be satisfied before the test is commenced.
This drive cycle should be performed following rectification work on the system.
Make sure the fuel tank is between one third and three quarters full. (Adding fuel will increase
vapor generation; the diagnostic will not run if the vapor concentration is too great).
Make sure the ambient air temperature is above -5°C (23°F).
Flow check monitor drive cycle (non-Federal)
Drive the vehicle for a minimum of 15 minutes, avoiding severe or excessive fuel movement.
Avoiding excessive fuel movement, gently bring the vehicle to rest (coast to a stop).
Allow the vehicle to idle for two minutes.

Full Evaporative system monitor drive cycle conditions
NOTE:
These conditions must be satisfied before the test is commenced.
Make sure the fuel filler cap is correctly fitted.
Clear the DTCs. (Perform a code clear, even if no codes are present. This will reset TIDs).
Make sure the fuel tank is between one third and three quarters full (adding fuel will increase
vapor generation; the diagnostic will not run if the vapor concentration is too great).
Drive the vehicle for a minimum of two minutes, and until fully warm (temperature gauge just
below mid-point).
Make sure that the purge valve is operating, either by touch, sound, or using datalogger (purge
vapor management valve-duty cycle). If the purge is not active, perform the "drive cycle for
green ECM" in this section.
Full Evaporative system monitor drive cycle
Drive the vehicle to a suitable road where the test can be carried out, switch off the ignition.
Leave the ignition switched off for 30 seconds.
Restart the engine, accelerate briskly to 80 kilometers per hour (50 miles per hour), making sure
that the engine speed reaches at least 3500 rpm for a minimum of five seconds.
40 thou test, using the Jaguar approved diagnostic system
Avoiding high engine loads, drive the vehicle steadily between 64 and 97 kilometers per hour (40
and 60 miles per hour). Using the Jaguar approved diagnostic system, monitor the
evaporative valve duty cycle (purge vapor management valve-duty cycle), CCV status
(canister close valve-vapor recovery system), and the FTPS (fuel tank pressure-vapor
recovery system). The Jaguar approved diagnostic system will give an indication when the
test is active. Dependant on the level of vapor concentration, it may take up to 30 minutes
for the test to initialize. (Vapor concentration cannot be measured using the Jaguar approved
diagnostic equipment). When the test has initialized (CCV closed), it will take up to 90
seconds to complete. Avoid excessive fuel movement while the test is active.
20 thou test, using the Jaguar approved diagnostic system
Continue driving the vehicle steadily between 64 and 97 kilometers per hour (40 and 60 miles per
hour) avoiding high engine loads for a further 10 minutes.
Allow the vehicle to idle for 2 minutes.

Use the Jaguar approved diagnostic system to monitor the evaporative valve duty cycle (purge
vapor management valve-duty cycle), CCV status (canister close valve-vapor recovery
system), and the FTPS (fuel tank pressure-vapor recovery system). The Jaguar approved
diagnostic system will give an indication when the test is active. When the test has initialized
(CCV closed), it will take up to 90 seconds to complete.
If the 20 thou test has not run, it is likely that the vapor concentration in the purge system is too
great. In this case, carry out the following:
Drive the vehicle steadily for a further 30 minutes, avoiding excessive fuel movement.
Use the Jaguar approved diagnostic system to monitor the evaporative valve duty cycle (purge
vapor management valve-duty cycle), CCV status (canister close valve-vapor recovery
system), and the FTPS (fuel tank pressure-vapor recovery system). The Jaguar approved
diagnostic system will give an indication when the test is active. When the test has initialized
(CCV closed), it will take up to 90 seconds to complete.
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If the 20 thou test fails to run a second time, repeat the entire test.
Check for DTCs. Rectify as indicated.
40 thou test, using scan tool
Avoiding high engine loads, drive the vehicle steadily between 64 and 97 kilometers per hour (40
and 60 miles per hour).
When the test has initialized, using the scan tool, monitor the evaporative valve duty cycle, CCV
status, and the FTPS (the scan tool should give an indication when the test is active).
When the test has initialized (CCV closed), it will take up to 90 seconds to complete.
To make sure that the test has completed, TID 08 in mode 6 must be checked (if the test has not
completed, this TID will display 0. Any other value indicates test completion).
If the test did not complete, repeat the test.
20 thou test, using scan tool
Continue driving the vehicle steadily between 64 and 97 kilometers per hour (40 and 60 miles per
hour) avoiding high engine loads for a further 10 minutes.

When the test has initialized, using the scan tool, monitor the evaporative valve duty cycle, CCV
status, and the FTPS (the scan tool should give an indication when the test is active).
When the test has initialized (CCV closed), it will take up to 90 seconds to complete.
To make sure that the test has completed, TID 06 in mode 6 must be checked (if the test has not
completed, this TID will display 0. Any other value indicates test completion).
If the test did not complete, repeat the test.
If the 20 thou test has not run, it is likely that the vapor concentration in the purge system is too
great. In this case, drive the vehicle steadily for a further 30 minutes, avoiding excessive fuel
movement, then repeat the test.
Check for DTCs. Rectify as indicated.
40 thou and 20 thou tests using no additional equipment

The test procedure and conditions are as for the Jaguar approved diagnostic system or scan tool, but
no confirmation of the test having run is possible without the use of one of these instruments. The
DTC will be set if the fault still exists, but the possibility exists that the conditions for the test to run
may not have been met, in which case, the DTC may not be set until the owner reproduces the
conditions in which the fault originally occurred.
Drive cycle for "green" ECM
To enable the ECM to re-learn fuelling adaptations.
NOTE:
This procedure should be performed whenever the vehicle battery has been disconnected.
Due to component tolerance and wear during the normal running of a vehicle, fuelling and air
requirements for an engine will vary over time. The ECM has the ability to adjust for this variation by
"learning" the level of compensation that is required (these compensation values are referred to as
adaptations).
If the vehicle battery is disconnected, all adaptations held within the ECM will be lost (ie, set to zero).
The ECM is then referred to as "green". To enable the vehicle to function correctly, the ECM must
"relearn" these adaptations.
There are five areas or sites that need to be relearnt:
Allow the vehicle to idle until fully warm (temperature gauge just below mid-point).
Allow to idle for a further three minutes, minimum.

Drive the vehicle with the air conditioning OFF on a level road using a constant throttle, or speed
control if fitted, for at least one minute in the following gears, at the stated engine speeds for
each of the sites below.
"Green" ECM drive cycle chart. Site 1

NOTE:
The vehicle speed is for guidance only. DO NOT use the vehicle speed as the target to set
adaptions.
Monitor condition Parameters
GEAR P
ENGINE SPEED Idle
VEHICLE SPEED (GUIDE ONLY) 0 mph

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NOTE:
adaptions.
GEAR 2
ENGINE SPEED 1595 rpm
VEHICLE SPEED (GUIDE ONLY) 15.4 kph (9.56 mph)
GEAR 2

GEAR 2
GEAR 2

NOTE:
adaptions.
GEAR 2
GEAR 2
GEAR 2

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GEAR 2

NOTE:
adaptions.
GEAR 3

GEAR 3
GEAR 3
GEAR 3

NOTE:
adaptions.
GEAR 3

GEAR 3
GEAR 3

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GEAR 3
Bring the vehicle to rest, allow to idle for one minute.
WARNING: The following tests may involve parts which are hot.
If sufficient adaptations have occurred, the canister purge valve should now be operating. This can be
verified manually by either touching or listening to the valve. By touching the canister purge valve, it
should be possible to feel the valve switching. Listening to the canister purge valve is best done using
a workshop stethoscope, through which it should be possible to hear the valve operating.
Diagnostic Trouble Code (DTC) Index/Symptom Chart

NOTE:
NOTE:
NOTE:
Symptom Possible Source Action
Restriction in the vapor line between the fuel Refer to Action for DTC
Difficulty in filling
tank and the carbon canister P0446
outlet/atmospheric port
Carry out adaptations
Adaptations incomplete
Fuel smell procedure, check purge
Purge valve inoperative valve operation
Message center
Check fuel filler cap, refer to
display (see Fuel filler cap missing/not tightened after
refuelling Action for DTC P0455,
below)
Warning Light Message Default Mode DTC
ECM default. (Canister purge P0441, P0442, P0443, P0444,

Check engine
None inhibited, adaptive fuel metering P0445, P0446, P0447, P0448,
(after two trips)
inhibited). P0455, P0456
Check engine
None None P0450, P0452, P0453
(after two trips)
ECM default. (Canister purge

Check fuel
Red inhibited, adaptive fuel metering P0455
filler cap
inhibited).
Diagnostic
Trouble Description Possible Source Action
Code
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Evaporative canister
purge pipe
restricted, leaking,
disconnected
vent restricted
P0441 (Euro Incorrect purge GO to Pinpoint Test G307413p1.
only) flow Evaporative canister .
purge valve to
engine pipe(s)
disconnected
purge valve failure
Fuel tank filler cap seal
defective Check filler cap, system pipework,
fuel tank. GO to Pinpoint Test
System leak (canister G307413p2.
Leak detected. 40 damage, pipework . For fuel tank information, <<310-
P0442 damage)
thou 01>> Where K-Line or Vacutec
equipment is available, carry out the
Canister close valve appropriate test. See bulletin 05.1-
leaking
29, or Vacutec operating instructions
Fuel tank leak
P0443 Canister purge Canister purge valve Carry out system pressure check (K-
valve malfunction failure Line or Vacutec equipment. See
(leaking) bulletin 05.1-29, or Vacutec
operating instructions)
Canister purge valve

disconnected
Canister purge Canister purge valve to Check purge valve connections, GO

P0444 valve circuit open ECM drive circuit; to Pinpoint Test G307413p2.
circuit open circuit, high .
resistance

failure
Canister purge valve to
ECM drive circuit;
Canister purge
short circuit to GO to Pinpoint Test G307413p2.
P0445 valve circuit short
ground .
circuit
failure
Restricted flow through;
Canister close valve air vent, filter, CCV Inspect the components listed, and
P0446 malfunction (CCV or canister interconnecting pipework for
stuck closed) blockage, kinks or flattened areas
Canister close valve
failure
power supply
circuit; open circuit,
short circuit
Canister close valve Canister close valve to GO to Pinpoint Test G307413p3.

P0447
circuit open circuit. ECM drive circuit; .
open circuit, high
resistance, short

failure
Canister close valve to
ECM drive circuit;
Canister close valve short circuit to GO to Pinpoint Test G307413p3.
P0448 ground
circuit short circuit .

failure
Fuel tank pressure FTP sensor Check FTP sensor connections. GO to

P0450
disconnected
(FTP) sensor Pinpoint Test G307413p4.
malfunction (output FTP sensor failure .
stuck/not changing)
FTP sensor
disconnected
FTP sensor to ECM

Fuel tank pressure sense circuit; open For FTP sensor supply tests, <<303-
circuit, short circuit
(FTP) sensor circuit; 14>> GO to Pinpoint Test
P0452 to ground
low voltage (low G307413p4.
pressure) FTP sensor to splice in .
sensor supply
high resistance
FTP sensor failure

FTP sensor to splice in
sensor ground
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circuit; open circuit, Check fuel filler cap and seal,

Fuel tank pressure high resistance
pipework, etc. GO to Pinpoint Test
(FTP) sensor circuit;
P0453 G307413p2.
high voltage (high FTP sensor to ECM
pressure) sense circuit; open . For fuel tank information, <<310-
circuit, short circuit 01>>
to high voltage
FTP sensor failure

Fuel filler cap missing
Fuel filler cap seal

defective
System leak (canister

damage, pipework
damage) Check fuel filler cap and seal,
pipework, etc. GO to Pinpoint Test
P0455 Leak detected-large CCV stuck open G307413p2.
. For fuel tank information, <<310-
Canister purge valve to 01>>
engine purge pipe;
disconnected

stuck closed
Fuel tank leak

Fuel filler cap seal
defective
Check fuel filler cap and seal,
System leak (canister pipework, etc. GO to Pinpoint Test
Leak detected - 20
P0456 damage, pipework G307413p2.
thou damage) . For fuel tank information, <<310-
01>>
CCV leaking
Fuel tank leak
Pinpoint Tests

P0441; EVAPORATIVE SYSTEM
INCORRECT PURGE FLOW
G307413t1 : CHECK FUEL FILLER CAP FITMENT 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. Carry out a full evaporative system monitor drive cycle.
Recheck DTCs. For additional information, see "diagnostic drive cycles" above.
G307413t2 : CHECK EVAPORATIVE PURGE VALVE IS OPERATING

1. Disconnect the vapor pipe from the inlet port of the evaporative purge valve (ie, from fuel tank). 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
Recheck DTCs. Carry out a flow check monitor drive cycle. For additional information, see "diagnostic
drive cycles" above.
-> No
CHECK for DTC P0444, P0445. Conduct "green" ECM drive cycle. For additional information, see
"diagnostic drive cycles" above.

P0442, P0444, P0445, P0455, P0456; LEAK
DETECTED: LARGE/20 THOU/40 THOU,
PURGE VALVE CIRCUIT
MALFUNCTION, OPEN/SHORT
CIRCUIT,
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-> Yes
-> No
REPAIR as necessary. CLEAR the DTC. Carry out a full evaporative system monitor drive cycle.
Recheck DTCs. For additional information, see "diagnostic drive cycles" above.
G307413t4 : CHECK THE CANISTER PURGE VALVE DRIVE CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the canister purge valve electrical
connector, EC63. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance
between EC63, pin 02 (UY) and PI01, pin 66 (UY).
-> Yes
DTC. Carry out a full evaporative system monitor drive cycle.
-> No
G307413t5 : CHECK THE CANISTER PURGE VALVE DRIVE CIRCUIT FOR

SHORT TO HIGH VOLTAGE
Measure the voltage between EC63, pin 02 (UY) and GROUND.
-> Yes
Carry out a full evaporative system monitor drive cycle.
-> No
G307413t6 : CHECK THE CANISTER PURGE VALVE DRIVE CIRCUIT FOR

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EC63, pin 02 (UY)
and GROUND.
-> Yes
-> No
G307413t7 : CHECK THE CANISTER PURGE VALVE POWER SUPPLY

1. Turn the ignition switch to the ON position.
Make sure the EMS relay is energized. 2. Measure the voltage between EC63, pin 01 (GU) and
GROUND.
-> Yes
REPAIR the circuit between the canister purge valve and battery. This circuit includes the front power
distribution box, fuse 14, the EMS relay, and the high power protection module. For additional
information, refer to the wiring diagrams. CLEAR the DTC. Carry out a full evaporative system
monitor drive cycle.
-> No
INSTALL a new canister purge valve.
Evaporative Emission Canister Purge Valve - VIN Range: G00442->G45703 (17.15.30) Carry out a full
evaporative system monitor drive cycle. Recheck DTCs. For additional information, see "diagnostic
drive cycles" above.

P0447, P0448; CANISTER CLOSE VALVE
(CCV) CIRCUIT MALFUNCTION, OPEN
/SHORT CIRCUIT
G307413t8 : CHECK THE CANISTER CLOSE VALVE POWER SUPPLY
1. Disconnect the CCV electrical connector, CV02. 2. Turn the ignition switch to the ON position.
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Make sure the EMS relay is energized. 3. Measure the voltage between CV02, pin 02 (GU) and
GROUND.
-> Yes
-> No
REPAIR the circuit between the CCV and battery. This circuit includes the front power distribution
box, fuse 14, the EMS relay and the high power protection module. For additional information, refer
to the wiring diagrams. CLEAR the DTC. Carry out a full evaporative system monitor drive cycle.
G307413t9 : CHECK THE CANISTER CLOSE VALVE POWER SUPPLY CIRCUIT

FOR SHORT CIRCUIT
1. Turn the ignition switch to the OFF position. 2. Measure the voltage between CV02, pin 02 (GU)
and GROUND.
-> Yes
-> No
G307413t10 : CHECK THE CANISTER CLOSE VALVE DRIVE CIRCUIT FOR

HIGH RESISTANCE
Measure the resistance between CV02, pin 01 (O) and PI01, pin 67 (O).
-> Yes
-> No

1. Reconnect the battery negative terminal. 2. Measure the voltage between CV02, pin 01 (O) and
GROUND.
-> Yes
-> No

SHORT TO GROUND
1. Measure the resistance between CV02, pin 01 (O) and GROUND.
-> Yes
-> No
INSTALL a new CCV. CLEAR the DTC. Carry out a full evaporative system monitor drive cycle.
P0450, P0452, P0453; FUEL TANK
PRESSURE (FTP) SENSOR CIRCUIT
MALFUNCTION, LOW/HIGH VOLTAGE
G307413t13 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the FTP sensor electrical connector, FP01.
3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between FP01, pin 02
(RG) and PI01, pin 104 (RG).
-> Yes
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-> No
G307413t14 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH
VOLTAGE
Measure the voltage between FP01, pin 02 (RG) and GROUND.
-> Yes
-> No
G307413t15 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT TO

GROUND
1. Measure the resistance between FP01, pin 02 (RG) and GROUND.

-> Yes
-> No
INSTALL a new FTP sensor.
Fuel Tank Pressure Sensor (19.55.31) CLEAR the DTC. Carry out a full evaporative system monitor
drive cycle.
G45704->G99999
Overview
2006my changes
addition of secondary air injection and changes to Federal evaporative emissions (Europe is
unchanged) and all market exhaust gas recirculation to comply with stage four emissions
requirements.
The hardware changes to the Federal evaporative emissions system are the deletion of the canister
close valve and the fuel tank pressure sensor, which have been replaced with a combined unit
incorporating a DMTL (diagnostic monitoring of tank leakage) pump and a COV (change-over valve)
into one module.
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The software changes will have more effect on the technician, as there is no longer the need to carry
out extensive drive cycles to confirm the success of a repair.
DMTL conditions
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 and that the ambient temperature is above
0°C (32°F) and less than 40°C (104°F).
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.

Fuel filler cap and seal Fuses
Fuel filler neck Connectors

DMTL fresh air filter (restriction, etc) Harness(es)
Fuel tank (leaks, damage, etc) Purge valve
Fuel lines and joints, etc DMTL pump
Carbon canister
Purge valve
DMTL pump module
4 . 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
Symptom Possible Source Action
Restriction in the vapor line between Check for restrictions/damage, etc

Difficulty in filling
the fuel tank and the carbon (see visual inspection).
canister outlet/atmospheric port
Check for leaks, check the purge
System leak
Fuel smell valve operation. GO to Pinpoint
Purge valve inoperative Test G532445p1.
Message center
Check the fuel filler cap and seal
display (refer to the Fuel filler cap missing/not tightened
after refuelling (see visual inspection).
owners handbook)
Diagnostic
Trouble Description Possible Source Action
Code
P044100 Incorrect purge flow Evaporative canister purge For basic checks. GO to
pipe restricted, Pinpoint Test G532445p1.
leaking, disconnected Check for DTCs indicating a
purge valve fault.
Evaporative canister vent
restricted
Evaporative canister purge

valve to engine pipe(s)
disconnected
Evaporative canister purge

valve failure
Change-over valve (COV) For COV circuit tests, GO to
P044700 DMTL COV circuit short
control circuit circuit to ground Pinpoint Test G532445p3.
For COV circuit tests, GO to

P044800 COV control circuit DMTL COV circuit short
Check the fuel system

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integrity (see visual

Leak detected (very small
P045600 DMTL has detected a leak inspection). Carry out K line
leak) in the fuel system or Vacutec tests to identify
the leak.
Purge valve control circuit:

For purge valve circuit
P045800 Purge valve control circuit tests. GO to Pinpoint Test
Purge valve control circuit: G532445p2.
high resistance
For purge valve circuit
P045900 Purge valve control circuit Purge valve control circuit: tests. GO to Pinpoint Test
short circuit to power G532445p2.
For DMTL pump circuit

DMTL pump control DMTL pump control
P240100 tests. GO to Pinpoint Test
circuit circuit: short circuit to
ground G532445p4.
For DMTL pump circuit

DMTL pump control DMTL pump control
P240200 tests. GO to Pinpoint Test
circuit circuit: short circuit to
power G532445p4.
DMTL reference leak Check the DMTL pipework.

DMTL pump sense circuit
For DMTL pump tests, GO
P240429 range/performance - DMTL pump circuit: short
signal invalid circuit, high resistance to Pinpoint Test
G532445p4.
DMTL pipework
blocked/leaking
DMTL reference leak
Check the DMTL pipework.
DMTL pump circuit: short For DMTL pump tests, GO
P24042F range/performance -
circuit, high resistance to Pinpoint Test
signal erratic
G532445p4.
DMTL pipework
blocked/leaking
P240500 DMTL pump circuit: short to Pinpoint Test
low circuit, high resistance G532445p4.

P240600 DMTL pump circuit: short to Pinpoint Test
high circuit, high resistance G532445p4.
DMTL heater control

circuit: short circuit to For DMTL heater circuit
DMTL pump heater circuit
P240B00 ground tests. GO to Pinpoint Test
low
G532445p5.
DMTL heater control
For DMTL heater circuit
DMTL pump heater circuit DMTL heater control
P240C00 tests. GO to Pinpoint Test
high circuit: short circuit to
power G532445p5.

to Pinpoint Test
G532445p4.
DMTL pump circuit: short
COV performance/stuck For DMTL COV tests, GO to
open Pinpoint Test G532445p3.
DMTL COV stuck open If the circuits are good,
replace the DMTL
assembly.

to Pinpoint Test
G532445p4.
DMTL pump circuit: short
COV performance/stuck For DMTL COV tests, GO to
closed Pinpoint Test G532445p3.
DMTL COV stuck closed If the circuits are good,
replace the DMTL
assembly.
Pinpoint Tests
NOTE:
NOTE:
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EVAPORATIVE SYSTEM INCORRECT
PURGE FLOW
-> Yes
-> No
REPAIR as necessary. CLEAR the DTC, test the system for normal operation.
G532445t2 : 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 index above.
-> No
CHECK the purge valve circuits. GO to Pinpoint Test G532445p2.
PINPOINT TEST G532445p3 : CHANGE-

OVER VALVE (COV) CONTROL
CIRCUIT
G532445t8 : CHECK THE COV CONTROL CIRCUIT FOR SHORT CIRCUIT TO
GROUND
1. Key off. 2. Disconnect the DMTL electrical connector, CV09. 3. Measure the resistance between:
DMTL connector CV09, harness side Battery
-> Yes
-> No
G532445t9 : CHECK THE COV CONTROL CIRCUIT FOR SHORT CIRCUIT TO

POWER
DMTL connector CV09, harness side Battery

-> Yes
-> No
G532445t10 : CHECK THE COV CONTROL CIRCUIT FOR HIGH RESISTANCE

DMTL connector CV09, harness side ECM connector EC300, harness side
Pin 03 Pin 48

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-> Yes
-> No
INSTALL a new DMTL assembly. If the DTC is repeated, refer to the warranty policy and procedures
PINPOINT TEST G532445p2 : PURGE

VALVE CONTROL CIRCUIT
G532445t3 : CHECK THE POWER SUPPLY TO THE PURGE VALVE
1. Disconnect the purge valve connector, PI363. 2. Key on, engine off. 3. Measure the voltage
between:
Purge valve connector PI363, harness side Battery
-> Yes
REPAIR the circuit between the purge valve and battery. This circuit includes harness splices and fuse
14 of the front power distribution box. For additional information, refer to the wiring diagrams. Clear
the DTC, test the system for normal operation.
-> No
G532445t4 : CHECK THE PURGE VALVE CONTROL CIRCUIT FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No
G532445t5 : CHECK THE PURGE VALVE CONTROL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G532445t6 : CHECK THE PURGE VALVE CONTROL CIRCUIT FOR HIGH
RESISTANCE
Purge valve connector PI363, 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
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repeated, refer to the warranty policy and procedures manual if an ECM is suspect.

DIAGNOSTIC MONITORING OF FUEL
TANK LEAKAGE (DMTL) PUMP
CONTROL CIRCUIT
G532445t7 : CHECK THE POWER SUPPLY TO THE DMTL PUMP
1. Key off. 2. Disconnect the DMTL pump electrical connector, CV09. 3. Key on, engine off. 4.
DMTL pump connector CV09, harness side Battery
-> Yes
REPAIR the circuit between the DMTL pump and battery. This circuit includes harness splice ECS20
and fuse 14 of the front power distribution box. For additional information, refer to the wiring
diagrams. Clear the DTC, test the system for normal operation.
-> No
G532445t11 : CHECK THE DMTL PUMP CONTROL CIRCUIT FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No
G532445t12 : CHECK THE DMTL PUMP CONTROL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G532445t13 : CHECK THE DMTL PUMP CONTROL CIRCUIT FOR HIGH

RESISTANCE
DMTL pump connector CV09, harness side ECM connector EC300, 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

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DIAGNOSTIC MONITORING OF FUEL

TANK LEAKAGE (DMTL) HEATER
CIRCUIT
G532445t14 : CHECK THE POWER SUPPLY TO THE DMTL PUMP
1. Key off. 2. Disconnect the DMTL pump electrical connector, CV09. 3. Key on, engine off. 4.
-> Yes
REPAIR the circuit between the DMTL pump and battery. This circuit includes harness splice ECS20
and fuse 14 of the front power distribution box. For additional information, refer to the wiring
diagrams. Clear the DTC, test the system for normal operation.
-> No
G532445t15 : CHECK THE DMTL HEATER CONTROL CIRCUIT FOR SHORT
CIRCUIT TO GROUND
-> Yes
-> No
G532445t16 : CHECK THE DMTL HEATER CONTROL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G532445t17 : CHECK THE DMTL HEATER CONTROL CIRCUIT FOR HIGH

RESISTANCE
DMTL pump connector CV09, harness side ECM connector EC300, 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
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Evaporative Emission Canister - VIN

Range: G00442->G45703 (17.15.13)

HTJ1200-2
Removal
All vehicles
2 . Remove the left-hand luggage compartment side trim panel.

3 . Remove the left-hand air spring trim panel.
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4 . Disconnect the left-hand air spring electrical connector.
5
Detach the left-hand air pipe.

6 . Remove the left-hand air spring retaining nuts.

8 . Remove both rear mufflers and tail pipes.

For additional information, refer to Muffler and Tailpipe (30.10.52)
9
(if fitted).
flexible joint.

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11 . NOTE:
12 .
NOTE:

13 .
NOTE:

All vehicles
14 . NOTE:
15 . NOTE:

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Remove the noise, vibration and harshness brace retaining bolts.

17 . NOTE:
Remove and discard the rear subframe rear retaining bolt.
18 . NOTE:
Remove and discard the rear subframe front retaining bolt.
19
. CAUTION: Make sure the rear subframe does not come into contact with the fuel
tank filler pipe.
Lower the rear subframe to a suitable height.

20 . Disconnect the emission hose.
Disconnect the carbon canister electrical connector (if equipped).
21 . NOTE:
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Rear subframe shown removed for clarity.
Detach the evaporative emission canister.
22 . NOTE:
Remove the evaporative emission canister between the subframe and vehicle body.
Remove the evaporative emission canister.

Installation
All vehicles
1 . NOTE:
Install the evaporative emission canister between the subframe and vehicle body.
Install the evaporative emission canister.
Tighten to 7 Nm.
3 . Connect the emission hose.
Connect the carbon canister electrical connector (if equipped).
4 . NOTE:

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Loosely install the rear subframe front retaining bolt.
Install a new retaining bolt.
5 . NOTE:
Loosely install the noise, vibration and harshness brace retaining bolts.
7 . NOTE:
Install the rear subframe rear retaining bolt.
Install a new retaining bolt.
Tighten to 125 Nm.

8 . NOTE:
Tighten to 48 Nm.

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10 . NOTE:
Attach the rear air springs.
Tighten to 133 Nm.

11 .
NOTE:
Attach the brake caliper.
Tighten to 70 Nm.

12 .
NOTE:

13 . NOTE:
Attach the caliper.

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Tighten to 34 Nm.
All vehicles
Tighten to 88 Nm.
16 . Install both rear mufflers and tail pipes.
18 . Install the left-hand rear air spring retaining nuts.
Tighten to 25 Nm.
19 . Attach the left-hand air pipe.
Tighten to 5 Nm.
20 . Connect the air spring electrical connector.
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21 . Install the air spring trim panel.
22 . Install the luggage compartment side trim panel.

24 Start and run the engine for 2 minutes to allow the air spring to recharge and to allow the
. compressor to replenish the reservoir.
Evaporative Emission Canister - VIN
Range: G45704->G99999 (17.15.13)

HTJ1200-2
Removal
All vehicles
1 . Drain the fuel tank.
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For additional information, refer to Fuel Tank Draining - VIN Range: G00442->G45703
2 . Remove the rear wheels and tires.

3.
NOTE:
Detach the brake caliper and anchor plate.
4.
NOTE:
Mark the brake disc position in relation to the hub.
5.
NOTE:
Using a suitable tie strap, secure the brake caliper to the upper arm.
6 . NOTE:

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7 . Remove both rear exhaust mufflers and tail pipes.

8
(if fitted).
flexible joint.
9 . Remove the fuel tank filler pipe to fuel tank hose.
10 . Detach the rear axle electrical connectors.
11 . NOTE:
NOTE:
Using a suitable tool, mark the position of the rear subframe to the vehicle body.
Remove the noise, vibration and harshness (NVH) brace retaining bolts.
12
. WARNING: Rotate the special tool height adjustment valve slowly. Failure to
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Install the special tool to support the rear subframe.
13 . NOTE:
Remove the NVH brace.
Remove and discard the rear subframe front retaining bolts.

14 . NOTE:
Remove and discard the rear subframe rear retaining bolts.
15
CAUTION: Make sure the rear subframe weight is evenly supported on the special
tool. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure when lowering the rear subframe damage does not occur to
the surrounding components.
Using the special tool, lower the rear subframe to a maximum of 152mm (6 inch)
16 . NOTE:
Disconnect the fuel pump driver module electrical connector.

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17 . NOTE:
Remove the fuel pump driver module.
Remove the retaining clip.

All vehicles
18 . NOTE:
Disconnect the evaporative emission canister vent solenoid vent hose.
19 . NOTE:
Disconnect the evaporative emission canister vent solenoid electrical connector.
20 . NOTE:
Disconnect the evaporative emission canister vapor pipes.

For additional information, refer to Quick Release Coupling
21 . NOTE:
Detach the evaporative emission canister.

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22 . Remove the evaporative emission canister.
Installation
All vehicles
1 . Install the evaporative emission canister.
2 . NOTE:
Attach the evaporative emission canister.
Tighten to 7 Nm.
3 . NOTE:
Connect the evaporative emission canister vapor pipes.

For additional information, refer to Quick Release Coupling
4 . NOTE:
Connect the evaporative emission canister vent solenoid electrical connector.

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5 . NOTE:
Connect the evaporative emission canister vent solenoid vent hose.

6 . NOTE:
Install the fuel pump driver module.
Install the retaining clip.

7 . NOTE:
Connect the fuel pump driver module electrical connector.
All vehicles
8
. CAUTION: Make sure the rear subframe weight is evenly supported on the special
tool. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure when raising the rear subframe damage does not occur to the
surrounding components. Failure to follow this instruction may result in damage to the
vehicle.
Using the special tool, raise the rear subframe to the vehicle body.
Align the subframe to the original position in relation to the vehicle body.
9 . NOTE:
NOTE:
Install new rear subframe retaining bolts.

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Loosely install the rear subframe front retaining bolts.
Install the NVH brace
10 . NOTE:
Loosely install the NVH brace retaining bolts.

11 . NOTE:
NOTE:
Install new rear subframe retaining bolts.
Install the rear subframe rear retaining bolt.
Tighten to 125 Nm.
Align the subframe to the original position in relation to the vehicle body.
12 . NOTE:
Tighten the rear subframe front retaining bolt.
Tighten to 125 Nm.

13 . NOTE:
Tighten the NVH brace retaining bolts.

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Tighten to 48Nm.
14
Remove the special tool from the rear subframe.

15 . Attach the rear axle electrical connectors.
16 . Attach the fuel tank filler pipe to fuel tank hose.
17
Attach the driveshaft to the rear drive axle flange.
Install the driveshaft to the original position in relation to the rear drive
axle flange.
Tighten to 88 Nm.
If a balance nut is fitted, install onto the original bolt position and tighten
to 12 Nm .
18 . NOTE:
Tighten to 133 Nm.

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19 . NOTE:
Install the brake disc.
Install the brake disc to the original position in relation to the hub.
20 .
NOTE:
NOTE:
Remove and discard the securing tie strap.
NOTE:
Install new brake caliper anchor plate retaining bolts.
Attach the brake caliper and anchor plate.
21 . Install the rear wheels and tires.

23 . Fill the fuel tank with fuel.

Evaporative Emission Canister Purge Valve
- VIN Range: G00442->G45703 (17.15.30)
Removal
2 . Remove the left-hand front wheel and tire. <<204-04>>
3 . Remove the left-hand front fender splash shield. <<501-02>>
4 . Remove the bulkhead drain tube.

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5 . Disconnect the evaporative emission canister purge valve electrical connector.
6 . Disconnect the evaporative emission canister purge valve outlet hose.

7 . Disconnect the evaporative emission canister purge valve inlet hose.
8 . Remove the evaporative emission canister purge valve.
Installation
- 3.0L NA V6 - AJ27, VIN Range: G45704-
>G99999 (17.15.30)
Removal
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2 . Disconnect the evaporative emission canister purge valve hose.
3 . Detach the evaporative emission canister purge valve hose.

5 . Remove the evaporative emission canister purge valve retaining bolt.
Disconnect the evaporative emission canister purge valve hose.
Installation
Tighten to 6 Nm.
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- 4.2L SC V8 - AJV8/3.5L NA V8 - AJV8,
VIN Range: G45171->G99999 (17.15.30)
Removal
>G99999 (19.70.04)

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Installation
Tighten to 10 Nm.
- 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8,
VIN Range: G45171->G99999 (17.15.30)
Removal

5 . Remove the evaporative emission canister purge valve retaining bolt.
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6 . Reposition the engine cover left-hand mounting bracket.

Installation
Tighten to 10 Nm.
Evaporative Emission Canister Vent
Solenoid (17.15.45)
Removal
on or near any fuel related components. Highly flammable vapors are always present and may
WARNING: Do not carry or operate cellular phones when working on or near any fuel
related components. Highly flammable vapours are always present and may ignite. Failure to
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2 . Disconnect the evaporative emission canister vent solenoid vapor hose.
3 . Disconnect the evaporative emission canister vent solenoid electrical connector.

4 Remove the evaporative emission canister vent solenoid.
.
Remove and discard the evaporative emission canister vent solenoid O-ring
seal.
Installation
1 . NOTE:
Install a new evaporative emission canister vent solenoid O-ring seal.
Tighten to 6 Nm.
Fuel Tank Pressure Sensor (19.55.31)
Removal
1 . Remove the fuel tank. <<310-01>>
2 . Disconnect the fuel pressure sensor electrical connector.

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Installation
303-14A : Electronic Engine Controls – 3.0L NA V6 –
AJ27
Specifications
Specifications

Camshaft position (CMP) sensor retaining bolt 7 - 62
Heated oxygen sensor (H02S) 40 30 -
Catalyst monitor sensor 40 30
Crankshaft position (CKP) sensor retaining bolt 7 - 62
Knock sensor retaining bolt 25 18 -
Variable camshaft timing oil control solenoid retaining bolt 10 - 89
Intake manifold tuning (IMT) valve retaining bolts 10 - 89
Engine coolant temperature (ECT) sensor 17 13 -
Manifold absolute pressure (MAP) sensor retaining screws 10 - 89
Fuel rail pressure (FRP) sensor retaining bolts 10 - 89
Fuel rail pressure (FRP) sensor bracket upper retaining bolts 6 - 53
Fuel rail pressure (FRP) sensor bracket lower retaining bolt 10 - 89
Engine control module (ECM) electrical connector retaining bolt 5 - 44
Lubricants, fluids, sealers and adhesives
Sealant WSK-M4G-328-A3
General procedures

Adjustment
No Data Available
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1 — Throttle position (TP) sensor
2 — Engine coolant temperature (ECT) sensor

3 — Knock sensor - LH
4 — Oil pressure sensor
5 — Oil temperature sensor
6 — Fuel temperature sensor
7 — Crankshaft position (CKP) sensor
8 — Camshaft position (CMP) sensor
9 — Variable camshaft timing oil control solenoid

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1 — Fuel rail pressure (FRP) sensor

2 — Manifold absolute pressure (MAP) sensor
3 — Intake manifold tuning (IMT) valve
4 — Intake manifold tuning (IMT) valve
5 — Knock sensor - RH
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1 — Heated oxygen sensor (HO2S) - RH
2 — Catalyst monitor sensor - RH
3 — Catalyst monitor sensor - LH
4 — Heated oxygen sensor (HO2S) - LH
Engine Control Module (ECM)

The electronic engine control system consists of a engine control module (ECM), located behind the
glove compartment, and a number of sensing and actuating devices. The sensors supply the ECM
with input signals which relate to the engine operating conditions and driver requirements. The
sensor information is evaluated by the ECM using the results to activate the appropriate response
from the actuating devices. The system provides the necessary engine control accuracy and
adaptability to:
minimize exhaust emissions and fuel consumption.

provide optimum driver control under all conditions.
minimize evaporative emissions.
provide system diagnostics.
In addition to these functions the ECM also interfaces with other vehicle systems through the
controller area network (CAN).
Camshaft Position (CMP) Sensor

The camshaft position (CMP) sensors monitor the position of both camshafts to allow the ECM to
control the phase of the inlet camshafts relative to the position of the crankshaft.
Variable Camshaft Timing Oil Control Solenoid

The variable camshaft timing oil control solenoid is a hydraulic actuator, which advances and retards
the inlet camshaft timing, thereby altering the camshaft to crankshaft phasing for optimum engine
performance.
Intake Manifold Tuning (IMT) Valve

There are two intake manifold tuning (IMT) valves, an upper and a lower, sometimes referred to as
number one and two respectively. They are a two position (open and close) device used to create a
variable air intake system. The IMT valve positions are switched by signals from the ECM to optimize
torque across the engine's speed and load range. The upper IMT valve opens between 4,100 and
6,150 rpm while the lower IMT valve opens between 3,900 and 6,150 rpm.
Knock Sensors (KS)

The knock sensors (KS) detect combustion knock within the engine cylinders and sends a signal to the
ECM. The ECM uses this information to gradually adjust the ignition timing until the combustion
knock is eliminated.
Mass Air flow (MAF) Sensor

The mass air flow (MAF) sensor informs the ECM of the rate of air flow entering the engine by
producing a voltage which is proportional to the rate of air flow into the engine. The voltage
produced by the MAF sensor increases as the rate of air flow increases. The ECM also takes into
account the density of the air entering the air intake system so that it is possible to maintain the
required air to fuel ratio, and to compensate for variations in atmospheric pressure.
Integral to the MAF sensor is the intake air temperature sensor (IAT) which measures the
temperature of the air entering the air intake system. The ECM uses this information to compensate
for higher than normal air intake temperatures.
Fuel Rail Pressure (FRP) Sensor

The fuel rail pressure (FRP) 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.
Throttle Position (TP) Sensor
The ECM monitors the angle of the throttle blade within the throttle housing through the throttle
position (TP) sensor. The TP sends a voltage to the ECM which is proportional to the angle of the
throttle plate. The voltage from the TP increases with the angle of the throttle plate. There are two
sensor tracks within the TP sensor.
Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor is an inductive pulse generator, which scans protrusions on a
pulse ring fitted to the front of the crankshaft to inform the ECM of the crankshaft's position and
speed. The CKP sensor produces an alternating voltage. The frequency of this voltage increases
proportional to engine speed.
Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor is a thermistor type sensor that provides an input
signal to the ECM which is proportional to the engine coolant temperature. The ECT sensor is a
negative temperature coefficient (NTC) sensor and its resistance decreases with a proportional
increase in engine coolant temperature.
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Oil Temperature Sensor

The oil temperature sensor is a thermistor type sensor that provides an input signal to the ECM
which is proportional to the engine oil temperature.
Oil Pressure Switch

The oil pressure switch is connected to the instrument cluster and is not directly part of the
electronic engine control system.

The heated oxygen sensor (HO2S) is a linear characteristic type sensor, fitted forward of the exhaust
system's catalytic converter. The ECM uses this as it's primary sensor to measure the oxygen content
of the exhaust gasses within the exhaust system to provide closed-loop fuelling control.
Catalyst Monitor Sensor

The catalyst monitor sensor is a non-linear characteristic type sensor fitted to the exhaust system's
catalytic converter. The ECM uses this as it's secondary sensor to measure the oxygen content of the
exhaust gasses within the exhaust after they have passed through the catalytic converter. As well as
providing additional closed-loop fuelling control the ECM uses this information to determine the
efficiency of the catalytic converter.

G00442->G45703
NOTE:
driver information table for Diagnostic Trouble Codes (DTCs) associated with the display, then to
the DTC index table for possible sources and actions. Some warnings will appear to clear when
the ignition is cycled. This is often because the warning has flagged as a result of one of the
vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not
run when the ignition is switched ON, the warning will not reflag until the routine does run. See
the DTC summaries for drive cycle routines.

Engine oil level
Cooling system coolant level Fuses
Fuel level Wiring harness
Fuel contamination/grade/quality Electrical connector(s)
Throttle body Sensor
Poly-vee belt
G45704->G99999
Overview
addition of secondary air injection, changes to evaporative emissions and exhaust gas recirculation to
comply with stage four emissions requirements.


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Engine oil level and condition

Fuses
Wiring harness
Fuel level
Sensor(s)
Throttle body
Poly-vee belt
Air cleaner condition
Air intake system
Cooling system
Charging system
Fuel charging system
Ignition system
2 . If an obvious cause for an observed or reported symptom is found, correct the cause (if possible)
retrieve the fault codes before proceeding to the DTC Index, or the symptom chart if no DTCs are set.
Symptom Chart
Symptom
(general)
Security system
/Immobiliser engaged
Check that the security system
Engine in shut-down mode is disarmed. Check for DTCs.
For ECM relay tests, GO to
ECM relay Pinpoint Test G531330p32.
Engine does not crank Battery
Battery For Park/Neutral tests,
Park/Neutral switch External Controls For starting
system,
Starting system For engine information,
Engine
Harness
Engine seized
system,
Engine breather system Engine Emission Control - VIN
Non-Start
d
Ignition system Engine Ignition - VIN Range:
G45704->G99999 For fuel
Engine cranks, but does
Fuel system system,
not fire
Harness VIN Range: G45704->G99999
For CKP tests, GO to Pinpoint
sensor Test G531330p17.
ECM fault and procedures manual if an
ECM is suspect.
Evaporative emissions For purge valve tests,

Engine cranks and fires, purge valve Evaporative Emissions - VIN
but will not start Range: G45704->G99999 For
Fuel pump
fuel pump circuit tests,
Spark plugs Fuel Charging and Controls -
Check for water ingress For ignition system,
into spark plug wells Engine Ignition - VIN Range:
G45704->G99999
HT short to ground
(tracking) check rubber
boots for
cracks/damage
Harness
Check the coolant anti-freeze
content. For battery
information,
Coolant anti-freeze
GO to Pinpoint Test
content
G531330p17.
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Battery For EGR valve tests,

CKP sensor Range: G45704->G99999
Check the fuel pressure,
Exhaust gas recirculation Fuel Tank and Lines - 4.2L NA
(EGR) valve stuck open V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
Fuel pump
Purge valve G45704->G99999 For purge
Difficult to valve tests,
start Evaporative Emissions - VIN
Range: G45704->G99999
Injector leak For injector information,

(EFT) sensor VIN Range: G45704->G99999
For EFT sensor tests, GO to
Intake air temperature Pinpoint Test G531330p34.
(IAT) sensor For IAT sensor tests, GO to
Mass air flow (MAF) sensor For MAF sensor tests, GO to
Purge valve
Fuel pump Evaporative Emissions - VIN
Range: G45704->G99999
Ignition system
Injector leak
EFT sensor
IAT sensor
hot soak (vehicle
MAF sensor
temperature) Purge valve
Fuel pump
Ignition system
Check compressions,
Compressions high/low Engine For battery
Engine cranks too
information,
fast/slow Battery
Battery For starting system,
Starting system

system,
Breather system
disconnected/restricte ECM relay tests, GO to Pinpoint
d Test G531330p32.
For MAF sensor tests, GO to
For ignition system tests,
Harness Engine Ignition - VIN Range:
G45704->G99999 Check the
MAF sensor
Engine stalls soon after fuel lines,
Engine start Ignition system Fuel Tank and Lines - 4.2L NA
stalls V8 - AJV8/4.2L SC V8 -
Fuel lines AJV8/3.0L NA V6 - AJ27/3.5L
Fuel rail pressure (FRP) G45704->G99999 For FRP
sensor sensor tests, GO to Pinpoint
Test G531330p21.
For air filter and intake system
Air leakage information,
Filtering - VIN Range: G45704-
>G99999
ECM relay For ECM relay tests, GO to

Engine stalls on
overrun Throttle position (TP) For TP sensor tests, GO to
sensors Pinpoint Test G531330p4.
and GO to Pinpoint Test
G531330p5.

For CKP sensor tests, GO to
Engine stalls at steady CKP sensor Pinpoint Test G531330p17.
speed For TP sensor tests, GO to
TP sensors Pinpoint Test G531330p4.
Harness
G531330p5.
Engine stalls with ECM relay For ECM relay tests, GO to

speed control enabled Pinpoint Test G531330p32.
Harness
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ECM relay
TP sensors For TP sensor tests, GO to
Additional engine loads and GO to Pinpoint Test
Engine stalls when (PAS, air conditioning,
G531330p5.
maneuvering etc)
For accessory drive
Transmission malfunction information,
For transmission information,
Controller area network For CAN network tests,
(CAN) network
malfunction
Fuel pump Check the fuel pressure, check
the fuel lines,
Fuel pressure Fuel Tank and Lines - 4.2L NA
V8 - AJV8/4.2L SC V8 -
Fuel lines
AJV8/3.0L NA V6 - AJ27/3.5L
Injector leak NA V8 - AJV8, VIN Range:
G45704->G99999 For injector
Poor Engine hesitates/poor information,
Air leakage
driveability acceleration Fuel Charging and Controls -
TP sensors VIN Range: G45704->G99999
For intake system,
Throttle motor Intake Air Distribution and
Ignition system
>G99999 For TP sensor tests,
EGR valve stuck open GO to Pinpoint Test
G531330p4.
HO2 sensors and GO to Pinpoint Test
G531330p5.
Transmission malfunction For throttle motor tests, GO to
(carpet, etc)
Accelerator pedal position G45704->G99999 For EGR
(APP) sensor valve tests,
Range: G45704->G99999
Check for DTCs relating to HO2
sensors. Refer to the DTC index
for pinpoint tests for DTC set.
Check accelerator pedal travel.
For APP sensor tests, GO to
G531330p23.
For fuel pump and line tests,

V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
Fuel pump G45704->G99999 For intake
system,
Fuel lines Intake Air Distribution and
Air leakage
>G99999 For MAF sensor
MAF sensor tests, GO to Pinpoint Test
Engine backfires G531330p1.
HO2 sensors Check for DTCs relating to HO2
Ignition system for pinpoint tests for DTC set.
Sticking variable camshaft
timing (VCT) hub
G45704->G99999 For VCT
APP sensor information,
Variable Camshaft Timing (VCT)
Oil Control Solenoid (18.30.90)
G531330p23.
For fuel pump and line tests,

V8 - AJV8/4.2L SC V8 -
Fuel pump AJV8/3.0L NA V6 - AJ27/3.5L
Fuel lines G45704->G99999 For MAF
sensor tests, GO to Pinpoint
MAF sensor
Test G531330p1.
Engine surges For TP sensor tests, GO to
Harness
TP sensors and GO to Pinpoint Test
G531330p5.
Throttle motor For throttle motor tests, GO to
Ignition system For ignition system tests,
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G45704->G99999
For KS circuit tests, GO to

Knock sensor (KS)/circuit G531330p16.
malfunction For fuel pump and line tests,
Fuel pump V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
Fuel lines
G45704->G99999 For FRP
Fuel quality
Engine FRP sensor Test G531330p21.
detonates/knocks For MAF sensor tests, GO to
MAF sensor Pinpoint Test G531330p1.
HO2 sensors sensors. Refer to the DTC index
Air leakage
For intake system,
Sticking VCT hub Intake Air Distribution and
BARO sensor malfunction >G99999 Check DTCs for VCT
(internal ECM fault) range/performance fault. For
VCT information,
Engine BARO sensor, refer to
the warranty policy and
procedures manual if an ECM is
suspect.

, and GO to Pinpoint Test
APP sensor malfunction G531330p23.
For TP sensor tests, GO to
Throttle motor G531330p5.
For throttle motor tests, GO to
Check the message center for

default messages. For speed
Default mode enabled control switches,
Speed Control - VIN Range:
Speed control switch G45704->G99999 For TP
Speed control inhibited sensor tests, GO to Pinpoint
or disabled TP sensors Test G531330p4.
Brake pedal switch G531330p5.
For brake pedal switch tests,
CAN fault
GO to Pinpoint Test
G531330p25.

TP sensors G531330p23.
ECT sensor Pinpoint Test G531330p4.
MAF sensor G531330p5.
Poor throttle response For ECT sensor tests, GO to
Traction control event For MAF sensor tests, GO to
Air leakage For transmission information,
For intake system,
Breather system Intake Air Distribution and
disconnected/restricte Filtering - VIN Range: G45704-
d >G99999 For breather system
information,
Range: G45704->G99999
For Park/Neutral tests,

Park/Neutral switch External Controls For TP
TP sensors Test G531330p4.
Engine defaults,
warning light and
MAF sensor G531330p5.
messages.
For ECT sensor tests, GO to
Harness
DTC index
NOTE:
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Left front wheel speed Invalid data received from Anti-Lock Control -
C003100
sensor ABS: left front wheel Stability Assist - VIN
speed signal Range: G45704->G99999
Right front wheel speed Invalid data received from Anti-Lock Control -
C003400
sensor ABS: right front wheel Stability Assist - VIN
Left rear wheel speed Invalid data received from Anti-Lock Control -
C003700
sensor ABS: left rear wheel Stability Assist - VIN
Right rear wheel speed Invalid data received from

C003A00 Anti-Lock Control -
sensor ABS: right rear wheel
speed signal Stability Assist - VIN
Range: G45704->G99999
Intake (A) camshaft position Cam timing has not been set Check the engine timing,
P001100 timing - over-advanced up correctly Timing Drive Components
(right hand bank) (12.65.13)
Timing chain has slipped
P001200 timing - over-retarded (right up correctly Timing Drive Components
hand bank) (12.65.13)
Reset the sensor
positions.
Crankshaft position The relative positions of the Camshaft Position (CMP)
(CKP)/Camshaft position CKP and CMP teeth are Sensor LH (18.31.12)
P001600
(CMP) sensor correlation, not correct Sensors Camshaft Position (CMP)
right hand bank incorrectly aligned on Sensor RH (18.31.11)
rebuild
Crankshaft Position (CKP)
Sensor (18.30.12)
Reset the sensor

positions.
P001800
(CMP) sensor correlation, not correct Sensors Camshaft Position (CMP)
left hand bank incorrectly aligned on Sensor RH (18.31.11)
rebuild
Sensor (18.30.12)
P002100 timing - over-advanced (left up correctly Timing Drive Components
hand bank) (12.65.13)
P002200 timing - over-retarded (left up correctly Timing Drive Components
hand bank) (12.65.13)
Oil contamination
Variable camshaft timing
For right hand bank VCT
(VCT) control solenoid VCT oil flow fault
solenoid circuit tests, GO
P002672 circuit range/performance
VCT solenoid fault to Pinpoint Test
(right hand bank) - actuator
G531330p29.
stuck open
VCT/Camshaft mechanical
failure
P002677 VCT control solenoid circuit Oil contamination For right hand bank VCT
range/performance (right solenoid circuit tests, GO
hand bank) - commanded VCT oil flow fault to Pinpoint Test
position not reachable G531330p29.
VCT solenoid fault
failure
Oil contamination
VCT control solenoid circuit For left hand bank VCT
VCT oil flow fault
range/performance (left solenoid circuit tests, GO
P002872
hand bank) - actuator stuck VCT solenoid fault to Pinpoint Test
open G531330p30.
failure
Oil contamination
VCT control solenoid circuit For left hand bank VCT
VCT oil flow fault
range/performance (left solenoid circuit tests, GO
P002877
hand bank) - commanded VCT solenoid fault to Pinpoint Test
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position not reachable G531330p30.

failure
HO2S heater power supply
HO2S heater control circuit: For right hand bank HO2S

HO2S heater control circuit
P003100 high resistance heater circuit tests, GO to
low (right hand bank)
HO2S heater ground circuit(s)
fault
HO2S heater failure

HO2S heater control circuit: For right hand bank HO2S

P003200 high resistance heater circuit tests, GO to
high (right hand bank)
fault
HO2S heater failure

Catalyst monitor sensor For right hand bank
Catalyst monitor heater heater control circuit:
catalyst monitor heater
P003600 control circuit (right hand short circuit to ground
circuit tests, GO to
bank)
Catalyst monitor sensor Pinpoint Test G531330p9.
heater control circuit:
high resistance
Catalyst monitor sensor

heater failure
For left hand bank HO2S
HO2S heater control circuit:
HO2S heater control circuit heater circuit tests, GO to
low (left hand bank) Pinpoint Test
HO2S heater ground circuit(s) G531330p11.
fault
HO2S heater failure

HO2S heater control circuit heater circuit tests, GO to
high (left hand bank) Pinpoint Test
fault
HO2S heater failure

short circuit to ground For left hand bank catalyst
Catalyst monitor heater
monitor heater circuit
P005600 control circuit (left hand Catalyst monitor sensor
heater control circuit: tests, GO to Pinpoint Test
bank)

heater failure
For MAP sensor circuit
Manifold absolute pressure MAP sensor failure G531330p33.
P006900 (MAP) - Barometric pressure Refer to the warranty
correlation BARO sensor failure (internal policy and procedure
ECM fault) manual if an ECM is
suspect.
Ambient air temperature

P007100 Ambient temperature value
sensor range/performance missing from CAN bus Control Components

P007200 Ambient air temperature
sensor circuit low sensor circuit: high Control Components
resistance

sensor circuit: short
circuit to ground
Ambient air temperature Ambient air temperature
P007300
sensor circuit high sensor circuit: short Control Components
circuit to power
VCT solenoid valve
disconnected For right hand bank VCT
P007500 (VCT) control circuit (right VCT solenoid valve to ECM
PWM drive circuit: high to Pinpoint Test
hand bank)
VCT solenoid failure

VCT solenoid valve
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P007600 (VCT) control circuit low VCT solenoid valve to ECM
PWM drive circuit: short to Pinpoint Test
(right hand bank)

VCT solenoid valve
P007700 (VCT) control circuit high VCT solenoid valve to ECM
(right hand bank)

VCT solenoid valve
disconnected For left hand bank VCT
P008100 (VCT) control circuit (left VCT solenoid valve to ECM
hand bank)

VCT solenoid valve
(left hand bank)

VCT solenoid valve
(left hand bank)

Fuel rail pressure (FRP) sensor
disconnected
For FRP sensor circuit
FRP sensor to ECM sensing tests, GO to Pinpoint Test
circuit: high resistance or G531330p21.
short circuit to ground Check the fuel pressure,
check the fuel lines,
Fuel rail/system pressure - FRP sensor supply circuit:
P008700 high resistance Fuel Tank and Lines - 4.2L
too low
NA V8 - AJV8/4.2L SC V8 -
FRP sensor failure AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
Fuel pump failure VIN Range: G45704-
>G99999
Fuel line leak

to Pinpoint Test
FRP sensor to ECM wiring G531330p21.
(supply/sense): short For fuel line tests,
FRP sensor to ECM sense NA V8 - AJV8/4.2L SC V8 -
circuit: short circuit to AJV8/3.0L NA V6 -
power AJ27/3.5L NA V8 - AJV8,
Fuel rail/system pressure - VIN Range: G45704-
P008800
too high FRP sensor ground circuit: >G99999 Check the fuel
high resistance pressure, check the fuel
lines,
FRP sensor failure
Restricted fuel line NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
Fuel pump short circuit to AJ27/3.5L NA V8 - AJV8,
battery VIN Range: G45704-
>G99999
Mass or volume air flow A For intake system

P010100 Blocked air cleaner
circuit range/performance information,
Air intake leak Filtering - VIN Range:
G45704->G99999 Check
Engine breather leak the engine breather
system,
Mass air flow (MAF) sensor to
Engine Emission Control -
ECM sensing circuit: high
resistance, intermittent VIN Range: G45704-
short circuit to ground >G99999 For MAF sensor
MAF sensor supply circuit: Pinpoint Test G531330p1.
high resistance
Throttle adaption fault (check

throttle position voltage
at Ignition ON)
MAF sensor supply circuit:
Mass or volume air flow A high resistance, short
P010200 tests, GO to Pinpoint Test
circuit low input circuit to ground
G531330p1.
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MAF sensor failure

MAF sensor to ECM sensing
power
Mass or volume air flow A
circuit high input MAF sensor to ECM sensor
ground circuit: high G531330p1.
resistance
MAF sensor failure

Intake manifold air leak (loose
or missing component) For intake system
information,
MAP sensor to ECM circuit(s) Intake Air Distribution and
Manifold absolute pressure
fault Filtering - VIN Range:
P010600 (MAP)/BARO sensor
G45704->G99999 For
range/performance Throttle adaption fault (check MAP sensor circuit tests,
GO to Pinpoint Test
at Ignition ON)
G531330p33.
MAP sensor failure
Intake air temperature (IAT)
IAT sensor to ECM wiring: For IAT sensor circuit
sensor circuit
P011123 high resistance tests, GO to Pinpoint Test
range/performance - signal
G531330p2.
stuck low IAT sensor failure
IAT sensor circuit IAT sensor to ECM wiring: For IAT sensor circuit
P011124 range/performance - signal high resistance tests, GO to Pinpoint Test
stuck high G531330p2.
IAT sensor failure
IAT sensor circuit IAT sensor to ECM wiring: For IAT sensor circuit
P011129 range/performance - signal high resistance tests, GO to Pinpoint Test
invalid G531330p2.
IAT sensor failure
IAT sensor disconnected
For IAT sensor circuit
P011200 IAT sensor circuit low input IAT sensor to ECM wiring: tests, GO to Pinpoint Test
IAT sensor failure

IAT sensor to ECM wiring:
P011300 IAT sensor circuit high input IAT sensor to ECM sensing tests, GO to Pinpoint Test
circuit: short circuit to G531330p2.
power
IAT sensor failure

Low coolant level
Engine coolant temperature ECT sensor to ECM sensing

For ECT sensor circuit
(ECT) sensor circuit circuit: intermittent high
range/performance - signal resistance
G531330p3.
stuck low
Engine thermostat failure
ECT sensor failure

Low coolant level
ECT sensor to ECM sensing

ECT sensor circuit circuit: intermittent high For ECT sensor circuit
P011624 range/performance - signal resistance tests, GO to Pinpoint Test
stuck high G531330p3.
Engine coolant thermostat
failure
ECT sensor failure

Low coolant level

ECT sensor circuit circuit: intermittent high For ECT sensor circuit
P011629 range/performance - signal resistance tests, GO to Pinpoint Test
invalid G531330p3.
failure
ECT sensor failure

ECT sensor disconnected
For ECT sensor circuit
P011700 ECT sensor circuit low input tests, GO to Pinpoint Test
circuit: high resistance,
ECT sensor failure

Engine overheat For cooling fan circuit
condition/cooling fan tests, GO to Pinpoint Test
failure
ECT sensor 1 circuit high G531330p19.
P011800
input ECT sensor to ECM wiring: For ECT sensor circuit
short circuit to ground tests, GO to Pinpoint Test
G531330p3.
ECT sensor failure
TP sensor to ECM wiring: high For TP sensor circuit 1
resistance tests, GO to Pinpoint Test
G531330p4.
P012100 circuit range/performance, TP sensor to ECM sensing
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circuits: (TP 1 or TP 2) For TP sensor circuit 2

circuit 1 and 2
short circuit to power tests, GO to Pinpoint Test
G531330p5.
TP sensor failure
TP sensor to ECM sensing
For TP sensor circuit 1
circuit 1: short circuit to
P012200 TP sensor circuit 1 low input tests, GO to Pinpoint Test
G531330p4.
TP sensor failure
circuit (TP1): short circuit
to power
G531330p4.
TP sensor failure
Low coolant level
ECT sensor to ECM sensing Check the coolant level.

Insufficient coolant temp for circuit: intermittent high For ECT sensor circuit
P012500
closed loop fuel control resistance tests, GO to Pinpoint Test
G531330p3.
Engine thermostat failure
ECT sensor failure

Contaminated coolant
Check the coolant anti-
Coolant thermostat (coolant freeze content and
P012800 temp below thermostat condition. Check the
failure
regulating temperature) thermostat condition and
ECT sensor failure ECT sensor function. Check for ECT
DTC may also be flagged
sensor DTCs.
H02S disconnected
For right hand bank HO2
H02S to ECM variable current
sensor circuit tests, GO to
H02 sensor circuit low circuit fault
P01311A Pinpoint Test G531330p6.
voltage (right hand bank)
ECM to HO2S constant and GO to Pinpoint Test
current circuit fault G531330p7.
H02S failure
H02S disconnected
H02S to ECM variable current
H02 sensor circuit high circuit fault
P01321B Pinpoint Test G531330p6.
voltage (right hand bank)
ECM to HO2S constant and GO to Pinpoint Test
current circuit fault G531330p7.
H02S failure
HO2S to ECM wiring shield
high resistance For right hand bank HO2
HO2 sensor circuit slow
P013300 Exhaust leak Pinpoint Test G531330p6.
response (right hand bank)
Fuel control system fault G531330p7.
HO2 sensor failure

HO2 sensor circuit no sensor circuit tests, GO to
P013400 activity detected (right hand Pinpoint Test G531330p6.
HO2S slow activation
bank) and GO to Pinpoint Test
G531330p7.

disconnected
For right hand bank
Catalyst monitor sensor to catalyst monitor circuit
ECM wiring: high
Catalyst monitor circuit low tests, GO to Pinpoint Test
P013700 resistance
voltage (right hand bank) G531330p8.
Catalyst monitor sensor: and GO to Pinpoint Test
short circuit to ground G531330p9.

failure
P013800 Catalyst monitor circuit high Catalyst monitor sensor For right hand bank
sensing circuit: short catalyst monitor circuit
voltage (right hand bank) circuit to power tests, GO to Pinpoint Test
G531330p8.
Catalyst monitor sensor and GO to Pinpoint Test
ground braided shield: G531330p9.
high resistance

failure
For right hand bank
catalyst monitor circuit
P013900 circuit slow response (right Catalyst monitor sensor slow
response G531330p8.
hand bank)
G531330p9.
Catalyst monitor
disconnected
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Catalyst monitor mechanical

damage
Catalyst monitor to ECM For right hand bank

wiring: high resistance catalyst monitor circuit
Catalyst monitor circuit no
P014000 activity detected (right hand
Catalyst monitor sensing G531330p8.
bank) circuit: short circuit to and GO to Pinpoint Test
power G531330p9.
Catalyst monitor: short circuit
to ground
Catalyst monitor ground (BRD

braided shield) high
resistance
For right hand bank
Catalyst monitor sensor catalyst monitor circuit
Catalyst monitor heater tests, GO to Pinpoint Test
circuit (right hand bank) G531330p8.
Catalyst monitor sensor and GO to Pinpoint Test
heater failure G531330p9.

H02 sensor circuit low HO2 sensing circuit: short circuit tests, GO to
voltage (left hand bank) - Pinpoint Test
P01511A circuit to power, high
circuit resistance below resistance G531330p10.
threshold and GO to Pinpoint Test
HO2S failure G531330p11.
H02 sensor circuit low H02S sensing circuit: short circuit tests, GO to
voltage (left hand bank) - Pinpoint Test
P01521B circuit to power, high
circuit resistance above resistance G531330p10.
threshold and GO to Pinpoint Test
H02S failure G531330p11.
H02S to ECM wiring shield For left hand bank HO2S

high resistance circuit tests, GO to
H02S circuit slow response Pinpoint Test
P015300 Exhaust leak
(left hand bank) G531330p10.
Fuel control system fault and GO to Pinpoint Test
G531330p11.
H02S failure
H02S circuit no activity Pinpoint Test
P015400
detected (left hand bank) H02S slow activation G531330p10.
G531330p11.

disconnected
Catalyst monitor sensor to For left hand bank catalyst

ECM wiring high monitor circuit tests, GO
Catalyst monitor sensor resistance
to Pinpoint Test
P015700 circuit low voltage (left hand
bank) Catalyst monitor sensor short G531330p14.
circuit to ground and GO to Pinpoint Test
G531330p12.
Fuel control system lean fault

failure
sensing circuit: short For left hand bank catalyst
circuit to power monitor circuit tests, GO
to Pinpoint Test
P015800 circuit high voltage (left Catalyst monitor sensor
ground (BRD braided G531330p14.
hand bank)
shield) high resistance and GO to Pinpoint Test
G531330p12.
failure
P015900 Catalyst monitor sensor Catalyst monitor sensor slow For left hand bank catalyst
circuit slow response (left response monitor circuit tests, GO
hand bank) to Pinpoint Test
G531330p14.
G531330p12.

disconnected

mechanical damage
Catalyst monitor sensor to For left hand bank catalyst

ECM wiring high monitor circuit tests, GO
to Pinpoint Test
P016000 circuit no activity detected
Catalyst monitor sensor G531330p14.
(left hand bank)
sensing circuit: short and GO to Pinpoint Test
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Catalyst monitor sensor short

circuit to ground

ground (BRD braided
shield) high resistance
For left hand bank catalyst
monitor circuit tests, GO
Catalyst monitor sensor to Pinpoint Test
P016100 heater circuit (left hand
heater control circuit G531330p14.
bank) malfunction and GO to Pinpoint Test
G531330p12.
For intake system

information,
Air intake leak between MAF
sensor and cylinder head
G45704->G99999 Check
Fuel filter/system restriction the fuel pressure, check
System too lean (right hand the fuel lines,
P017100 Fuel Tank and Lines - 4.2L
bank) Fuel injector restriction
MAF sensor fault (low intake AJV8/3.0L NA V6 -
air flow) AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
>G99999 For fuel injector
information,
G531330p1.
Check the exhaust system
(before catalyst) for
condition and security,
For intake system

information,
Leaking fuel injector(s) Filtering - VIN Range:
G45704->G99999 For fuel
Oil contaminated with fuel injector information,
System too rich (right hand
P017200 (too many cold starts Fuel Injectors (18.10.02)
bank) with vehicle subsequently Check the oil condition, if
not getting hot enough contamination is present,
for long enough)
MAF sensor fault (high intake filter. For MAF sensor
air flow) circuit tests, GO to
For intake system

information,
G45704->G99999 Check
the fuel pressure, check
the fuel lines,
Air intake leak between MAF
sensor and cylinder head
Fuel filter/system restriction AJV8/3.0L NA V6 -
System too lean (left hand AJ27/3.5L NA V8 - AJV8,
P017400
bank) Fuel injector restriction VIN Range: G45704-
>G99999 For fuel injector
MAF sensor fault (low intake information,
air flow)
Exhaust leak (before catalyst) For MAF sensor circuit
G531330p1.
Check the exhaust system
(before catalyst) for
condition and security,
For intake system
information,
Leaking fuel injector(s) Filtering - VIN Range:
G45704->G99999 For fuel
Oil contaminated with fuel injector information,
System too rich (left hand
P017500 (too many cold starts Fuel Injectors (18.10.02)
bank) with vehicle subsequently Check the oil condition, if
not getting hot enough contamination is present,
for long enough)
MAF sensor fault (high intake filter. For MAF sensor
air flow) circuit tests, GO to
EFT sensor to ECM sensing

Engine fuel temperature short circuit to ground,
For EFT sensor circuit
(EFT) sensor A circuit short circuit to power
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EFT sensor ground circuit: G531330p34.
stuck low
high resistance
EFT sensor failure

EFT sensor circuit For EFT sensor circuit
P018124 range/performance - signal tests, GO to Pinpoint Test
stuck high EFT sensor ground circuit: G531330p34.
high resistance
EFT sensor failure

EFT sensor A circuit For EFT sensor circuit
invalid EFT sensor ground circuit: G531330p34.
high resistance
EFT sensor failure

circuit: short circuit to For EFT sensor circuit
P018200 EFT sensor circuit low input ground tests, GO to Pinpoint Test
G531330p34.
EFT sensor to splice sensor
ground circuit: short
circuit
EFT sensor failure

EFT sensor disconnected

P018300 EFT sensor circuit high input tests, GO to Pinpoint Test
EFT sensor to splice sensor G531330p34.
ground circuit: high
resistance
EFT sensor failure

For FRP sensor circuit
FRP sensor circuit
P019100 FRP sensor range and tests, GO to Pinpoint Test
range/performance performance G531330p21.

circuit: high resistance or For FRP sensor circuit
P019200 FRP sensor circuit low input short circuit to ground tests, GO to Pinpoint Test
G531330p21.
FRP sensor to supply circuit:
high resistance
FRP sensor failure

FRP sensor to ECM wiring
(supply, sense): short
FRP sensor to ECM sense For FRP sensor circuit

P019300 FRP sensor circuit high input circuit: short circuit to tests, GO to Pinpoint Test
power G531330p21.
FRP sensor ground circuit:

high resistance
FRP sensor failure

Engine oil temperature EOT sensor to ECM sensing
For EOT sensor circuit
(EOT) sensor circuit circuit: intermittent high
G531330p13.
stuck low
EOT sensor failure
P019624 EOT sensor circuit EOT sensor to ECM sensing For EOT sensor circuit
range/performance - signal circuit: intermittent high tests, GO to Pinpoint Test
stuck high resistance G531330p13.
EOT sensor failure

EOT sensor to ECM sensing
EOT sensor circuit For EOT sensor circuit
circuit: intermittent high
resistance
invalid G531330p13.
EOT sensor failure
P019700 EOT sensor circuit low input tests, GO to Pinpoint Test
ground
G531330p13.
EOT sensor failure
EOT sensor disconnected
P019800 EOT sensor circuit high input tests, GO to Pinpoint Test
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EOT sensor failure

Cylinder 1 injector Injector harness wiring: high Fuel Charging and
P020100
circuit/open resistance, short circuit to Controls - VIN Range:
ground G45704->G99999
Injector failure
P020200
ground G45704->G99999
Injector failure
P020300
ground G45704->G99999
Injector failure
P020400
ground G45704->G99999
Injector failure
P020500
ground G45704->G99999
Injector failure
P020600
ground G45704->G99999
Injector failure
TP sensor circuit 2: short
circuit to ground
TP sensor circuit 2: high G531330p5.
resistance
TP sensor circuit 2 high
P022300 TP sensor circuit 2: short tests, GO to Pinpoint Test
input circuit to power G531330p5.
APP sensor circuit 1: short

Accelerator pedal position circuit to ground For APP sensor circuit 1
P022700 (APP) sensor circuit 1 low tests, GO to Pinpoint Test
input Accelerator pedal position G531330p22.
(APP) sensor circuit 1:
high resistance
For APP sensor circuit 1
APP sensor circuit 1 high
P022800 APP sensor circuit 1: short tests, GO to Pinpoint Test
input circuit to power G531330p22.
ECM to ignition coil primary For ignition coil and spark

circuit faults (cylinder plug tests,
misfire detected DTCs Engine Ignition - VIN
also logged) Range: G45704->G99999
Check the cylinder
Ignition coil failure compressions,
Random/multiple cylinder
P030000 Engine Check the fuel
misfire detected Spark plug
pressure,
gap Fuel Tank and Lines - 4.2L
Cylinder compression low AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
Fuel delivery pressure VIN Range: G45704-
(low/high) >G99999 For fuel injector
circuit tests,
Fuel injector circuit fault(s) Fuel Charging and
(injector DTCs also Controls - VIN Range:
logged)
G45704->G99999 For
Fuel injectors injector information,
restricted/leaking Fuel Injectors (18.10.02)
Check the fuel for
Fuel injectors continuously contamination, grade and
open quality. For camshaft and
valve information,
Fuel contamination
Worn camshaft/broken valve AJV8/4.2L SC V8 -
springs AJV8/3.0L NA V6 -
Valve clearance adjustment
Refer to P030000 possible
P030100 Cylinder 1 misfire detected Refer to P030000 actions
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sources

sources

sources

sources

sources

sources
Check for fuel level sensor

Misfire detected with low codes, add fuel. Clear the
P031300 Misfire detected during low
fuel fuel level condition DTC and test for normal
operation.
Misfire detected on first 1000 Carry out the tests

Engine misfire detected on revs indicated for a normal
P031600
startup misfire code, but on a cold
Refer to P030000 possible engine.
sources
Poor sensor contact with the
cylinder block For right hand bank KS
Knock sensor (KS) 1 circuit circuit tests, GO to
P032700
low input (right hand bank) KS to ECM sense circuit: short Pinpoint Test
KS failure
KS 1 circuit high input (right circuit tests, GO to
P032800 KS to ECM sense circuit: high
hand bank) resistance, short circuit to Pinpoint Test
power G531330p15.
KS failure
cylinder block For left hand bank KS
KS 2 circuit low input (left circuit tests, GO to
P033200
hand bank) KS to ECM sense circuit: short Pinpoint Test
KS failure
KS 2 circuit high input (left circuit tests, GO to
hand bank) resistance, short circuit to Pinpoint Test
power G531330p16.
KS failure
CKP sensor disconnected
CKP Sensor gap incorrect/

foreign matter on sensor
Crankshaft position (CKP) face /damaged teeth on
For CKP sensor circuit
sensor A circuit - rotor
performance or incorrect
CKP sensor sensing circuit: G531330p17.
operation
high resistance, short
circuit to power
CKP sensor failure

CKP sensor A circuit -
unexpected operation CKP sensor gap incorrect/
foreign matter on sensor G531330p17.
face /damaged teeth on
rotor
CKP sensor sensing circuit:

circuit to power
CKP sensor failure

CKP sensor gap incorrect/
rotor
CKP sensor A circuit
P033600 CKP sensor sensing circuit: tests, GO to Pinpoint Test
range/performance intermittent high G531330p17.
resistance, short circuit to
ground, short circuit to
power
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CKP sensor failure

CMP sensor disconnected
CMP sensor gap incorrect/

Camshaft position (CMP) foreign matter on sensor For right hand bank CMP
sensor A circuit (right hand face /damaged rotor
P034092 bank or single sensor) -
CMP sensor sensing circuit: Pinpoint Test
high resistance, short G531330p18.
operation
circuit to power
CMP sensor 1 failure


foreign matter on sensor For right hand bank CMP
CMP sensor A circuit (right face /damaged rotor
P034094 hand bank or single sensor)
- unexpected operation
circuit to power

For right hand bank CMP
CMP sensor A circuit CMP sensor disconnected
P034100 range/performance (right
CMP sensor gap incorrect/ Pinpoint Test
hand bank or single sensor)
foreign matter on sensor G531330p18.
face /damaged rotor
CMP sensor sensing circuit:

circuit to power


foreign matter on sensor For left hand bank CMP
CMP sensor A circuit (left face /damaged rotor
P034592 hand bank) - performance
or incorrect operation
circuit to power


CMP sensor A circuit (left face /damaged rotor
P034594 hand bank) - unexpected
operation
high resistance short G531330p28.
circuit to power


CMP sensor A circuit face /damaged rotor
P034600 range/performance (left
hand bank)
circuit to power

For ignition coil tests,
Ignition coil 1 drive circuit: high
P035100 Engine Ignition - VIN
primary/secondary circuit resistance, short circuit to
ground Range: G45704->G99999
Ignition module/coil power

supply circuit: high
resistance (including
relay, if fitted)
drive circuit: short circuit
to ground, high resistance
Ignition coil 2 Ignition module/coil ground
primary/secondary circuit circuit: high resistance
Range: G45704->G99999
relay, if fitted)
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Range: G45704->G99999
relay, if fitted)
Range: G45704->G99999
relay, if fitted)
Ignition coil 5
primary/secondary circuit Ignition module/coil ground
circuit: high resistance Range: G45704->G99999

relay, if fitted)
Range: G45704->G99999
relay, if fitted)
For secondary air injection
Secondary air injection tests,
P041300 switching valve A circuit Secondary air check valve Engine Emission Control -
open control circuit high VIN Range: G45704-
>G99999

P041400 switching valve A circuit Secondary air check valve Engine Emission Control -
shorted control circuit low VIN Range: G45704-
>G99999
Catalyst failure due to:

overheating damage
caused by misfire and/or Check the oil and fuel
Catalyst system efficiency
lean combustion condition/level. Check the
P042000 below threshold (right hand
catalysts for damage.
bank) Catalyst failure due to:
poisoning caused by
excessive oil consumption
and/or contaminated fuel
overheating damage
Catalyst system efficiency
lean combustion condition/level. Check the
P043000 below threshold (left hand
catalysts for damage.
poisoning caused by
excessive oil consumption
and/or contaminated fuel
Evaporative emission tests,
P044100 Purge valve range
system incorrect purge flow performance Evaporative Emissions -
VIN Range: G45704-
>G99999
For evaporative emissions

Diagnostic monitoring of
tests,
fuel tank leakage (DMTL)
P044700 DMTL COV circuit ground Evaporative Emissions -
system change-over valve short VIN Range: G45704-
(COV) control circuit open
>G99999
DMTL COV power supply

circuit: high resistance, For evaporative emissions
short circuit
tests,
DMTL system COV control
P044800 Evaporative Emissions -
circuit shorted DMTL COV to ECM drive
circuit: high resistance, VIN Range: G45704-
short circuit to power >G99999
DMTL COV failure

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P045600 system leak detected (very DMTL system has detected a Evaporative Emissions -
small leak) leak VIN Range: G45704-
>G99999
Purge valve control circuit: For evaporative emissions

P045800 system purge control valve Evaporative Emissions -
circuit low high resistance VIN Range: G45704-
>G99999
Purge valve failure
P045900 system purge control valve Purge valve control circuit: Evaporative Emissions -
circuit high short circuit to power VIN Range: G45704-
>G99999
Fuel level sensor to rear For fuel level sensor

electronic module (REM) circuit tests,
circuits; intermittent Fuel Tank and Lines - 4.2L
Fuel level sensor A circuit short circuit or high
P046129 range/performance - signal resistance
AJV8/3.0L NA V6 -
invalid
Fuel level sensor failure AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
REM fault (incorrect fuel level >G99999
data)
P04612F range/performance - signal resistance
AJV8/3.0L NA V6 -
erratic
VIN Range: G45704-
data)
short circuit to ground or
Fuel level sensor A circuit NA V8 - AJV8/4.2L SC V8 -
low input AJV8/3.0L NA V6 -
VIN Range: G45704-
data)
For fuel level sensor
Fuel level sensor to rear
Fuel level sensor A circuit short circuit to power NA V8 - AJV8/4.2L SC V8 -
P046300
high input AJV8/3.0L NA V6 -
VIN Range: G45704-
REM fault (incorrect fuel level
>G99999
data)
Electric fan control circuit:

For cooling fan circuit
P048023 Fan 1 control circuit low tests, GO to Pinpoint Test
Electric fan control circuit: G531330p19.
high resistance
P048024 Fan 1 control circuit high Electric fan control circuit: tests, GO to Pinpoint Test
short circuit to battery G531330p19.
Clear any obstruction,

Cooling fan difficult to turn
P048309 Fan rationality check replace the fan as
Fan/Motor damaged necessary.
Check the battery

Fan control module reports condition. Check the
P048316 Fan rationality check
battery voltage less than charging system and fan
9 volts circuits.
Fan control module reports Check the charging
battery voltage greater system and fan circuits.
than 18 volts
Cooling fan jammed
necessary.
Vehicle speed sensor

malfunction vehicle speed
P050082 Vehicle speed: invalid signal Check for ABS DTCs.
invalid signal received over received over CAN
CAN
Vehicle speed sensor

malfunction vehicle speed
P050086 Vehicle speed: invalid signal Check for TCM DTCs.
invalid signal received over received over CAN
CAN
Vehicle speed sensor A

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P050162 range/performance - signal Vehicle speed: range Check for ABS/TCM DTCs.
plausibility failure performance
The brake pressure reading Anti-Lock Control -

P050400 Brake switch A/B correlation
does not agree with the Stability Assist - VIN
brake light switch value Range: G45704->G99999
Brake switch high fault: Brake

lights stuck on Gearshift
interlock inoperative For brake switch and
Speed control inoperative circuit tests, GO to
Pinpoint Test
Brake switch low fault: Brake G531330p25.
lights inoperative
Gearshift stuck in Park
Reduced engine braking
Check the air intake
system.
Air intake restriction Filtering - VIN Range:
Idle air control system RPM G45704->G99999 Check
P050600
the accessory drive belt
(defective/seized
component) and components.
Accessory Drive Belt - 3.0L
NA V6 - AJ27, VIN Range:
G45704->G99999
(12.10.40)

system.
Idle control system RPM Air intake restriction
G45704->G99999 Check
lower than expected cold
P050624 the accessory drive belt
start emission strategy ISC Accessory drive overload
(defective/seized and components.
system lower than expected
component) Accessory Drive Belt - 3.0L
NA V6 - AJ27, VIN Range:
G45704->G99999
(12.10.40)

system,
Intake air leak between MAF Intake Air Distribution and
sensor and throttle Filtering - VIN Range:
Idle air control system RPM G45704->G99999 Inspect
P050700 Intake air leak between
higher than expected throttle and engine the engine breather
system,
Engine crankcase breather Engine Emission Control -
leak VIN Range: G45704-
>G99999

system,
Intake air leak between MAF Intake Air Distribution and
Idle control system RPM sensor and throttle Filtering - VIN Range:
higher than expected cold
G45704->G99999 Inspect
P050723 start emission strategy ISC Intake air leak between
throttle and engine the engine breather
system higher than
system,
expected
>G99999
Check for engine ignition

Cold start ignition timing Cold start emission reduction related codes.
P050B84
performance strategy engine spark Engine Ignition - VIN
timing too retarded Range: G45704->G99999
Cold start ignition timing Cold start emission reduction Check for engine ignition
P050B85 related codes.
performance strategy engine spark
timing too advanced Engine Ignition - VIN
Range: G45704->G99999

Starter request circuit - ECM/ignition switch For starter request circuit
P05120C circuit voltage above circuit: short circuit to tests, GO to Pinpoint Test
threshold power G531330p27.

ECM/ignition switch
Starter request circuit - ground For starter request circuit
P05120E circuit voltage below tests, GO to Pinpoint Test
threshold Starter relay coil to G531330p27.
ECM/ignition switch

Programme keys using the
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P051300 Incorrect immobilizer key Jaguar approved

Security key invalid
diagnostic system.
Air conditioning (A/C) For A/C pressure sensor

P053200 refrigerant pressure sensor A/C refrigerant pressure tests, GO to Pinpoint Test
A circuit low input sensor circuit low input G531330p35.
For A/C pressure sensor

A/C refrigerant pressure
P053300 A/C Refrigerant pressure tests, GO to Pinpoint Test
sensor A circuit high input sensor circuit high input G531330p35.
For battery back-up tests,

P056013 System voltage GO to Pinpoint Test
Battery back-up malfunction
G531330p20.

to Pinpoint Test
G531330p21.
For MAP sensor tests, GO
to Pinpoint Test
P056100 System voltage unstable
System voltage comparison G531330p33.
G531330p5.
P056200 System voltage low

ECM to sensors sensor supply For FRP sensor tests, GO
voltage circuit(s): short to Pinpoint Test
to Pinpoint Test
G531330p33.
G531330p5.

to Pinpoint Test
G531330p21.
ECM to sensors supply
to Pinpoint Test
P056300 System voltage high voltage circuit(s): high
resistance, short circuit to G531330p33.
power For TP sensor tests, GO to
G531330p5.
For speed control,

Speed control input circuit
P057616 Speed Control - VIN
low Speed control low input
Range: G45704->G99999
For speed control,

high Speed control high input
Range: G45704->G99999
Speed control multi- For speed control,

P057800 function input A circuit Speed Control - VIN
Speed switch stuck fault
stuck Range: G45704->G99999

P05791C function input A circuit Speed control switch Speed Control - VIN
range/performance deadband detection Range: G45704->G99999
For speed control,

Speed control multi-
function input B circuit stuck Active speed limiter fault
Range: G45704->G99999
Internal control module Refer to the warranty

P060143 memory check sum error - policy and procedures
CPU communication. - sub
special memory failure manual if an ECM is
suspect.
Refer to the warranty

Internal control module
policy and procedures
P060145 memory check sum error -
CPU communication manual if an ECM is
program memory failure
suspect.

random access memory policy and procedures
P060442
(RAM) error - general Initial RAM test manual if an ECM is
memory failure suspect.

P060443
(RAM) error - special Shut off RAM test manual if an ECM is

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P060444
(RAM) error - data memory RAM check sum manual if an ECM is
failure suspect.

P060445
(RAM) error - program ECM failure manual if an ECM is

Internal Control Module
P060500 Read Only Memory (ROM) EEPROM/flash checksum
error manual if an ECM is
Error
suspect.

Internal Control Module
P060529 Read Only Memory (ROM)
ROM error manual if an ECM is
Error ROM Error
suspect.

read only memory (ROM) policy and procedures
P060542
error - general memory ROM check sum manual if an ECM is
failure suspect.

P060543 read only memory (ROM) policy and procedures
Shut off ROM test
error - special memory manual if an ECM is
failure suspect.

P060544 read only memory (ROM)
Initial ROM test manual if an ECM is
error - data memory failure
suspect.

P060545
error - program memory Continuous ROM test manual if an ECM is
failure suspect.

Continuous ROM test manual if an ECM is
error
suspect.

P060548
error - supervision software Shut off ROM test manual if an ECM is
failure suspect.

ROM error - sub manual if an ECM is
error
suspect.

P060600 PCM processor fault Watchdog error
manual if an ECM is
suspect.

ECM/PCM processor - policy and procedures
P060601
general electrical failure Controller test - sub manual if an ECM is
suspect.

P060604 ECM/PCM processor
System internal failures manual if an ECM is
suspect.

P060605 ECM/PCM processor - Throttle return spring failure
system programming (throttle body failure)
manual if an ECM is
failures suspect.

P060641
general checksum failure Watch dog timer fault - sub manual if an ECM is
suspect.

P060642 Error Capturing instructions (
general memory failure ECI) manual if an ECM is
suspect.

P060643
special memory failure Duplication memory fault manual if an ECM is
suspect.

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ECM/PCM processor - data policy and procedures

P060644 Duplication memory fault -
memory failure sub manual if an ECM is
suspect.

P060645 Detection of write to internal
program memory failure ROM manual if an ECM is
suspect.
ECM/PCM processor - Configure the module

P060646 calibration/parameter Detection of write to internal using the Jaguar approved
memory failure ROM - sub diagnostic system.
Configure the module

P060647 ECM/PCM processor fault using the Jaguar approved
Watch dog timer fault
diagnostic system.

ECM/PCM processor -
P060648 using the Jaguar approved
supervision software failure Scheduling sequence check
diagnostic system.

P060649
internal electronic failure Controller test manual if an ECM is
suspect.
Control module policy and procedures
P060700
performance Sub - CPU watch dog manual if an ECM is
suspect.
Clear the DTC and retest.

Internal control module If the DTC resets, refer to
P060A64 monitoring processor the warranty policy and
monitoring processor
performance performance procedure manual if an
ECM is suspect.

ECM is suspect.

P060D00 accelerator pedal position
APP sensor communication manual if an ECM is
performance
suspect.

throttle position Throttle motor amplifier policy and procedures
P060E62
performance - signal failure for valve sensor manual if an ECM is
compare failure malfunction suspect.

throttle position policy and procedures
P060E64
performance - signal TPS Communication manual if an ECM is
plausibility failure suspect.

Control module vehicle
options error VID block fault
diagnostic system.

For starter relay tests, GO
P06160E Starter relay circuit low to Pinpoint Test

Starter relay drive circuit: For starter relay tests, GO
P06170C Starter relay circuit high short circuit to power
to Pinpoint Test
Starter relay failure G531330p27.

Internal control module policy and procedures
P061A00
torque performance Pedal follower error manual if an ECM is
suspect.

Absolute engine torque policy and procedures
P061A29 torque performance - signal
calculation failure - sub- manual if an ECM is
invalid processor suspect.

P061A64 torque performance - signal Absolute engine torque
calculation failure manual if an ECM is
plausibility failure
suspect.

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P061B29 torque calculation Absolute and dynamic engine
performance - signal invalid torque calculation failure manual if an ECM is
suspect.

torque calculation policy and procedures
P061B64 Absolute and dynamic engine
performance - signal torque calculation failure manual if an ECM is
For fuel pump tests,

Fuel pump A control
P062700 Invalid fuel pump duty AJV8/3.0L NA V6 -
circuit/open requested by the ECM AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
>G99999

VIN Not programmed or
incompatible - ECM/PCM CCF to CAN VIN mismatch
diagnostic system.
Intake manifold tuning IMT circuit(s): short circuit to For IMT tests, GO to
P066100 (IMT) valve control circuit ground Pinpoint Test
low, right hand bank G531330p38.
IMT circuit(s): high resistance
P066200 IMT valve control circuit IMT circuit(s): short circuit to For IMT tests, GO to
power Pinpoint Test
high, right hand bank G531330p38.
IMT circuit(s): short circuit to For IMT tests, GO to

IMT valve control circuit
P066400 ground Pinpoint Test
low, left hand bank
G531330p37.
IMT circuit(s): high resistance
For IMT tests, GO to
IMT valve control circuit
P066500 IMT circuit(s): short circuit to Pinpoint Test
high, left hand bank power G531330p37.
For EMS relay tests, GO to

ECM/PCM power relay
P068773 EMS control relay Pinpoint Test
control circuit high malfunction G531330p32.
Output speed sensor circuit

P072186 TCM output shaft speed
range/performance sensor error received
For Park/Neutral switch

Park/Neutral switch input
P08510E Park/Neutral switch input tests,
circuit low circuit low

P08520C Park/Neutral switch input tests,
circuit high circuit high
For generator tests,

P114600 Generator load low
Generator - C line circuit low
Generator load high input For generator tests,

P124400
(see P062600) Generator - C line circuit high
Configure the system

Immobilizer to PCM signal
P125900 Incorrect ID received from using the Jaguar approved
error instrument pack diagnostic system.
ECM to ignition coil primary For ignition coil circuit

circuit fault (cylinder tests,
misfire detected DTC also Engine Ignition - VIN
flagged) Range: G45704->G99999
P131500 Persistent misfire Check the fuel pressure,
Fuel delivery pressure low
Fuel injector circuit fault(s) NA V8 - AJV8/4.2L SC V8 -
(injector DTCs also AJV8/3.0L NA V6 -
flagged) AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
Ignition coil failure >G99999 For injector
circuit tests,
Spark plug Fuel Charging and
failure/fouled/incorrect Controls - VIN Range:
gap
G45704->G99999 For
Cylinder compression low ignition coil circuit and
spark plug tests,
Range: G45704->G99999
Check the cylinder
compressions.
AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
Check for associated DTCs

Injector driver misfire -
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P131600 Injector driver module codes and refer to the DTC

emissions damage detected index.

ECM: high resistance,
short circuit to ground, For ignition system tests,
P136700 Ignition amplifier group A short circuit to power Engine Ignition - VIN
Range: G45704->G99999
Ignition module/coils ground
circuit fault, right hand
bank
P136800 Ignition amplifier group B short circuit to power Engine Ignition - VIN
Range: G45704->G99999
circuit fault left hand
bank
policy and procedure
P160300 EEPROM error
ECM fault manual if an ECM is
suspect.

ECM electronic throttle
Dynamic torque monitoring policy and procedure
P162600 monitoring / self test -
error torque monitoring manual if an ECM is
problem suspect.
P162900 Internal voltage regulator
Generator - F line failure
Smart alternator faults For generator tests,

P163200
sensor/circuit Generator - L line failure
Check for HO2 sensor

Fuel trim too lean, right
P209600 codes. Check for air intake
hand bank HO2S fuel adaption - lean
faults

Fuel trim too rich, right
hand bank HO2S fuel adaption - rich
faults

Fuel trim too lean, left hand
bank HO2S fuel adaption - lean
faults

Fuel trim too rich, left hand
bank HO2S fuel adaption - rich
faults
Check for a message in

the instrument cluster.
Throttle range/performance Replace the throttle body.
P210129 Jammed throttle blade,
- sub-processor gearing or motor Throttle Body - VIN
Range: G45704->G99999
(19.70.04)

Throttle actuator control
P210162 motor circuit Jammed throttle blade,
gearing or motor Throttle Body - VIN
range/performance
Range: G45704->G99999
(19.70.04)

P210164 Throttle range/performance Jammed throttle blade,
gearing or motor Throttle Body - VIN
Range: G45704->G99999
(19.70.04)
P210177 Throttle actuator motor Throttle blade stuck open Check for throttle related
control circuit DTCs. Check the intake
range/performance Intake air system leak system for leaks.
(commanded position not Intake Air Distribution and
reachable) Filtering - VIN Range:
G45704->G99999

motor circuit tests,
Fuel Charging and
Control circuit: short circuit to
Throttle actuator motor Controls - VIN Range:
P210329 power
control circuit high G45704->G99999 Refer
ECM fault to the warranty policy and
procedures manual if an
ECM is suspect.

Fuel Charging and
Throttle actuator motor Control circuit: short circuit to
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P210364 control circuit high - signal power
G45704->G99999 Refer
ECM is suspect.

the reason for the fuel
P210500 system - forced engine Throttle MIL request due to
fuel cut cut. Follow the action
shutdown
indicated for those DTCs.

P210629 system - forced limited
Signal invalid Throttle Body - VIN
power
Range: G45704->G99999
(19.70.04)

P210664 system - forced limited
Signal plausibility failure Throttle Body - VIN
power
Range: G45704->G99999
(19.70.04)

P211800 Throttle actuator motor Control circuit: short circuit to
control current power, short circuit to
Fuel Charging and
range/performance ground, high resistance Controls - VIN Range:
G45704->G99999 Refer
ECM is suspect.

P211900 throttle body
Throttle spring faulty Throttle Body - VIN
range/performance
Range: G45704->G99999
(19.70.04)
For APP sensor tests. GO

Accelerator pedal position to Pinpoint Test
P212200 (APP) sensor D circuit low APP sensor: circuit 2 low G531330p22.
input input and GO to Pinpoint Test
G531330p23.
For APP sensor tests. GO

P212300 (APP) sensor D circuit high APP sensor: circuit 2 high G531330p22.
G531330p23.
Check connections, etc,

clear the DTCs and retest.
P213528 (APP) sensor A/B voltage APP sensor: incorrect start
value (not zero) If the code resets, replace
correlation
the APP sensor.

Accelerator pedal position APP sensor: excessive
clear the DTCs and retest.
P213529 (APP) sensor voltage difference between raw
correlation values of circuit 1 and 2 - If the code resets, replace
sub-processor the APP sensor.

APP sensor: incorrect start clear the DTCs and retest.
P213562 (APP) sensor 1 and 2 voltage
value (not zero) sub- If the code resets, replace
correlation processor the APP sensor.

APP sensor: excessive clear the DTCs and retest.
P213564 (APP) sensor voltage
difference between raw If the code resets, replace
correlation values of circuit 1 and 2 the APP sensor.
Barometric pressure circuit policy and procedures
P222800 BARO sensor failure (internal
low input ECM fault) manual if an ECM is
suspect.

high input ECM fault) manual if an ECM is
suspect.
Evaporative emission For evaporative emissions

system diagnostic tests,
P240100 monitoring of tank leakage DMTL pump circuit(s): short Evaporative Emissions -
(DMTL) pump control circuit circuit to ground VIN Range: G45704-
low >G99999

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P240200 system DMTL pump control DMTL pump circuit(s): short Evaporative Emissions -
circuit high circuit to power VIN Range: G45704-
>G99999
DMTL reference leak For evaporative emissions

Evaporative emission
tests,
system DMTL pump sense DMTL pump circuit: short
circuit range/performance - circuit, high resistance
VIN Range: G45704-
signal invalid
DMTL pipework >G99999
blocked/leaking
DMTL reference leak For evaporative emissions
Evaporative emission
tests,
system DMTL pump sense DMTL pump circuit: short
P24042F Evaporative Emissions -
circuit range/performance - circuit, high resistance
VIN Range: G45704-
signal erratic
blocked/leaking
P240500 system DMTL pump sense DMTL pump circuit: short Evaporative Emissions -
circuit low circuit, high resistance VIN Range: G45704-
>G99999
Evaporative emission For evaporative emissions

P240600 system DMTL pump sense DMTL pump circuit: short tests,
circuit high circuit, high resistance Evaporative Emissions -
VIN Range: G45704-
>G99999

P240B00 system DMTL pump heater DMTL heater control circuit Evaporative Emissions -
circuit low low VIN Range: G45704-
>G99999

P240C00 system DMTL pump heater DMTL heater control circuit Evaporative Emissions -
circuit high high VIN Range: G45704-
>G99999
Secondary air injection Secondary air injection For secondary air injection
pump/valve/pipework
system air flow/pressure tests,
leaks
P243100 sensor circuit Engine Emission Control -
range/performance, right Secondary air injection pump VIN Range: G45704-
hand bank >G99999
tests,
system air flow/pressure Secondary air injection
P243200 Engine Emission Control -
sensor circuit low input, system MAP sensor
circuit low VIN Range: G45704-
right hand bank
>G99999

tests,
sensor circuit high input, system MAP sensor
circuit high VIN Range: G45704-
right hand bank
>G99999

P244400 system pump stuck ON, Engine Emission Control -
system pump control
right hand bank circuit low VIN Range: G45704-
>G99999

Secondary air injection pump circuit tests,
P244500 system pump stuck OFF, Secondary air pump control Engine Emission Control -
right hand bank circuit high VIN Range: G45704-
>G99999
Evaporative emission (EVAP)
tests,
system change-over valve
P245000 DMTL pump circuit: short Evaporative Emissions -
(COV) performance/stuck circuit, high resistance VIN Range: G45704-
open
>G99999

P245100 control system COV stuck DMTL pump circuit: short Evaporative Emissions -
closed circuit, high resistance VIN Range: G45704-
>G99999
Generator -
For charging system tests,
P250300 Charging system voltage low range/performance -
output voltage low when
high requested
Generator -
Charging system voltage For charging system tests,
P250400 range/performance -
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high output voltage high when

low requested
ECT sensor fault
Ambient temperature sensor
a fault with any of the
ECM/PCM Internal engine fault
P261064 components listed. Follow
off timer performance
Body processor module fault the action listed for those
(time) DTCs.
CAN error
ECT sensor fault
ECM/PCM Internal engine fault
P261087 components listed. Follow
off timer performance
Body processor module fault the action listed for those
(time) DTCs.
CAN error
For REM to fuel pump
ECM to rear electronic module circuit tests,
Fuel pump A low module (REM) drive Fuel Tank and Lines - 4.2L
circuit; short circuit, high
flow/performance (fuel NA V8 - AJV8/4.2L SC V8 -
P263500 resistance
pump not activated when AJV8/3.0L NA V6 -
requested by ECM) Fuel pump module failure AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
REM failure >G99999
Control module For network tests,
U007300
communication bus off CAN Link circuit malfunction
Lost communication with

For network tests,
U010100 transmission control CAN Link ECM/TCM network
module malfunction
Lost communication with For network tests,

U010300 CAN Link ECM/gear shift
gear shift control module network malfunction

U010400 CAN Link ECM/ACC module
speed control module network malfunction

For network tests,
U012100 anti-lock brake system (ABS) CAN Link ECM/ABSCM
control module network malfunction
Lost communication with CAN Link ECM/Electric park For network tests,
U012800
park brake control module brake signal missing
network malfunction
Lost communication with CAN Link ECM/suspension For network tests,
U013200
suspension control module control module network
malfunction
U015100 Lost comms - CAN or
restraints control module hardwired

For network tests,
U015500 instrument panel cluster CAN Link ECM/INSTCM
(IPC) control module network malfunction

For network tests,
U016400 heating ventilation and air CAN Link ECM/HEVAC
conditioning control module network malfunction
Lost communication with Programme the keys using

U016700 vehicle immobilizer control Security challenge response the Jaguar approved
module timeout diagnostic system.

For network tests,
U023500 speed control front distance
Adaptive speed control fault
range sensor
For transmission tests.

U040264 Invalid data received From
Actual gear position status
transmission control
module
Invalid data received from

For transmission tests.
U040267 transmission control
Gear shift position status
module
Invalid data received from For transmission tests.

U040281
TCM Output shaft speed

For network tests,
U041500 anti-lock brake system
BPS CAN node
control module

For network tests,
MSR monitoring - plausibility
control module

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For network tests,

MSR monitoring - rationality
control module

For network tests,
U042386 instrument panel control
Battery voltage level
module - signal invalid

For network tests,
U042481 instrument pack control
External ambient temp
module
Invalid data received from Configure the module

U042600 vehicle immobilizer control using the Jaguar approved
Security code mismatch
module diagnostic system.
Warning indicator
For network tests,
U206400 requested by another
Crash event has occurred
control module
Pinpoint Tests
PINPOINT TEST G531330p1 : MASS AIR

FLOW (MAF) SENSOR CIRCUIT
G531330t4 : CHECK THE MAF SENSOR SUPPLY CIRCUIT VOLTAGE
1. Disconnect the MAF sensor electrical connector, PI14. 2. Key on, engine off. 3. Measure the
voltage between:
MAF sensor connector PI14, harness side Battery
-> Yes
-> No
REPAIR the circuit between the MAF sensor electrical connector and the battery. This circuit includes
the EMS control relay and fuse 14 of the front power distribution box. For additional information,
refer to the wiring diagrams. CLEAR the DTC and test the system for normal operation.
G531330t3 : CHECK THE MAF SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531330t82 : CHECK THE MAF SENSOR GROUND CIRCUIT FOR SHORT

CIRCUIT TO POWER
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-> Yes
-> No
G531330t1 : CHECK THE MAF SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
MAF sensor connector PI14, harness side ECM connector PI300, harness side
Pin 03 Pin 70
-> Yes
-> No
G531330t81 : CHECK THE MAF SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 02 Pin 18
-> Yes
-> No
INSTALL a new MAF sensor.
Mass Air Flow (MAF) Sensor (18.30.15) CLEAR the DTC and test the system for normal operation.

AIR TEMPERATURE (IAT) SENSOR
CIRCUIT
G531330t7 : CHECK THE IAT SENSOR SENSING CIRCUIT FOR SHORT CIRCUIT
TO GROUND
1. Disconnect the MAF sensor electrical connector, PI14. 2. Measure the resistance between:

-> Yes
-> No
TO POWER

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-> Yes
-> No
G531330t5 : CHECK THE IAT SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
Pin 04 Pin 66
-> Yes
-> No
G531330t99 : CHECK THE IAT SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 05 Pin 12
-> Yes
-> No
Mass Air Flow (MAF) Sensor (18.30.15) CLEAR the DTC and test the system for normal operation.
PINPOINT TEST G531330p3 : ENGINE

COOLANT TEMPERATURE (ECT)
SENSOR CIRCUIT
G531330t10 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Disconnect the ECT sensor electrical connector, PI25. 2. Measure the resistance between:
ECT sensor connector PI25, harness side Battery
-> Yes
-> No
G531330t9 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT CIRCUIT
TO POWER
-> Yes
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-> No
G531330t8 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
ECT sensor connector PI25, harness side ECM connector PI300, harness side
Pin 02 Pin 68
-> Yes
-> No
G531330t121 : CHECK THE ECT SENSOR GROUND CIRCUIT FOR HIGH
RESISTANCE
ECT sensor connector PI25, harness side ECM connector PI300, harness side
Pin 01 Pin 12
-> Yes
-> No
INSTALL a new ECT sensor.
Engine Coolant Temperature (ECT) Sensor - VIN Range: G00442->G45703 (18.30.10) CLEAR the DTC.

THROTTLE POSITION (TP) SENSOR 1
CIRCUIT
G531330t95 : CHECK THE TP SENSOR SUPPLY CIRCUIT VOLTAGE
1. Disconnect the TP sensor electrical connector, PI26. 2. Key on, engine off. 3. Measure the voltage
between:
TP sensor connector PI26, harness side Battery
-> Yes
REPAIR the 5 volt supply circuit between the TP sensor and the ECM. For additional information,
-> No
G531330t96 : CHECK THE TP SENSOR SUPPLY CIRCUIT FOR SHORT CIRCUIT
TO POWER
-> Yes
-> No
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G531330t13 : CHECK THE TP SENSOR SENSING CIRCUIT TP1 FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No
G531330t11 : CHECK THE TP SENSOR SENSING CIRCUIT TP1 FOR HIGH

RESISTANCE
TP sensor connector PI26, harness side ECM connector PI300, harness side
Pin 06 Pin 65
-> Yes
-> No
G531330t97 : CHECK THE TP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 03 Pin 11

-> Yes
-> No
INSTALL a new TP sensor.
normal operation.

THROTTLE POSITION (TP) SENSOR 2
CIRCUIT
G531330t98 : CHECK THE TP SENSOR SUPPLY CIRCUIT VOLTAGE
1. Disconnect the TP sensor electrical connector, PI26. 2. Key on, engine off. 3. Measure the voltage
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between:
-> Yes
REPAIR the 5 volt supply circuit between the TP sensor and the ECM. For additional information,
-> No
G531330t177 : CHECK THE TP SENSOR SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

RESISTANCE
Pin 04 Pin 67
-> Yes
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-> No
G531330t180 : CHECK THE TP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 03 Pin 11
-> Yes
-> No
normal operation.
PINPOINT TEST G531330p6 : RIGHT-
HAND H02S VARIABLE AND
CONSTANT CIRCUITS
G531330t19 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT CIRCUIT TO
GROUND
1. Disconnect the H02S electrical connector, PI10. 2. Measure the resistance between:
H02S connector PI10, harness side Battery
-> Yes
-> No

POWER
-> Yes
-> No
G531330t22 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT CIRCUIT
TO GROUND
-> Yes
-> No
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TO POWER
-> Yes
-> No
G531330t17 : CHECK THE H02S VARIABLE CIRCUIT FOR HIGH RESISTANCE

H02S connector PI10, harness side ECM connector PI300, harness side
Pin 04 Pin 28
-> Yes
-> No
G531330t20 : CHECK THE H02S CONSTANT CIRCUIT FOR HIGH RESISTANCE

Pin 03 Pin 29
-> Yes
-> No
INSTALL a new H02S.
Heated Oxygen Sensor (HO2S) CLEAR the DTC and test the system for normal operation.

HAND H02S HEATER SUPPLY AND
CONTROL CIRCUITS
G531330t23 : CHECK H02S HEATER POWER SUPPLY CIRCUIT
1. Disconnect the H02S electrical connector, PI10. 2. Key on, engine off. 3. Make sure the O2S heater
relay is engaged. 4. Measure the voltage between:

-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the O2S heater relay and
fuse 33 of the front power distribution box. For additional information, refer to the wiring diagrams.
CLEAR the DTC and test the system for normal operation.
G531330t26 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR

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-> Yes
-> No


-> Yes
-> No

HIGH RESISTANCE
Pin 02 Pin 76
-> Yes
-> No
INSTALL a new H02S.
Heated Oxygen Sensor (HO2S) CLEAR the DTC and test the system for normal operation.

HAND CATALYST MONITOR SENSOR
SENSING AND GROUND CIRCUITS
G531330t29 : CHECK THE CATALYST MONITOR SENSOR SENSING CIRCUIT
1. Disconnect the catalyst monitor electrical connector, PI11. 2. Measure the resistance between:
Catalyst monitor connector PI11, harness side Battery

-> Yes
-> No


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-> Yes
-> No

FOR HIGH RESISTANCE
Catalyst monitor connector PI11, harness side ECM connector PI300, harness side
Pin 04 Pin 40
-> Yes
-> No
G531330t30 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT

FOR HIGH RESISTANCE
Pin 03 Pin 22
-> Yes
-> No
INSTALL a new catalyst monitor sensor.
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC and test the system for normal operation.

SUPPLY AND HEATER CONTROL
CIRCUITS
G531330t31 : CHECK THE CATALYST MONITOR HEATER POWER SUPPLY
CIRCUIT
1. Disconnect the catalyst monitor sensor electrical connector, PI11. 2. Key on, engine off. 3. Make
sure the O2S heater relay is energized. 4. Measure the voltage between:
-> Yes
-> No
REPAIR the power supply circuit to the catalyst monitor heater. This circuit includes the O2S heater
relay and fuse 33 of the front power distribution box. For additional information, refer to the wiring
diagrams. CLEAR the DTC and test the system for normal operation.
G531330t170 : CHECK THE CATALYST MONITOR HEATER CONTROL


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-> Yes
-> No

-> Yes
-> No
G531330t32 : CHECK THE CATALYST MONITOR HEATER CONTROL CIRCUIT
FOR HIGH RESISTANCE
Pin 02 Pin 88
-> Yes
-> No
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC and test the system for normal operation. If the
DTC is repeated, refer to the warranty policy and procedures manual if an ECM is suspect.
PINPOINT TEST G531330p10 : LEFT-

HAND H02S VARIABLE AND
CONSTANT CIRCUITS
GROUND
1. Disconnect the H02S electrical connector, PI12. 2. Measure the resistance between:
-> Yes
-> No
G531330t34 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO CIRCUIT

TO POWER
-> Yes
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-> No

TO GROUND
-> Yes
-> No
G531330t37 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO

CIRCUIT TO POWER
-> Yes
-> No

Pin 04 Pin 26
-> Yes
-> No

Pin 03 Pin 27

-> Yes
-> No
INSTALL a new H02S.
Heated Oxygen Sensor (HO2S) CLEAR the DTC and test the system for normal operation. If the DTC is

HAND H02S HEATER SUPPLY AND
CONTROL CIRCUITS
1. Disconnect the H02S electrical connector, PI12. 2. Key on, engine off. 3. Measure the voltage
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between:
-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the O2S heater relay and
fuse 34 of the front power distribution box. For additional information, refer to the wiring diagrams.
CLEAR the DTC and test the system for normal operation.


-> Yes
-> No

-> Yes
-> No

HIGH RESISTANCE
Pin 02 Pin 77
-> Yes
-> No
INSTALL a new H02S.
Heated Oxygen Sensor (HO2S) CLEAR the DTC and test the system for normal operation. If the DTC is

SENSING AND GROUND CIRCUITS
1. Disconnect the catalyst monitor electrical connector, PI13. 2. Measure the resistance between:

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-> Yes
-> No

-> Yes
-> No

FOR HIGH RESISTANCE
Pin 04 Pin 41
-> Yes
-> No

FOR HIGH RESISTANCE
Pin 03 Pin 45
-> Yes
-> No
SUPPLY AND HEATER CONTROL
CIRCUITS
G531330t43 : CHECK THE CATALYST MONITOR HEATER POWER SUPPLY
CIRCUIT
sure the O2S heater relay is engaged. 4. Measure the voltage between:

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-> Yes
-> No
REPAIR the power supply circuit to the catalyst monitor heater. This circuit includes the O2S heater

-> Yes
-> No

-> Yes
-> No
G531330t44 : CHECK THE CATALYST MONITOR SENSOR HEATER CONTROL

Pin 02 Pin 89
-> Yes
-> No
OIL TEMPERATURE (EOT) SENSOR
CIRCUIT
G531330t47 : CHECK THE EOT SENSOR SENSING CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Disconnect the EOT sensor electrical connector, PI24. 2. Measure the resistance between:
EOT sensor connector PI24, harness side Battery

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-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531330t45 : CHECK THE EOT SENSOR SENSING CIRCUIT FOR HIGH
RESISTANCE
EOT sensor connector PI24, harness side ECM connector PI300, harness side
Pin 02 Pin 23
-> Yes
-> No
G531330t48 : CHECK THE EOT SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 01 Pin 10
-> Yes
-> No
INSTALL a new EOT sensor.
Oil Temperature Sensor (18.31.01) CLEAR the DTC and test the system for normal operation. If the
DTC is repeated, refer to the warranty policy and procedures manual if an ECM is suspect.

HAND KNOCK SENSOR (KS) CIRCUIT
G531330t55 : CHECK KS SENSING CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Disconnect the KS electrical connector, PI60. 2. Measure the resistance between:
KS connector PI60, harness side Battery
-> Yes
-> No
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G531330t54 : CHECK KS SENSING CIRCUIT FOR SHORT TO CIRCUIT TO

POWER
-> Yes
-> No
G531330t53 : CHECK KS SENSING CIRCUIT FOR HIGH RESISTANCE

KS connector PI60, harness side ECM connector PI300, harness side
Pin 01 Pin 42
-> Yes
-> No
G531330t56 : CHECK KS GROUND CIRCUIT FOR HIGH RESISTANCE

Pin 02 Pin 19
-> Yes
-> No
INSTALL a new KS.
Knock Sensor (KS) RH (18.30.93) CLEAR the DTC and test the system for normal operation.

HAND KNOCK SENSOR (KS) CIRCUIT
1. Disconnect the KS electrical connector, PI61. 2. Measure the resistance between:

-> Yes
-> No
G531330t58 : CHECK KS SENSING CIRCUIT FOR SHORT CIRCUIT TO POWER


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-> Yes
-> No

Pin 01 Pin 43
-> Yes
-> No
Pin 02 Pin 20
-> Yes
-> No
INSTALL a new KS.
Knock Sensor (KS) LH (18.30.92) CLEAR the DTC and test the system for normal operation.

CRANKSHAFT POSITION (CKP)
SENSOR CIRCUIT
G531330t61 : CHECK THE CKP SENSOR FOR CORRECT INSTALLATION
1. Check the CKP sensor for correct installation.
Is the CKP sensor correctly installed?
-> Yes
-> No
INSTALL the CKP sensor correctly.
Crankshaft Position (CKP) Sensor (18.30.12) Reconnect the sensor. CLEAR the DTCs and test the
G531330t62 : CHECK THE CKP SENSOR FOR DEBRIS

1. Remove the CKP sensor and inspect for debris.
Is the CKP sensor free of debris?
-> Yes
-> No
CLEAN the sensor and wheel. INSTALL the sensor.
Crankshaft Position (CKP) Sensor (18.30.12) Reconnect the sensor. CLEAR the DTCs and test the
G531330t65 : CHECK THE CKP SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO GROUND
1. Disconnect the CKP sensor electrical connector, PI21. 2. Measure the resistance between:
CKP sensor connector PI21, harness side Battery

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-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531330t63 : CHECK THE CKP SENSOR SENSING CIRCUIT FOR HIGH
RESISTANCE
CKP sensor connector PI21, harness side ECM connector PI300, harness side
Pin 02 Pin 30
-> Yes
-> No
G531330t66 : CHECK THE CKP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 01 Pin 06
-> Yes
-> No
INSTALL a new CKP sensor.
Crankshaft Position (CKP) Sensor (18.30.12) CLEAR the DTC and test the system for normal
operation.
HAND CAMSHAFT POSITION (CMP)
SENSOR CIRCUIT
G531330t67 : CHECK THE CMP SENSOR FOR CORRECT INSTALLATION
1. Check the CMP sensor for correct installation.
Is the CMP sensor correctly installed?
-> Yes
-> No
INSTALL the CMP sensor correctly.
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Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTCs and test the system for normal
operation.
G531330t68 : CHECK THE CMP SENSOR FOR FOREIGN DEBRIS

1. Remove the CMP sensor and inspect for foreign debris.
Is the CMP sensor free of foreign debris?
-> Yes
-> No
Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTCs and test the system for normal
operation.
G531330t71 : CHECK THE CMP SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO GROUND
1. Disconnect the CMP sensor electrical connector, PI23. 2. Measure the resistance between:
CMP sensor connector PI23, harness side Battery

-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531330t69 : CHECK THE CMP SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
CMP sensor connector PI23, harness side ECM connector PI300, harness side
Pin 02 Pin 34
-> Yes
-> No
G531330t72 : CHECK THE CMP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 01 Pin 07
-> Yes
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-> No
INSTALL a new CMP sensor.
Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTC and test the system for normal
operation.

SENSOR CIRCUIT
-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTCs and test the system for normal
operation.

-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTCs and test the system for normal
operation.

CIRCUIT TO GROUND
1. Disconnect the CMP sensor electrical connector, PI22. 2. Measure the resistance between:
-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

RESISTANCE
Pin 01 Pin 33
-> Yes
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-> No

RESISTANCE
Pin 02 Pin 08
-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTC and test the system for normal
operation.
RADIATOR COOLING FAN MODULE
DRIVE CIRCUIT
G531330t73 : CHECK THE RADIATOR FAN MODULE PERMANENT SUPPLY
1. Disconnect the fan module electrical connector, EC20. 2. Measure the voltage between:
Fan module connector EC20, harness side Battery
-> Yes
REPAIR the circuit between the cooling fan module and battery. This circuit includes fuse 35 of the
front power distribution box. For additional information, refer to the wiring diagrams. CLEAR the DTC
-> No
G531330t75 : CHECK THE RADIATOR FAN MODULE EMS SWITCHED SUPPLY

1. Disconnect the fan module electrical connector, GC01. 2. Key on, engine off. 3. Make sure the EMS
relay is engaged. 4. Measure the voltage between:
Fan module connector GC01, harness side Battery
-> Yes
front power distribution box and the EMS control relay. For additional information, refer to the
wiring diagrams. CLEAR the DTC and test the system for normal operation.
-> No
G531330t78 : CHECK THE RADIATOR FAN MODULE CONTROL CIRCUIT FOR
-> Yes
-> No
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-> Yes
-> No

HIGH RESISTANCE
Fan module connector GC01, harness side ECM connector EC300, harness side
Pin 01 Pin 49
-> Yes
-> No
G531330t74 : CHECK THE RADIATOR FAN MODULE GROUND FOR HIGH

RESISTANCE
Fan module connector EC20, harness side Battery
-> Yes
-> No
INSTALL a new radiator cooling fan module. CLEAR the DTC and test the system for normal operation.

BATTERY POWER SUPPLY VOLTAGE
G531330t79 : CHECK THE BATTERY POWER SUPPLY TO THE ECM
1. Disconnect the ECM electrical connector, EC300. 2. Measure the voltage between:
ECM connector EC300, harness side Battery

-> Yes
Recheck the DTCs.
-> No
REPAIR the battery power supply circuit. This circuit includes fuse 17 of the front power distribution
box. For additional information, refer to the wiring diagrams. CLEAR the DTC and test the system for
normal operation.

ACCELERATOR PEDAL POSITION
(APP) SENSOR CIRCUIT 1
G531330t86 : CHECK THE APP SENSOR SUPPLY VOLTAGE AT THE SENSOR
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1. Disconnect the APP sensor electrical connector, CR14. 2. Key on, engine off. 3. Measure the
voltage between:
APP sensor connector CR14, harness side Battery
-> Yes
REPAIR the 5 volt supply circuit between the APP sensor and the ECM. For additional information,
-> No
G531330t163 : CHECK THE APP SENSOR SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER

-> Yes
-> No
G531330t85 : CHECK THE APP SENSOR SENSING CIRCUIT 1 FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531330t83 : CHECK THE APP SENSOR SENSING CIRCUIT 1 FOR HIGH

RESISTANCE
APP sensor connector CR14, harness side ECM connector EC300, harness side
Pin 01 Pin 24
-> Yes
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-> No
G531330t164 : CHECK THE APP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 06 Pin 08
-> Yes
-> No
INSTALL a new APP sensor.
Accelerator Pedal (19.20.01) CLEAR the DTC and test the system for normal operation.
(APP) SENSOR CIRCUIT 2
1. Disconnect the APP sensor electrical connector, CR14. 2. Key on, engine off. 3. Measure the
voltage between:
-> Yes
REPAIR the 5 volt supply circuit between the APP sensor and the ECM. For additional information,
-> No
G531330t165 : CHECK THE APP SENSOR SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
CIRCUIT TO GROUND
-> Yes
-> No
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CIRCUIT TO POWER
-> Yes
-> No

RESISTANCE
Pin 04 Pin 38
-> Yes
-> No
G531330t166 : CHECK THE APP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 03 Pin 07
-> Yes
-> No
Accelerator Pedal (19.20.01) CLEAR the DTC and test the system for normal operation.

THROTTLE MOTOR CONTROL
CIRCUIT
G531330t93 : CHECK THE THROTTLE MOTOR TO ECM NEGATIVE CIRCUIT
FOR HIGH RESISTANCE
1. Disconnect the throttle motor electrical connector, PI26. 2. Disconnect the ECM electrical
connector, PI300. 3. Measure the resistance between:
Throttle motor connector PI26, harness side ECM connector PI300, harness side
Pin 01 Pin 74
-> Yes
-> No
G531330t94 : CHECK THE THROTTLE MOTOR TO ECM POSITIVE CIRCUIT

FOR HIGH RESISTANCE
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Throttle motor connector PI26, harness side ECM connector PI300, harness side
Pin 02 Pin 75
-> Yes
-> No
INSTALL a new throttle body.
normal operation.

RAIL PRESSURE (FRP) SENSOR
CIRCUIT
G531330t100 : CHECK THE FRP SENSOR SUPPLY CIRCUIT VOLTAGE
1. Disconnect the FRP sensor electrical connector, IL12. 2. Key on, engine off. 3. Measure the voltage
between:
FRP sensor connector IL12, harness side Battery
-> Yes
REPAIR the 5 volt supply circuit between the FRP sensor and the ECM. For additional information,
-> No
G531330t101 : CHECK THE FRP SENSOR SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G531330t102 : CHECK THE FRP SENSOR SIGNAL CIRCUIT FOR SHORT

CIRCUIT TO GROUND

-> Yes
-> No

CIRCUIT TO POWER
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-> Yes
-> No

RESISTANCE
1. Disconnect the ECM sensor electrical connector, PI300. 2. Measure the resistance between:
FRP sensor connector IL12, harness side ECM connector PI300, harness side
Pin 03 Pin 71

-> Yes
-> No
G531330t110 : CHECK THE FRP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
FRP sensor connector IL12, harness side ECM connector PI300, harness side
Pin 02 Pin 10
-> Yes
-> No
INSTALL a new FRP sensor.
Fuel Rail Pressure (FRP) Sensor (18.30.98) CLEAR the DTC and test the system for normal operation.

STARTER RELAY SIGNAL
G531330t87 : CHECK THE STARTER RELAY TO ECM CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Key off. 2. Remove the starter relay. 3. Measure the resistance between:
Starter relay base Battery

-> Yes
-> No

CIRCUIT TO POWER

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-> Yes
-> No
G531330t133 : CHECK THE STARTER RELAY TO ECM CIRCUIT FOR HIGH

RESISTANCE
Starter relay base ECM connector EC300, harness side
Pin 02 Pin 51
-> Yes
-> No
INSTALL a new starter relay. Clear the DTC and test the system for normal operation. If the DTC
resets, refer to the warranty policy and procedures manual if an ECM is suspect.

HAND VARIABLE CAMSHAFT TIMING
(VCT) OIL CONTROL SOLENOID
CIRCUIT
G531330t140 : CHECK ECM TO VCT SOLENOID SUPPLY CIRCUIT VOLTAGE
1. Disconnect the VCT solenoid electrical connector, PI16. 2. Key on, engine off. 3. Measure the
voltage between:
VCT solenoid connector PI16, harness side Battery
-> Yes
-> No
REPAIR the circuit between the VCT solenoid electrical connector and battery. This circuit includes
fuse 12 of the front power distribution box and the EMS control relay. For additional information,
G531330t143 : CHECK VCT SOLENOID CONTROL CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Measure the resistance between:
VCT solenoid connector PI16, harness side ECM connector PI300, harness side
Pin 01 Pin 86
-> Yes
-> No
INSTALL a new VCT oil control solenoid.
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90) CLEAR the DTC and test the system

CIRCUIT
G531330t142 : CHECK ECM TO VCT SOLENOID SUPPLY CIRCUIT VOLTAGE
1. Disconnect the VCT solenoid electrical connector, PI17. 2. Key on, engine off. 3. Measure the
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voltage between:
VCT solenoid connector PI17, harness side Battery
-> Yes
-> No
REPAIR the circuit between the VCT solenoid electrical connector and battery. This circuit includes
fuse 12 of the front power distribution box and the EMS control relay. For additional information,
G531330t147 : CHECK VCT SOLENOID CONTROL CIRCUIT FOR HIGH

RESISTANCE
VCT solenoid connector PI17, harness side ECM connector PI300, harness side
Pin 01 Pin 87
-> Yes
-> No
INSTALL a new VCT oil control solenoid.
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90) CLEAR the DTC and test the system
PINPOINT TEST G531330p32 : EMS

CONTROL RELAY CIRCUITS
G531330t149 : CHECK THE EMS RELAY PERMANENT SUPPLY VOLTAGES
1. Remove the EMS relay. 2. Measure the voltage between:
EMS relay base, harness side Battery
Are both voltages greater than 10 volts?
-> Yes
-> No
REPAIR the circuit between the relay base and battery. For additional information, refer to the wiring
G531330t92 : CHECK THE ECM TO EMS RELAY CONTROL CIRCUIT FOR


-> Yes
-> No


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-> Yes
-> No

HIGH RESISTANCE
EMS relay base, harness side ECM connector EC300, harness side
Pin 02 Pin 16
-> Yes
-> No
G531330t150 : CHECK THE EMS RELAY TO ECM IGNITION CIRCUITS FOR

HIGH RESISTANCE
EMS relay base, harness side ECM connector EC300, harness side
Pin 05 Pin 04
Pin 05 Pin 06
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. These circuits include fuses 2 and 12 of the front power
distribution box. For additional information, refer to the wiring diagrams. CLEAR the DTC and test the
-> No
INSTALL a new EMS control relay. CLEAR the DTC and test the system for normal operation.

MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR CIRCUIT
G531330t80 : CHECK THE MAP SENSOR SUPPLY CIRCUIT VOLTAGE
1. Disconnect the MAP sensor electrical connector, PI29. 2. Key on, engine off. 3. Measure the
voltage between:
MAP sensor connector PI29, harness side Battery
-> Yes
REPAIR the 5 volt supply circuit between the MAP sensor and the ECM. For additional information,
-> No
G531330t109 : CHECK THE MAP SENSOR SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER

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-> Yes
-> No
G531330t154 : CHECK THE MAP SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO GROUND
-> Yes
-> No
CIRCUIT TO POWER
-> Yes
-> No
G531330t152 : CHECK THE MAP SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
MAP sensor connector PI29, harness side ECM connector PI300, harness side
Pin 01 Pin 69
-> Yes
-> No
G531330t124 : CHECK THE MAP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
Pin 04 Pin 10
-> Yes
-> No
INSTALL a new MAP sensor.
Manifold Absolute Pressure (MAP) Sensor (18.30.86) CLEAR the DTC and test the system for normal
operation.

FUEL TEMPERATURE (EFT) SENSOR
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CIRCUIT
G531330t157 : CHECK THE EFT SENSOR SENSING CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Disconnect the EFT sensor electrical connector, IL09. 2. Measure the resistance between:
EFT sensor connector IL09, harness side Battery
-> Yes
-> No

CIRCUIT TO POWER
EFT sensor connector IL09, harness side Battery
-> Yes
-> No
G531330t155 : CHECK THE EFT SENSOR SENSING CIRCUIT FOR HIGH

RESISTANCE
EFT sensor connector IL09, harness side ECM connector PI300, harness side
Pin 02 Pin 46
-> Yes
-> No
G531330t126 : CHECK THE EFT SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
EFT sensor connector IL09, harness side ECM connector PI300, harness side
Pin 01 Pin 15
-> Yes
-> No
INSTALL a new EFT sensor.
Fuel Temperature Sensor (18.30.99) CLEAR the DTC and test the system for normal operation.
PINPOINT TEST G531330p35 : AIR

CONDITIONING (A/C) PRESSURE
SENSOR CIRCUIT
G531330t146 : CHECK THE A/C PRESSURE SENSOR POWER SUPPLY CIRCUIT
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VOLTAGE
1. Disconnect the A/C pressure sensor electrical connector, EC11. 2. Key on, engine off. 3. Measure
A/C pressure sensor connector EC11, harness side Battery
-> Yes
REPAIR the 5 volt supply circuit between the A/C pressure sensor and the ECM. For additional
-> No
G531330t161 : CHECK THE A/C PRESSURE SENSOR POWER SUPPLY CIRCUIT


-> Yes
-> No
G531330t160 : CHECK THE A/C PRESSURE SENSOR SENSING CIRCUIT FOR

-> Yes
-> No

-> Yes
-> No

HIGH RESISTANCE
A/C pressure sensor connector EC11, harness side ECM connector EC300, harness side
Pin 02 Pin 12
-> Yes
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-> No
G531330t162 : CHECK THE A/C PRESSURE SENSOR GROUND CIRCUIT FOR

HIGH RESISTANCE
Pin 01 Pin 08
-> Yes
-> No
INSTALL a new A/C pressure sensor.
Pressure Cutoff Switch - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 - AJV8
(82.10.32) CLEAR the DTC and test the system for normal operation.
MANIFOLD TUNING (IMT) VALVE 1
(TOP) CIRCUIT
G531330t168 : CHECK THE IMT VALVE POWER SUPPLY CIRCUIT VOLTAGE
1. Disconnect the IMT valve electrical connector, PI30. 2. Key on, engine off. 3. Measure the voltage
between:
IMT valve connector PI30, harness side Battery
-> Yes
-> No
REPAIR the circuit between the IMT valve electrical connector and battery. This circuit includes fuse
14 of the front power distribution box and the EMS control relay. For additional information, refer to
G531330t148 : CHECK THE IMT VALVE DRIVE CIRCUIT FOR SHORT CIRCUIT
TO GROUND
-> Yes
-> No
TO POWER
-> Yes
-> No
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G531330t169 : CHECK THE IMT VALVE DRIVE CIRCUIT FOR HIGH

RESISTANCE
IMT valve connector PI30, harness side ECM connector PI300, harness side
Pin 02 Pin 84
-> Yes
-> No
INSTALL a new IMT valve,
Intake Manifold Tuning (IMT) Valve LH (19.70.30) CLEAR the DTC and test the system for normal
operation.
MANIFOLD TUNING (IMT) VALVE 2
(BOTTOM) CIRCUIT
G531330t176 : CHECK THE IMT VALVE POWER SUPPLY CIRCUIT VOLTAGE
1. Disconnect the IMT valve electrical connector, PI31. 2. Key on, engine off. 3. Measure the voltage
between:
-> Yes
-> No
REPAIR the circuit between the IMT valve electrical connector and battery. This circuit includes fuse
14 of the front power distribution box and the EMS control relay. For additional information, refer to
TO GROUND
-> Yes
-> No
TO POWER
-> Yes
-> No
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G531330t167 : CHECK THE IMT VALVE DRIVE CIRCUIT FOR HIGH

RESISTANCE
IMT valve connector PI31, harness side ECM connector PI300, harness side
Pin 02 Pin 90
-> Yes
-> No
INSTALL a new IMT valve,
Intake Manifold Tuning (IMT) Valve LH (19.70.30) CLEAR the DTC and test the system for normal
operation.

SWITCH
RELEASED)
1. Key off. 2. Disconnect the brake switch electrical connector, CR78. 3. Make sure the brake pedal is
not pressed. 4. Measure the resistance between:
Pin 01 Pin 02
-> Yes
-> No

PRESSED)
Pin 01 Pin 02
-> Yes
-> No


-> Yes
-> No

CIRCUIT TO GROUND

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-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

RESISTANCE
Pin 02 Pin 41
-> Yes
-> No
REFER to the warranty policy and procedures manual if an ECM is suspect.

Removal
1 . Switch the ignition on.
2 . Position the front seat fully rearwards.
3 . Switch the ignition off.

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4 . Remove the driver's side footwell trim panel.
5 . Release the brake pedal position (BPP) switch.
Rotate the BPP switch 45 degrees counter-clockwise.

6 . Remove the BPP switch.
Installation
1
. CAUTION: Make sure that the brake pedal remains in the rest position during this
procedure.
CAUTION: The bracket is keyed to avoid incorrect orientation. Failure to correctly

align the switch may result in damage to the vehicle.
CAUTION: Make sure that the pedal box, booster-to-brake pedal assembly and
switch bracket are all installed correctly before installing the switch.
Install the BPP switch.
Locate the BPP switch in the bracket.
Rotate the BPP switch 45 degrees clockwise.
3 . Install the driver's side footwell trim panel.

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Align the trim panel with the guide.
Install the 3 clips.

Camshaft Position (CMP) Sensor LH
(18.31.12)
Removal
3 . Detach the fuel injection supply manifold.
4 . Disconnect the camshaft position (CMP) sensor electrical connector.
5 . Remove the CMP sensor.

Installation
Tighten to 7 Nm.
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Camshaft Position (CMP) Sensor RH
(18.31.11)
Installation
Tighten to 7 Nm.
Removal
2 . Detach the catalyst monitor sensor electrical connector.

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3 . Disconnect the catalyst monitor sensor electrical connector.
4 Detach the catalyst monitor sensor wiring harness from the retaining clip on the automatic
. transmission.
5
. CAUTION: Do not twist the catalyst monitor sensor wiring harness on removal.
Failure to follow this instruction may result in damage to the component.
Remove the catalyst monitor sensor.
Installation
1
. CAUTION: Do not twist the catalyst monitor sensor wiring harness on installation.
Tighten to 40 Nm.
2 NOTE:
.

Test
(18.30.12)
Removal

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Installation
Tighten to 7 Nm.
5 Point Security Torx Bit

418-535
Removal

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1) Remove the engine compartment panel retaining bolt.
2) Remove the engine compartment panel.
6 NOTE:
.
the electrical connector.
Using the special tool, loosen the ECM electrical connector retaining bolt.
7 . Disconnect the ECM electrical connector.
8 . Remove the instrument panel lower trim panel.
1) Remove the retaining clips.
2) Remove the instrument panel lower trim panel.

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9 . Remove the ECM retaining bracket.
10 . Remove the ECM.
1) Detach the retaining clips.

2) Remove the ECM.
Installation
1
. CAUTION: Make sure that the electrical connector is located correctly in the ECM.
Do not force or overtighten the electrical connector. Failure to follow this instruction may
CAUTION: Make sure the ECM support bracket is located correctly.
Tighten to 5 Nm.
- VIN Range: G00442->G45703 (18.30.10)
Removal
1
personal injury.
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injury.
2 . Remove the engine coolant temperature (ECT) sensor.
1) Disconnect the ECT electrical connector.
2) Remove the ECT sensor.
Remove and discard the ECT sensor sealing washer.

Installation
Install a new ECT sensor sealing washer.
Tighten the ECT sensor to 17 Nm.
Fill the cooling system up to the MAX mark on the coolant expansion tank.
- VIN Range: G45704->G99999 (18.30.10)
Removal
1
personal injury.
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injury.


4 . Remove the ECT sensor.
Remove the ECT sensor retaining clip.
Installation
2 . Fill the cooling system up to the MAX mark on the coolant expansion tank.
Removal
1 . Depressurize the fuel system. <<310-00>>
2 . Remove the fuel rail pressure (FRP) sensor bracket retaining bolt.
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3 . Remove the FRP sensor bracket.
4 . NOTE:
Disconnect the FRP sensor electrical connector and vacuum hose.

5 . NOTE:
Remove the FRP sensor.
Installation
1 . NOTE:
Install a new O-ring seals.
Tighten to 10 Nm.
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Removal
2 . Remove the air outlet tube. <<303-12A>>
4 . Remove the fuel temperature sensor. <<310-00>>
Installation
1 . To install, reverse removal procedure.
Removal
2 . Detach the heated oxygen sensor (HO2S) electrical connector.

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3 . Disconnect the HO2S electrical connector.
4
. CAUTION: Do not twist the H02S wiring harness on removal. Failure to follow this
instruction may result in damage to the component.
Remove the HO2S.

Installation
1
. CAUTION: Do not twist the H02S wiring harness on installation. Failure to follow this
Tighten to 40 Nm.
Intake Manifold Tuning (IMT) Valve LH
(19.70.30)
Removal
2 . Remove the intake manifold tuning (IMT) valve.

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Installation
Tighten to 10 Nm.
Removal
1 . Remove the fuel supply manifold. <<303-04A>>
2 . Disconnect the knock sensor electrical connector.
3 . Remove the knock sensor.
Installation
Tighten to 25 Nm.
Removal
2 . Disconnect the knock sensor electrical connector.

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3 . Remove the knock sensor.
Installation
Tighten to 25 Nm.
Manifold Absolute Pressure (MAP) Sensor
(18.30.86)
Removal
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2 . Remove the MAP sensor.
Installation
Tighten to 10 Nm.
Removal
1 . Remove the mass airflow (MAF) sensor.
1) Disconnect the MAF sensor electrical connector.
2) Remove the mass airflow MAF sensor.
Remove and discard the MAF sensor O-ring seal.
Installation
Install a new MAF sensor O-ring seal.
2 NOTE:
.

Test
Removal

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3 . Remove the oil temperature sensor.
Installation
1 NOTE:
.
If the oil temperature sensor is to be re-used apply a small bead of sealant meeting
Jaguar specification on the first three threads of the oil temperature sensor.
To install, reverse the removal procedure
Tighten to 15 Nm.
Variable Camshaft Timing (VCT) Oil
Control Solenoid (18.30.90)
Removal
2 . Remove the variable camshaft timing oil control solenoid.

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Installation
Tighten to 10 Nm.
2 NOTE:
.
Test
303-14B : Electronic Engine Controls – 4.2L NA V8 –
AJV8/4.2L SC V8 – AJV8/3.5L NA V8 – AJV8
Specifications
Specifications

Heated oxygen sensor (H02S) 40 30 -
Catalyst monitor sensor 40 30
Knock sensor retaining nut 25 18 -
Fuel temperature sensor 7 - 62
Fuel rail pressure (FRP) sensor retaining bolts 5 - 44
Intake air temperature (IAT) sensor 35 26 -
Engine coolant temperature (ECT) sensor 17 13 -
Manifold absolute pressure (MAP) sensor 10 - 89
Mass air flow (MAF) sensor retaining screws 2 - 18
Engine compartment support retaining bolts 25 18 -
Engine control module (ECM) electrical connector retaining bolt 5 - 44
Variable camshaft timing oil control solenoid retaining bolt 10 - 89
Lubricants, fluids, sealers and adhesives
Sealant WSK-M4G-328-A3
General procedures

Adjustment
No Data Available
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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.

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Powertrain Control Module (PCM) Short
Drive Cycle Self-Test
NOTE:
This procedure is an overcheck only. If fault codes are found, interrogation of the relevant
system must be carried out and claimed against.
2. Follow on screen prompts and check for engine management fault codes.
3. Clear the fault codes following the on screen procedure.
4. Start the engine.

• Allow the engine to idle for 30 seconds.
• Raise the engine speed to 1500 rpm and hold for 3 minutes until a temperature of 70ºC
(158 ºF) is achieved.
• Allow the engine to idle for 30 seconds.
• Switch off the engine.
5. NOTE:
If fault codes are found, interrogation of the relevant system must be carried out and
claimed against.
Follow on screen prompts and check for engine management fault codes.


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1 — Knock sensor (KS)

2 — Intake air temperature (IAT) sensor
4 — Throttle position sensor
9 — Crankshaft position (CPK) sensor

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1 — Throttle position sensor
2 — Knock sensor (KS)

7 — Crankshaft position (CPK) sensor
8 — Variable camshaft timing oil control solenoid

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1 — Heated oxygen sensor - RH
2 — Catalyst monitor sensor - RH
3 — Catalyst monitor sensor - LH
4 — Heated oxygen sensor (HO2S) - LH
Engine Control Module (ECM)

The electronic engine control system consists of a engine control module (ECM), located behind the
glove compartment, and a number of sensing and actuating devices. The sensors supply the ECM
with input signals which relate to the engine operating conditions and driver requirements. The
sensor information is evaluated by the ECM using the results to activate the appropriate response
from the actuating devices. The system provides the necessary engine control accuracy and
adaptability to:
minimize exhaust emissions and fuel consumption.

provide optimum driver control under all conditions.
minimize evaporative emissions.
provide system diagnostics.
In addition to these functions the ECM also interfaces with other vehicle systems through the
controller area network (CAN).
Camshaft Position (CMP) Sensor

The camshaft position (CMP) sensors monitor the position of both camshafts to allow the ECM to
control the phase of the inlet camshafts relative to the position of the crankshaft.
Variable Camshaft Timing Oil Control Solenoid

The variable camshaft timing oil control solenoid is a hydraulic actuator, which advances and retards
the inlet camshaft timing, thereby altering the camshaft to crankshaft phasing for optimum engine
performance.
Knock Sensors (KS)

The knock sensors (KS) detect combustion knock within the engine cylinders and sends a signal to the
ECM. The ECM uses this information to gradually adjust the ignition timing until the combustion
knock is eliminated.
Mass Air flow (MAF) Sensor

The mass air flow (MAF) sensor informs the ECM of the rate of air flow entering the engine by
producing a voltage which is proportional to the rate of air flow into the engine. The voltage
produced by the MAF sensor increases as the rate of air flow increases. The ECM takes into account
the density of the air entering the air intake system so that it is possible to maintain the required air
to fuel ratio, and to compensate for variations in atmospheric pressure.
Integral to the MAF sensor is the intake air temperature sensor (IAT) which measures the
temperature of the air entering the air intake system. The ECM uses this information to compensate
for higher than normal air intake temperatures.
Throttle Position (TP) Sensor

The ECM monitors the angle of the throttle blade within the throttle housing through the throttle
position (TP) sensor. The TP sends a voltage to the ECM which is proportional to the angle of the
throttle plate. The voltage from the TP increases with the angle of the throttle plate. There are two
sensor tracks within the TP sensor.

The crankshaft position (CKP) sensor is an inductive pulse generator, which scans protrusions on a
pulse ring fitted to the flywheel to inform the ECM of the crankshaft's position and speed. The CKP
sensor produces an alternating voltage. The frequency of this voltage increases proportional to
engine speed.
The fuel rail pressure (FRP) 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.

The engine coolant temperature (ECT) sensor is a thermistor type sensor that provides an input
signal to the ECM which is proportional to the engine coolant temperature. The ECT sensor is a
negative temperature coefficient (NTC) sensor and its resistance decreases with a proportional
increase in engine coolant temperature.
Oil Temperature Sensor

The oil temperature sensor is a thermistor type sensor that provides an input signal to the ECM
which is proportional to the engine oil temperature.
Oil Pressure Switch

The oil pressure switch is connected to the instrument cluster and is not directly part of the
electronic engine control system.
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The heated oxygen sensor (HO2S) is a linear characteristic type sensor, fitted forward of the exhaust
system's catalytic converter. The ECM uses this as it's primary sensor to measure the oxygen content
of the exhaust gasses within the exhaust system to provide closed-loop fuelling control.
Catalyst Monitor Sensor

The catalyst monitor sensor is a non-linear characteristic type sensor fitted to the exhaust system's
catalytic converter. The ECM uses this as it's secondary sensor to measure the oxygen content of the
exhaust gasses within the exhaust after they have passed through the catalytic converter. As well as
providing additional closed-loop fuelling control the ECM uses this information to determine the
efficiency of the catalytic converter.
Intake Air Temperature (IAT) Sensor. Vehicles with supercharger.

Vehicles with supercharger have an additional intake air temperature sensor located on the right-
hand charge air cooler. The IAT measures the temperature of the air entering the charge air cooler.
The ECM uses this information to compensate for higher than normal air intake temperatures.
Electronic Engine Controls – Armoured Vehicles
CAUTION: It is imperative that the correct calibration is installed into this engine control module (ECM). In the
event of any doubt, advise should be taken from the Jaguar technical help-line.
Maximum Speed Limit
Modifications have been made to the engine control module (ECM) calibration to improve drivability due to
the extra weight of the glass and armour fitted to the vehicle. If a new ECM is installed, the revised software
must be loaded using the approved Jaguar diagnostic tool. The maximum speed of the vehicle has been
limited to 195 kph (121 mile/h) due to the extra weight of the glass, armour and tire load and speed rating of
the vehicle.
Inertia Fuel Shutoff (IFS) Switch
The fuel pump relay earths through the ECM, via the inertia fuel shutoff (IFS) switch. If, the IFS is
activated, it breaks the path to earth of the fuel pump relay, turning off the fuel pump. The IFS override
switch bypasses the IFS and provides an earth for the fuel pump relay, allowing the vehicle to be driven in
an emergency situation.

G00442->G45703
NOTE:
driver information table for diagnostic trouble codes (DTCs) associated with the display, then to
the DTC index table for possible sources and actions. Some warnings will appear to clear when
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the ignition is cycled. This is often because the warning has flagged as a result of one of the
vehicle's on-board diagnostic routines having run to detect the fault. If the same routine is not
run when the ignition is switched ON, the warning will not reflag until the routine does run. See
the DTC summaries for drive cycle routines.

Air intake system
Cooling system
Charging system
Fuel charging system
Ignition system
NOTE:
a fault code reader to retrieve the fault codes before proceeding to the DTC index, or the symptom
chart if no DTCs are set.
NOTE:
NOTE:
Symptom Symptom (specific) Possible source Action

(general)
Security system
/Immobilizer engaged
Check for DTCS. Contact dealer
technical support for
Engine in shut-down mode
information on security system.
ECM relay For starting system,
Engine does not crank Battery Pinpoint Test G258127p32.
Park/Neutral switch Battery For Park/Neutral tests,
External Controls For engine
Starting system
information,
Harness Engine
Engine seized
Check engine breather system,
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d ignition system,
Ignition system G00442->G45703 For fuel
Non-Start Engine cranks, but system,
does not fire Fuel system Fuel Charging and Controls -
Harness
For CKP tests, GO to Pinpoint
Test G258127p17.
CKP sensor
ECM fault support for advice on possible
ECM failure.
Purge valve For evaporative emissions

components,
Fuel pump
Coolant temperature Range: G00442->G45703 For
sensor fuel system,
Engine cranks and fires, Fuel Charging and Controls -
but will not start Spark plugs VIN Range: G45704->G99999
Check for water ingress Pinpoint Test G258127p3.
into spark plug wells
HT short to ground Engine Ignition - VIN Range:
(tracking) check G00442->G45703
rubber boots for
cracks/damage
Harness
Check coolant anti-freeze GO to Pinpoint Test
content
G258127p17.
Battery For EGR system information,
CKP sensor Range: G00442->G45703 For
fuel system,
EGR valve stuck open Fuel Charging and Controls -
Fuel pump For ECT sensor tests, GO to
Coolant temperature
sensor For evaporative emissions
components,
Purge valve Evaporative Emissions - VIN
Range: G00442->G45703
For fuel system,

Injector leak Fuel Charging and Controls -
Difficult to VIN Range: G00442->G45703
start Fuel temperature sensor For fuel temperature sensor
IAT sensor G258127p34.
For IAT sensor tests, GO to
MAF sensor
Purge valve For MAF sensor tests, GO to
Fuel pump For evaporative emissions
components,
Ignition system Evaporative Emissions - VIN
Coolant temperature ECT sensor tests, GO to
sensor
Difficult to start after Injector leak For fuel system,

hot soak (vehicle Fuel Charging and Controls -
standing after engine Fuel temperature sensor VIN Range: G00442->G45703
has reached operating Fuel Charging and Controls -
temperature) IAT sensor VIN Range: G45704->G99999
For fuel temperature sensor
MAF sensor tests, GO to Pinpoint Test
G258127p34.
Purge valve For IAT sensor tests, GO to
Fuel pump
Ignition system Pinpoint Test G258127p1.
Coolant temperature components,
sensor Evaporative Emissions - VIN
ECT sensor tests, GO to
Check compressions,
Compressions high/low Engine For battery
Engine cranks too
information,
fast/slow Battery
Battery For starting system,
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Starting system

Breather system ECM relay tests, GO to Pinpoint
disconnected/restricte Test G258127p32.
d For MAF sensor tests, GO to
ECM relay
Harness
MAF sensor Engine Ignition - VIN Range:
G00442->G45703 For air filter
Engine Engine stalls soon after
Coolant temperature information,
stalls start sensor Intake Air Distribution and
Ignition system
>G45703 For fuel system, fuel
Air filter restricted pressure sensor tests,
Fuel lines VIN Range: G00442->G45703
Fuel pressure sensor VIN Range: G45704->G99999
For intake system information,
Air leakage Intake Air Distribution and
>G45703
For throttle sensor tests, GO to
Engine stalls on ECM relay
For fuel system,
overrun
Throttle sensors Fuel Charging and Controls -

For fuel system,
ECM relay Fuel Charging and Controls -
Engine stalls at steady CKP sensor
speed
Throttle sensors VIN Range: G45704->G99999
Harness Pinpoint Test G258127p17.
For throttle sensor tests, GO to
Engine stalls with ECM relay For ECM relay tests, GO to

speed control enabled Pinpoint Test G258127p32.
Harness
ECM relay
Throttle sensors For throttle position sensor
Engine stalls when Additional engine loads G258127p4.
maneuvering (PAS, air conditioning, For accessory drive
etc) information,
For CAN network tests,
CAN network malfunction Communications Network
Fuel pump For fuel pump, fuel pressure

sensor, fuel line and injector
Injector leak tests,
Poor Engine hesitates/poor Fuel Charging and Controls -
Fuel pressure
driveability acceleration VIN Range: G00442->G45703
Fuel lines
Air leakage For intake system,
Throttle sensors Filtering - VIN Range: G00442-
>G45703 For throttle position
Throttle motor sensor tests, GO to Pinpoint
Test G258127p4.
Ignition system
Exhaust gas recirculation Pinpoint Test G258127p24.
HO2 sensors Engine Ignition - VIN Range:
G00442->G45703 For exhaust
Transmission malfunction gas recirculation,
Restricted pedal travel Range: G00442->G45703
(carpet, etc)
APP sensor sensors. Refer to the DTC index
Check accelerator pedal travel.
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G258127p23.
For fuel pump and lines tests,

V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
Fuel pump G00442->G45703 For intake
system,
Fuel lines
Air leakage
>G45703 For MAF sensor tests,
MAF sensor GO to Pinpoint Test
Engine backfires G258127p1.
Ignition system for pinpoint tests for DTC set.
Sticking VCT hub
APP sensor G00442->G45703 For VCT
information,
GO to Pinpoint Test
G258127p22.
G258127p23.
Check fuel pressure. For fuel

line information,
Fuel pump
Fuel lines V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 - AJ27/3.5L
MAF sensor NA V8 - AJV8, VIN Range:
G00442->G45703 For MAF
Engine surges
Harness sensor, throttle sensor, and
throttle motor relay tests,
Throttle sensors Electronic Engine Controls - VIN
Throttle motor
ignition system,
G00442->G45703

G258127p16.
Check fuel pressure. For fuel
line information,
V8 - AJV8/4.2L SC V8 -
Fuel pump AJV8/3.0L NA V6 - AJ27/3.5L
Fuel lines G00442->G45703 For fuel
pressure sensor,
Fuel pressure sensor Fuel Charging and Controls -
Engine VIN Range: G00442->G45703
HO2 sensors VIN Range: G45704->G99999
Air leakage Pinpoint Test G258127p1.
Sticking VCT hub sensors. Refer to the DTC index
BARO sensor malfunction For intake system,
>G45703 Check DTCs for VCT
range/performance fault. For
VCT information,
Engine For BARO sensor,
contact dealer technical
support for advice on possible
ECM failure

G258127p23.
No throttle response For throttle position sensor
Throttle sensors
Check message center for

default message. For speed
Default mode enabled control switches,
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Speed Control - VIN Range:

Speed control inhibited Speed control switch
G00442->G45703 For throttle
or disabled
Throttle sensors position sensor tests, GO to
Stop light switch Check electrical guides for stop
light switch information.

APP sensor malfunction and GO to Pinpoint Test
G258127p23.
Throttle sensors For throttle position sensor
Coolant temperature
sensor G258127p4.
Poor throttle response For MAF sensor tests, GO to
Transmission malfunction Pinpoint Test G258127p1.
Traction control event
For intake system,
Air leakage
Breather system >G45703 For breather system
disconnected/restricte information,
d Engine Emission Control - VIN
Range: G00442->G45703
Park/Neutral switch For Park/Neutral tests,
External Controls For throttle
Engine defaults, Throttle sensors position sensor tests, GO to
warning light and
messages. Refer to the MAF sensor
driver information
Coolant temperature Pinpoint Test G258127p1.
table
sensor For ECT sensor tests, GO to
Harness

Warning
light

cylinders fuel cut)
P0121, P0122, P0123, P0222,

P0223
P1344, P1122, P1123, P1215,

P1216
P0304, P0305, P0306, P0307,
P0308, P1313, P1314
P0327, P0328, P0332, P0333,

P1648
P0351, P0352, P0353, P0354,

P1367, P1368
P0201, P0202, P0203, P0204,

P0205, P0206, P0207, P0208

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enabled

enabled

enabled

enabled
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
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Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance
Gearbox
performance

fault/Restricted
performance
Gearbox
performance
Gearbox
performance

performance enabled
Gearbox
performance
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Gearbox
performance
Gearbox
performance
Gearbox
performance

LIMP-HOME MODE
Throttle motor off
Fuel intervention
Speed control inhibited
Power limitation
NOTE:
HIGH IDLE
SAFETY REDUNDANCY
Power limitation
DTC index
VCT solenoid control valve

disconnected
Right-hand variable
For right-hand VCT tests, GO to
P0010 camshaft timing (VCT) VCT solenoid valve to ECM
circuit malfunction PWM drive circuit; open Pinpoint Test G258127p29.
circuit, short circuit,
high resistance
VCT solenoid control valve
disconnected
Left-hand variable
VCT solenoid valve to ECM For left-hand VCT tests, GO to
P0020 camshaft timing (VCT)
PWM drive circuit; open Pinpoint Test G258127p30.
circuit malfunction circuit, short circuit,
high resistance

circuit open circuit

open circuit, high
Right-hand HO2S heater resistance
For HO2S tests, GO to Pinpoint
P0031 control circuit, low
current HO2S heater ground circuit Test G258127p7.
fault (EM80, pin 29;
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EM80, pin 30)
HO2S heater failure
HO2S connections
Right-hand HO2S heater HO2S heater ground circuit

For HO2S tests, GO to Pinpoint
P0032 control circuit, high fault (EM80, pin 29;
EM80, pin 30) Test G258127p7.
current
HO2S heater failure
HO2S connections
heater control circuit
Right-hand catalyst short circuit to ground
For catalyst monitor sensor
monitor sensor heater
control circuit, low Catalyst monitor sensor
heater failure G258127p9.
resistance

connections
Right-hand catalyst Catalyst monitor sensor

heater control circuit For catalyst monitor sensor
P0038 open circuit, high tests, GO to Pinpoint Test
control circuit, high resistance G258127p9.
resistance
heater failure

connections

open circuit, high
resistance
Left-hand HO2S heater For heater control tests, GO to
P0051
control circuit low current HO2S heater ground circuit Pinpoint Test G258127p11.
fault (EM80, pin 81;
EM80, pin 82)
HO2S connections
HO2S heater failure

Left-hand HO2S heater
For heater control tests, GO to
P0052 control circuit, high HO2S heater ground circuit
fault (EM80, pin 81; Pinpoint Test G258127p11.
current
EM80, pin 82)
HO2S heater failure
Left-hand catalyst Catalyst monitor sensor

heater control circuit For heater control circuit tests,
P0057 short circuit to ground GO to Pinpoint Test
control circuit, low
G258127p12.
resistance Catalyst monitor sensor
heater failure
Left-hand catalyst heater control circuit
For heater control circuit tests,
monitor sensor heater open circuit, high
control circuit, high resistance
G258127p12.
resistance
heater failure
IAT2 sensor disconnected
Intake Air Temperature 2
For IAT2 sensor circuit tests, GO
P0096 (IAT2) sensor circuit IAT2 sensor to ECM sensing
circuit; open circuit to Pinpoint Test G258127p37.
range/performance
IAT2 sensor failure

Intake Air Temperature 2 IAT2 sensor disconnected
For IAT2 sensor circuit tests, GO
P0097 (IAT2) sensor circuit high
IAT2 sensor to ECM wiring; to Pinpoint Test G258127p37.
voltage (low air
open circuit, high
temperature) resistance
IAT2 sensor to ECM sensing

circuit; short circuit to
B+
IAT2 sensor failure

Intake Air Temperature 2
IAT2 sensor to ECM wiring;
(IAT2) sensor circuit low For IAT2 sensor circuit tests, GO
P0098 short circuit to ground
voltage (high air to Pinpoint Test G258127p37.
temperature) IAT2 sensor failure
Blocked air filter
Air intake leak Check air filter element, air

intake system for leaks. For
Engine breather leak further information,
Throttle control malfunction Filtering - VIN Range: G00442-
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>G45703 Check engine breather

Mass air flow (MAF) MAF sensor to ECM sensing system. For further information,
P0101 sensor circuit Engine Emission Control - VIN
intermittent short
range/performance circuit to ground Range: G00442->G45703 Check
for associated codes related to
MAF sensor supply circuit; throttle control. For MAF sensor
G258127p1.
MAF sensor failure Throttle adaptation is automatic
at key on.
Throttle adaptation fault
(check throttle position
voltage at ignition ON)
Blocked air filter
Air intake leak between

MAF sensor and throttle
Check air filter element, air
MAF sensor to ECM sensing intake system for leaks. For
circuit; high resistance, further information,
Mass air flow (MAF)
P0102 open circuit, Intake Air Distribution and
sensor circuit low voltage intermittent short Filtering - VIN Range: G00442-
circuit to ground >G45703 For MAF sensor tests,
MAF sensor supply circuit;
open circuit, short
circuit to ground
MAF sensor failure

Mass air flow (MAF) B+ voltage
P0103 sensor sensing circuit high
voltage MAF sensor to ECM ground Pinpoint Test G258127p1.
circuit; open circuit
MAF sensor failure

Intake manifold air leak
Check air intake system. For
(loose or missing
component) further information,
Manifold absolute MAP sensor to ECM Filtering - VIN Range: G00442-
P0105 pressure (MAP) sensor circuit(s) fault >G45703 For MAP sensor circuit
range/performance tests, GO to Pinpoint Test
MAP sensor failure G258127p33.
Throttle adaptation is automatic
Throttle adaptation fault
(check throttle position at key on.
voltage at ignition ON)
Contact dealer technical support
BARO sensor circuit
P0106 BARO failure (internal ECM for advice on possible ECM
range/performance fault) failure.

BARO sensor circuit, low
P0107 BARO failure (internal ECM for advice on possible ECM
voltage fault) failure.

P0108 BARO circuit, high voltage BARO failure (internal ECM for advice on possible ECM
fault) failure.
Blocked air filter

Check air filter element, air
Air intake leak intake system for leaks. For
further information,
Engine breather leak Intake Air Distribution and
Intake air temperature Filtering - VIN Range: G00442-
IAT sensor to ECM wiring;
P0111 (IAT) sensor >G45703 Check engine breather
open circuit or high
range/performance resistance system. For further information,
IAT sensor to ECM sensing Range: G00442->G45703 For
circuit; short circuit to IAT sensor tests, GO to Pinpoint
high voltage Test G258127p2.
IAT sensor failure

IAT sensor to ECM wiring;

Intake air temperature open circuit or high
(IAT) sensor circuit high resistance For IAT sensor tests, GO to
P0112
voltage (low air Pinpoint Test G258127p2.
temperature) IAT sensor to ECM sensing
circuit short circuit to B+
voltage
IAT sensor failure

Intake air temperature
IAT sensor to ECM wiring
(IAT) sensor circuit low For IAT sensor tests, GO to
P0113 short circuit to ground
voltage (high air Pinpoint Test G258127p2.
temperature) IAT sensor failure
Low coolant level

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Thermostat failure
ECT sensor to ECM sensing Refer to visual inspection table

circuit; open circuit, in this section, check sensor
Engine coolant high resistance when
connections, coolant level and
P0116 temperature (ECT) sensor hot, intermittent high
resistance condition, thermostat operation.
circuit range/performance
ECT sensor failure Pinpoint Test G258127p3.
Engine cooling fan stuck on

high speed
Above normal air flow

through engine
compartment, due to
accident damage and/or
missing panels
Engine coolant
temperature (ECT) sensor ECT sensor to ECM sensing
P0117 sensing circuit high circuit; high resistance,
open circuit, short Pinpoint Test G258127p3.
voltage (low coolant
temperature) circuit to B+ voltage
ECT sensor failure

Engine coolant Engine overheat condition Check for overheating, for
temperature (ECT) sensor further information,
P0118 sensing circuit low voltage ECT sensor to ECM wiring Engine Cooling For ECT sensor
(high coolant short circuit to ground tests, GO to Pinpoint Test
temperature) G258127p3.
ECT sensor failure
TP sensor to ECM wiring;
open circuit, high
Throttle position (TP) resistance
sensor circuit For TP sensor tests, GO to
P0121 TP sensor to ECM sensing
range/performance (TP1 circuits; (TP 1 or TP 2) Pinpoint Test G258127p4.
compared to TP2) short circuit to B+
voltage
TP sensor failure
Throttle position (TP) circuit (TP1); open
P0122 sensor circuit 1 low circuit, short circuit to
voltage ground, high resistance Pinpoint Test G258127p4.
TP sensor failure
Throttle position (TP)
circuit (TP1); short For TP sensor tests, GO to
P0123 sensor circuit 1 high
circuit to high voltage Pinpoint Test G258127p4.
voltage
TP sensor failure
Low coolant level
Refer to visual inspection table
Thermostat failure in this section, check sensor
Engine coolant connections, coolant level and
temperature (ECT) sensor ECT sensor to ECM sensing condition, thermostat operation.
P0125 response (for closed loop For ECT sensor tests, GO to
open circuit or short
fuel control) (coolant circuit to high voltage Pinpoint Test G258127p3.
thermostat monitor) Check for associated codes
Engine cooling fan stuck on related to cooling fan. Check the
high speed vehicle for panel damage.
Above normal air flow

through engine
compartment, due to
missing panels
Check coolant level and
Engine coolant thermostat condition, check thermostat
Coolant thermostat failure operation,
P0128
range/performance Engine Cooling Check for
ECT sensor failure associated codes related to ECT
sensor.
ECT sensor DTC may also be
flagged
H02S disconnected
Right-hand H02S sensing H02S to ECM variable

current circuit fault
circuit low current
(HO2S pin 3) For HO2S tests, GO to Pinpoint
P0131 (universal oxygen sensor;
Test G258127p6.
lean condition at ECM - ECM to HO2S constant
high current at sensor) current circuit fault
(HO2S pin 4)
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H02S failure
H02S disconnected
Right-hand H02S sensing H02S to ECM variable

circuit high current
Test G258127p6.
rich condition at ECM - ECM to HO2S constant
low current at sensor) current circuit fault
(HO2S pin 4)
H02S failure
Engine misfire Check for associated codes

related to misfire, (P0300 to
H02S disconnected P0308) inspect the HO2S for
connection/damage. For HO2S
H02S mechanical damage diagnosis, GO to Pinpoint Test
G258127p6.
H02S to ECM wiring fault
For HO2S heater diagnosis, GO
Right-hand H02S sensing
P0133 to Pinpoint Test G258127p9.
circuit slow response H02S short circuit to ground
Check for exhaust leak, for
H02S to ECM wiring shield further information,
open circuit Exhaust temperature will be low
if misfire/poor fuel supply
HO2S heater circuit fault condition exists. Catalytic
converter efficiency will be poor
H02S failure
until it reaches "light-off".
Exhaust leak
Catalyst efficiency decrease
Low exhaust temperature
Injector flow partially

blocked
disconnected
Catalyst monitor sensor to

Right-hand catalyst For catalyst monitor sensor
ECM wiring open circuit
P0137 monitor sensor sensing tests, GO to Pinpoint Test
circuit low voltage Catalyst monitor sensor G258127p8.

failure
sensing circuit short
circuit to high voltage
Right-hand catalyst For catalyst monitor sensor
P0138 monitor sensor sensing Catalyst monitor sensor tests, GO to Pinpoint Test
circuit high voltage ground braided shield G258127p8.
open circuit

failure
disconnected
Catalyst monitor sensor Inspect the HO2S for

mechanical damage
connection/damage. For HO2S
Catalyst monitor sensor to sensor diagnosis, GO to Pinpoint
ECM wiring open circuit Test G258127p8.
Right-hand catalyst Check for exhaust leak, for
P0140 monitor sensor sensing Catalyst monitor sensor further information,
circuit no activity sensing circuit short Exhaust temperature will be low
circuit to high voltage if misfire/poor fuel supply
condition exists. Catalytic
Catalyst monitor sensor RH
short circuit to ground converter efficiency will be poor
ground braided shield
open circuit
Exhaust leak

failure
H02S disconnected
Left-hand H02S sensing H02S to ECM variable

circuit low current
Test G258127p10.
lean condition at ECM - ECM to HO2S constant
high current at sensor) current circuit fault
(HO2S pin 4)
H02S failure
H02S disconnected
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Left-hand H02S sensing H02S to ECM variable

circuit high current
Test G258127p10.
rich condition at ECM - ECM to HO2S constant
low current at sensor) current circuit fault
(HO2S pin 4)
H02S failure
Engine misfire
H02S disconnected
Check for associated codes
H02S mechanical damage related to misfire, (P0300 to
P0308) inspect the HO2S for
H02S to ECM wiring fault connection/damage. For HO2S
H02S short circuit to ground
Test G258127p10.
Left-hand H02S sensing
P0153 Check for exhaust leak, for
circuit slow response H02S to ECM wiring shield
open circuit further information,
Exhaust temperature will be low
HO2S heater circuit fault if misfire/poor fuel supply
H02S failure converter efficiency will be poor
Exhaust leak
Catalyst efficiency decrease

Injector flow partially

blocked
disconnected

Left-hand catalyst For catalyst monitor sensor
ECM wiring open circuit
P0157 monitor sensor sensing tests, GO to Pinpoint Test
circuit low voltage Catalyst monitor sensor G258127p14.

failure
sensing circuit; short
Left-hand catalyst For catalyst monitor sensor
P0158 monitor sensor sensing Catalyst monitor sensor tests, GO to Pinpoint Test
circuit high voltage ground braided shield G258127p14.
open circuit

failure
disconnected

mechanical damage
Catalyst monitor sensor to Inspect the HO2S for

ECM wiring open circuit connection/damage. For HO2S
sensor diagnosis, GO to Pinpoint
Catalyst monitor sensor Test G258127p14.
sensing circuit short
Left-hand catalyst Check for exhaust leak, for
P0160 monitor sensor sensing further information,
circuit no activity Catalyst monitor sensor LH Exhaust temperature will be low
short circuit to ground if misfire/poor fuel supply
Catalyst monitor sensor converter efficiency will be poor
ground braided shield until it reaches "light-off".
open circuit
Exhaust leak

failure
mass air flow (MAF) For intake system,
sensor and cylinder Intake Air Distribution and
head Filtering - VIN Range: G00442-
>G45703 For fuel injector,
Fuel injector restriction Fuel Charging and Controls - VIN
Range: G00442->G45703
Low fuel pump output Range: G00442->G45703 For
fuel filter and pump,
Fuel pressure (IP) sensor Fuel Tank and Lines - 4.2L NA V8
failure (low fuel - AJV8/4.2L SC V8 - AJV8/3.0L NA
pressure) V6 - AJ27/3.5L NA V8 - AJV8, VIN
HO2S/Catalyst monitor
Right-hand cylinders fuel pressure sensor,
P0171 sensor harness wiring
combustion too lean condition fault Fuel Charging and Controls - VIN
Range: G00442->G45703
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Fuel temperature (EFT) Fuel Charging and Controls - VIN

sensor fault (low fuel Range: G00442->G45703 For
temperature) HO2S/Catalyst monitor sensor
MAF sensor fault (low
G258127p6.
intake air flow)
Exhaust leak (before GO to Pinpoint Test G258127p8.
catalyst) For exhaust system,
Refer to individual pinpoint tests
ECM receiving incorrect for sensors listed. * If this DTC is
signal from one or more flagged, pay particular attention
of the following sensors; to the MAF sensor.
ECT, MAF*, IAT, IP, EFT,
TP
Engine misfire
Check for "misfire detected"
Restricted air filter DTCs (P0300 to P0308) in this
section. For intake system,
Leaking fuel injector(s) Intake Air Distribution and
Right-hand cylinders Fuel pressure (IP) sensor >G45703 For fuel injectors, fuel
P0172
combustion too rich failure (high fuel
pressure sensor,
pressure)
Fuel temperature (EFT) Range: G00442->G45703
sensor fault (high fuel Fuel Charging and Controls - VIN
temperature) Range: G00442->G45703 Refer
to individual pinpoint tests for
MAF sensor fault (high
intake air flow) sensors and circuits listed.
sensor harness wiring
condition fault
ECM receiving incorrect

signal from one or more
of the following sensors;
ECT, MAF, IAT, IP, EFT,
TP
For intake system,
Air intake leak between Intake Air Distribution and
MAF sensor and Filtering - VIN Range: G00442-
cylinder head
>G45703 For fuel injector,
Fuel filter/system restriction Fuel Charging and Controls - VIN
Range: G00442->G45703
Fuel injector restriction Fuel Charging and Controls - VIN
Fuel pressure (IP) sensor fuel filter and pump,
failure (low fuel Fuel Tank and Lines - 4.2L NA V8
pressure)
- AJV8/4.2L SC V8 - AJV8/3.0L NA
V6 - AJ27/3.5L NA V8 - AJV8, VIN
Low fuel pump output
HO2S/Catalyst monitor fuel pressure sensor,
Left-hand cylinders sensor harness wiring Fuel Charging and Controls - VIN
P0174
combustion too lean condition fault Range: G00442->G45703
Fuel temperature (EFT) Range: G00442->G45703 For
sensor fault (low fuel
temperature)
MAF sensor fault (low G258127p10.
intake air flow) GO to Pinpoint Test
G258127p11.
Exhaust leak (before GO to Pinpoint Test
catalyst) G258127p12.
For exhaust system,
signal from one or more Refer to individual pinpoint tests
of the following sensors for sensors listed. * If this DTC is
- ECT, MAF*, IAT, IP, flagged, pay particular attention
EFT, TP. to the MAF sensor.
Engine misfire Check for "misfire detected"

Left-hand cylinders DTCs (P0300 to P0308) in this
P0175
combustion too rich Restricted air filter section. For intake system,
Leaking fuel injector(s) Filtering - VIN Range: G00442-
>G45703 For fuel injectors, fuel
Fuel pressure (IP) sensor pressure sensor,
failure (high fuel Fuel Charging and Controls - VIN
pressure)
Range: G00442->G45703
Fuel temperature (EFT) Fuel Charging and Controls - VIN
sensor fault (high fuel Range: G00442->G45703 Refer
temperature) to individual pinpoint tests for
sensors and circuits listed.
MAF sensor fault (high
intake air flow)
sensor harness wiring
condition fault

signal from one or more
of the following sensors;
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ECT, MAF, IAT, IP, EFT,

TP

open circuit, short
circuit to ground, short For EFT sensor sensing circuit
circuit to high voltage tests, GO to Pinpoint Test
Engine fuel temperature G258127p34.
P0181 (EFT) sensor For sensor ground tests, GO to
range/performance resistance, open circuit Pinpoint Test G258127p26.
Check the vehicle for panel
Above normal air flow damage.
through engine
compartment, due to
missing panels
EFT sensor failure

circuit; short circuit to For EFT sensor sensing circuit
Engine fuel temperature ground
(EFT) sensor circuit low
P0182 G258127p34.
voltage (high EFT sensor to splice sensor
ground circuit; short For sensor ground tests, GO to
temperature)
circuit Pinpoint Test G258127p26.
EFT sensor failure


circuit; high resistance, For EFT sensor sensing circuit
Engine fuel temperature open circuit, short tests, GO to Pinpoint Test
P0183 (EFT) sensor circuit high circuit to high voltage G258127p34.
voltage (low temperature) For sensor ground tests, GO to
EFT sensor to splice sensor Pinpoint Test G258127p26.
EFT sensor failure

Fuel system leak
Incorrect fuel pump output
FRP sensor to ECM sensing For fuel filter, pump and lines,
Fuel Tank and Lines - 4.2L NA V8
open circuit, short
circuit to ground, short - AJV8/4.2L SC V8 - AJV8/3.0L NA
circuit to high voltage V6 - AJ27/3.5L NA V8 - AJV8, VIN
P0191 sensor circuit
FRP sensor to splice in FRP sensor tests,
range/performance sensor supply circuit; Fuel Charging and Controls - VIN
high resistance, open Range: G00442->G45703
circuit
FRP sensor to splice in Range: G00442->G45703
sensor ground circuit;
high resistance, open
high voltage
FRP sensor failure


circuit; open circuit or For FRP sensor tests,
short circuit to ground Fuel Charging and Controls - VIN
P0192 Range: G00442->G45703
sensor circuit low input FRP sensor to splice in Fuel Charging and Controls - VIN
sensor supply circuit; Range: G00442->G45703
circuit
FRP sensor failure

(supply/sense) short
For FRP sensor tests,
Fuel rail pressure (FRP) circuit; short circuit to
P0193 Range: G00442->G45703
sensor circuit high input high voltage
FRP sensor to splice in Range: G00442->G45703
sensor ground circuit;
open circuit
FRP sensor failure

circuit; high resistance
Engine oil temperature when hot, intermittent For EOT sensor tests, GO to
P0196 (EOT) sensor high resistance Pinpoint Test G258127p13.
range/performance Check for ECT sensor DTCs.
EOT sensor failure
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ECT sensor malfunction

Engine oil temperature For EOT sensor tests, GO to
P0197 (EOT) sensor low voltage Pinpoint Test G258127p13.
ground
(high oil temperature) Check for ECT sensor DTCs.
EOT sensor failure
Engine oil temperature EOT sensor to ECM sensing For EOT sensor tests, GO to
P0198 (EOT) sensor high voltage circuit; high resistance, Pinpoint Test G258127p13.
(low oil temperature) open circuit or short Check for ECT sensor DTCs.
EOT sensor failure

Check injector connections. For
Injector disconnected injector circuit tests,
Fuel injector circuit Fuel Charging and Controls - VIN
P0201 Injector wiring open or
malfunction, Cyl 1 short circuit Range: G00442->G45703
Injector failure Range: G00442->G45703






TP sensor to ECM sensing For TP sensor tests, GO to

P0222 Throttle position (TP)
circuit (TP2); open Pinpoint Test G258127p5.
sensor circuit 2 (TP2) low
voltage ground or high
resistance
TP sensor failure
Throttle position (TP)
circuit (TP2); short For TP sensor tests, GO to
P0223 sensor circuit 2 (TP2) high
circuit to high voltage Pinpoint Test G258127p5.
voltage
TP sensor failure
circuit faults (cylinder
misfire detected DTCs
also logged)

(injector DTCs also
logged)

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Spark plug
gap Engine For fuel system,
Cylinder compression low Range: G00442->G45703
P0300 Random misfire detected Fuel Charging and Controls - VIN
Fuel delivery pressure Range: G00442->G45703 For
(low/high) ignition system,
Fuel injectors
restricted/leaking G00442->G45703

open
Fuel contamination
Worn camshaft/broken
valve springs

P0301 Misfire detected, Cyl 1 Refer to P0300 possible sources Refer to P0300 Actions
Poor sensor contact with

cylinder block Check KS for correct fitment,
Right-hand knock sensor
REFER to Knock sensor (KS) in
P0327 (KS) sensing circuit out of
KS to ECM sensing circuit; this section. For KS tests, GO to
range (low voltage) short circuit to ground Pinpoint Test G258127p15.
KS failure
cylinder block
Right-hand knock sensor Check KS for correct fitment,
KS to ECM sensing circuit;
P0328 (KS) sensing circuit out of For KS tests, GO to Pinpoint Test
range (high voltage) circuit, short circuit to G258127p15.
high voltage
KS failure
cylinder block
Left-hand knock sensor Check KS for correct fitment,
P0332 (KS) sensing circuit out of For KS tests, GO to Pinpoint Test
KS to ECM sensing circuit;
range (low voltage) short circuit to ground G258127p16.
KS failure
cylinder block
Check KS for correct fitment,
Left-hand knock sensor
KS to ECM sensing circuit; REFER to Knock sensor (KS) in
P0333 (KS) sensing circuit out of
high resistance, open this section. For KS tests, GO to
range (high voltage) circuit, short circuit to Pinpoint Test G258127p16.
high voltage
KS failure
Crankshaft position (CKP) For CKP sensor tests, GO to
P0335 CKP sensor gap
sensor circuit malfunction incorrect/foreign matter Pinpoint Test G258127p17.
on sensor face
CKP sensor sensing circuit;
open circuit, short
CKP sensor failure

CKP sensor reluctor; foreign
matter/damaged teeth
Crankshaft position (CKP) CKP sensor sensing circuit;

P0336 sensor intermittent open
circuit, short circuit to Pinpoint Test G258127p17.
range/performance
high voltage
CKP sensor failure

CMP sensor gap

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incorrect/foreign matter
Right-hand camshaft on sensor face
For CMP sensor tests, GO to
P0340 position (CMP) sensor
circuit malfunction CMP sensor sensing circuit; Pinpoint Test G258127p18.
open circuit, short
CMP sensor failure

CMP sensor gap

Right-hand camshaft on face
CMP sensor sensing circuit Pinpoint Test G258127p18.
range/performance
open circuit, short
CMP sensor failure

Ignition coil primary high resistance
P0351 Engine Ignition - VIN Range:
circuit malfunction, Cyl 1
Ignition coil ground circuit; G00442->G45703
open circuit, high
resistance
high resistance For ignition system tests,
Ignition coil primary
circuit malfunction, Cyl 2 Ignition coil ground circuit; G00442->G45703
open circuit, high
resistance

open circuit, high
resistance

open circuit, high
resistance

open circuit, high
resistance

Ignition coil primary short circuit to ground,
circuit malfunction, Cyl 6 high resistance
G00442->G45703
Ignition coil ground circuit;
open circuit, high
resistance

open circuit, high
resistance

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open circuit, high

resistance

EGR valve incorrectly fitted
or loose
For EGR system information,
Exhaust gas recirculation EGR pipe blocked
P0400 Engine Emission Control - VIN
(EGR) flow malfunction
EGR valve stuck Range: G00442->G45703
open/closed, blocked
EGR valve failure

circuit; open circuit
Exhaust gas recirculation EGR valve to ECM drive For EGR system information,
P0405 (EGR) valve drive circuits circuit pair (EGR valve Engine Emission Control - VIN
low voltage pins 1/4, 6/3); open Range: G00442->G45703
circuit, high resistance
EGR valve failure (stepper

motor open circuit)
EGR valve to ECM drive
circuit pair (EGR valve
Exhaust gas recirculation For EGR system information,
pins 1/4, 6/3); short
P0406 (EGR) valve drive circuits Engine Emission Control - VIN
circuit to ground or high
high voltage voltage Range: G00442->G45703
EGR valve failure (stepper

motor short circuit)
Monitoring conditions
Start engine and bring to

normal operating
temperature
Allow to idle for 2 minutes
Rev engine to between 2500

and 2700 rpm for 5
Catalytic converter failure minutes
Right-hand catalytic
(melted, fractured)
P0420 converter efficiency Drive vehicle for at least 1
below threshold Catalytic converter minute (general
contaminated (sulphur) conditions)
Check for DTCs
Stop the engine
Examine the catalytic converters

for damage/contamination.
Follow the DTC index for any
other codes indicated.
Monitoring conditions
Start engine and bring to

normal operating
temperature
Allow to idle for 2 minutes
Rev engine to between 2500

Catalytic converter failure and 2700 rpm for 5
Left-hand catalytic
(melted, fractured) minutes
P0430 converter efficiency
below threshold Catalytic converter Drive vehicle for at least 1
contaminated (sulphur) minute (general
conditions)
Check for DTCs
Stop the engine
Examine the catalytic converters

for damage/contamination.
Follow the DTC index for any
other codes indicated.
EVAP canister purge pipe

disconnected
EVAP canister vent

Evaporative emissions restricted For EVAP system components,
P0441 system (EVAP) incorrect Evaporative Emissions - VIN
purge flow EVAP canister purge valve to Range: G00442->G45703
engine pipe(s)
disconnected
EVAP canister purge valve

failure
Fuel cap seal defective
EVAP system leak (canister

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damage, pipework
damage)
EVAP canister purge valve to

high resistance

power supply circuit;
Evaporative emissions For EVAP system components,
open circuit, short
P0442 system (EVAP) leak circuit
detected - small (0.040 in) Range: G00442->G45703
engine purge pipe;
disconnected

operating vacuum hose
leak/restriction

failure
Fuel tank leak

Evaporative emissions EVAP canister purge valve to
For EVAP system components,
system (EVAP) canister ECM drive circuit; open
P0443 Evaporative Emissions - VIN
purge valve circuit circuit, short circuit,
high resistance Range: G00442->G45703
malfunction
open circuit, short
circuit

leak/restriction

failure
disconnected
Evaporative emissions
system (EVAP) canister EVAP canister purge valve to
purge valve circuit open ECM drive circuit; open
circuit circuit, high resistance Range: G00442->G45703

failure
Evaporative emissions EVAP canister purge valve to

ECM drive circuit; short For EVAP system components,
system (EVAP) canister
P0445 circuit to ground Evaporative Emissions - VIN
purge valve circuit short
Range: G00442->G45703
circuit EVAP canister purge valve
failure
CCV power supply circuit;
open circuit, short
Evaporative emissions circuit
P0446 CCV to ECM drive circuit; Evaporative Emissions - VIN
close valve (CCV) open circuit, high Range: G00442->G45703
malfunction resistance, short circuit
to B+ voltage
CCV failure
CCV power supply circuit;
open circuit, short
Evaporative emissions circuit
P0447 CCV to ECM drive circuit Evaporative Emissions - VIN
close valve (CCV) circuit open circuit, high Range: G00442->G45703
open circuit resistance, short circuit
to B+ voltage
CCV failure
Evaporative emissions CCV to ECM drive circuit;
P0448 system (EVAP) canister For EVAP system components,
close valve (CCV) circuit
short circuit CCV failure Range: G00442->G45703
FTP sensor disconnected
FTP sensor to ECM sensing

short circuit to B+
voltage
Fuel tank pressure (FTP)
sensor circuit malfunction FTP sensor to splice sensor
supply circuit; open Range: G00442->G45703
FTP sensor to splice ground

high resistance
FTP sensor failure

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FTP sensor disconnected

Fuel tank pressure (FTP) For EVAP system components,
P0452 sensor circuit low voltage Evaporative Emissions - VIN
(low pressure) FTP sensor to splice sensor Range: G00442->G45703
supply circuit; open
FTP sensor failure

FTP sensor to splice sensor
ground circuit; open
Fuel tank pressure (FTP) For EVAP system components,
P0453 sensor circuit high voltage Evaporative Emissions - VIN
(high pressure) circuit; short circuit to Range: G00442->G45703
high voltage
FTP sensor failure

Fuel filler cap missing
Fuel filler cap seal defective

EVAP system leak
P0455 EVAP system leak (canister Evaporative Emissions - VIN
detected - large damage, pipework Range: G00442->G45703
damage)

high resistance

open circuit, short
circuit

engine purge pipe
disconnected

leak/restriction

failure
Fuel tank leak

Fuel cap seal defective
EVAP system leak (canister

damage, pipework
damage)
EVAP purge valve to ECM

drive circuit; open
high resistance
EVAP system leak EVAP purge valve power For EVAP system components,
P0456 detected - very small supply circuit; open Evaporative Emissions - VIN
(0.020) circuit, short circuit Range: G00442->G45703
EVAP purge valve to engine

purge pipe;
restricted/leaking
EVAP purge valve operating

vacuum hose
leak/blockage
EVAP purge valve failure
Fuel tank leak

Fuel level sensor circuit Fuel level sensor to For fuel level sensor circuit tests,
P0460 Fuel Tank and Lines - 4.2L NA V8
range/performance instrument cluster
circuits intermittent - AJV8/4.2L SC V8 - AJV8/3.0L NA
short or open circuit, V6 - AJ27/3.5L NA V8 - AJV8, VIN
Fuel level sensor failure
Instrument cluster fault

(incorrect fuel level
data)
ECM to radiator cooling fan
module drive circuit;
short circuit, open
Radiator cooling fan For radiator cooling fan module
P0480 module drive circuit tests, GO to Pinpoint Test
malfunction Radiator cooling fan fault G258127p19.
Radiator cooling fan module

fault
Check air intake system for
restriction,
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Air intake restriction Intake Air Distribution and

Accessory drive overload
>G45703 Check accessory drive
Idle rpm lower than (defective/siezed
P0506 components,
expected component)
Check throttle body operation,
Throttle valve stuck closed Fuel Charging and Controls - VIN
Range: G00442->G45703
Throttle body failure Fuel Charging and Controls - VIN
Range: G00442->G45703
Inspect air intake system.

Air intake leak between Intake Air Distribution and
MAF sensor and throttle Filtering - VIN Range: G00442-
>G45703 For breather system,
Idle rpm higher than throttle and engine
P0507 Range: G00442->G45703 For
expected
Engine breather leak throttle body,
Throttle valve stuck open Range: G00442->G45703
Throttle assembly failure Range: G00442->G45703
Air conditioning pressure For A/C pressure sensor tests,

Air conditioning pressure sensor disconnected GO to Pinpoint Test
P0532 sensor circuit low voltage G258127p35.
(high pressure) Air conditioning pressure
For sensor supply circuit tests,
sensor to ECM sensing
circuit; open circuit, GO to Pinpoint Test
short circuit to ground G258127p25.
For air conditioning system
Air conditioning pressure information,
sensor to splice sensor Air Conditioning
Air conditioning pressure

sensor failure
Air conditioning pressure
For A/C pressure sensor tests,
sensor to splice sensor
ground circuit; open GO to Pinpoint Test
circuit, high resistance G258127p35.
Air conditioning pressure For sensor ground circuit tests,
P0533 sensor circuit high voltage Air conditioning pressure GO to Pinpoint Test
(low pressure) sensor to ECM sensing G258127p26.
circuit; short circuit to For air conditioning system
high voltage
information,
Air conditioning pressure Air Conditioning
sensor failure
Battery power supply ECM battery power supply For ECM power supply tests, GO
P0560
voltage malfunction open circuit, high to Pinpoint Test G258127p20.
resistance
Speed control switches
internal steering wheel
ground
Steering wheel cassette For speed control tests,

Speed control CANCEL
P0566 reel; short circuit to Speed Control - VIN Range:
switch ON fault ground G00442->G45703
Cassette reel to ECM circuit;

CANCEL switch failure (stuck

ON)
ground For speed control tests,
Speed control RESUME
P0567 Speed Control - VIN Range:
switch ON fault Steering wheel cassette G00442->G45703
reel; short circuit to
ground

RESUME switch failure

(stuck ON)
high resistance
For speed control tests,
Speed control input signal
P0568 Steering wheel cassette Speed Control - VIN Range:
low/high resistance reel; open circuit, high G00442->G45703
resistance

open circuit, high
resistance
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ground
Speed control SET/- Steering wheel cassette
switch ON fault reel; short circuit to
ground G00442->G45703

SET/- switch failure

ground
Steering wheel cassette For speed control tests,

Speed control SET/+
P0570 reel; short circuit to Speed Control - VIN Range:
switch ON fault ground G00442->G45703

SET/+ switch failure (stuck

ON)
Engine control module Contact dealer technical support
P0603 (ECM) keep alive memory for advice on possible ECM
ECM failure
error failure.
P0605 Transmission control For transmission tests,

TCM/Control valve failure
module (TCM) self-test
error
Transmission control
For transmission tests,
P0606 module (TCM) "watch-
dog" circuit malfunction
Transmission control
P0610 module (TCM)
Reconfigure TCM
configuration error
Starter relay drive circuit Starter relay drive circuit;

high voltage/starter relay short circuit to high For starter system tests,
P0617
request on (ignition voltage
switch position III, START)
Sensor supply voltage For transmission tests,
P0641
circuit malfunction TCM/Control valve failure
Pressure regulator and

P0651 shift solenoid supply
circuit malfunction
Substrate temperature TCM/Control valve failure For transmission tests,

P0666
sensor circuit malfunction
ABS system failure
For ABS system tests,
P0701 TCM control errors Anti-Lock Control - Stability
ABS system failure Assist - VIN Range: G00442-
>G45703
Battery power supply fuse

TCM battery power failure
P0702 supply low voltage (short
time) Battery power supply;
intermittent open
circuit
Gear position switch For transmission tests,
P0705
circuit malfunction TCM/Control valve failure
For CAN tests,

TCM/J-Gate module CAN
Gear selector position Communications Network For J-
P0706 fault
plausibility fault Gate module tests,
J-Gate module failure External Controls
Gear selector
For J-Gate module tests,
P0709 intermediate position
fault
Transmission fluid
P0710 temperature sensor
circuit malfunction
For transmission fluid renewal

Transmission fluid
P0711 Transmission fluid burnt and level checking,
temperature range fault (requires replacement)
Turbine speed sensor For transmission tests,

P0715
circuit failure TCM/Control valve failure
Output speed sensor For transmission tests,

P0720
circuit failure TCM/Control valve failure
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Transmission mechanical
Output speed sensor For transmission tests,
P0721 failure
signal gradient fault
Engine over-speed range For CAN tests,
P0725
fault TCM/ECM CAN fault Communications Network

P0729 Sixth gear ratio fault Transmission mechanical
failure

P0730 Gear ratio fault Transmission mechanical
failure

P0731 First gear ratio fault Transmission mechanical
failure

P0732 Second gear ratio fault Transmission mechanical
failure

P0733 Third gear ratio fault Transmission mechanical
failure
P0734 Fourth gear ratio fault failure

P0735 Fifth gear ratio fault failure

P0736 Reverse gear ratio fault Transmission mechanical
failure
Torque converter clutch

pressure regulator For transmission tests,
P0740
solenoid circuit TCM/Control valve failure
malfunction
Torque converter clutch TCM/Control valve failure

P0741 pressure regulator
solenoid stuck open Transmission mechanical
failure
Torque converter clutch
pressure regulator For transmission tests,
P0743
solenoid circuit TCM/Control valve failure
plausibility error
Pressure regulator
P0750 solenoid 1 circuit
malfunction
Pressure regulator
plausibility error
Pressure regulator
malfunction
Pressure regulator
plausibility error
Pressure regulator
malfunction
Pressure regulator
plausibility error
Pressure regulator
malfunction
Pressure regulator
plausibility error
Pressure regulator
malfunction
Pressure regulator
plausibility error

P0780 Gear load fault Transmission mechanical
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failure

P0781 1-2/2-1 Gear load fault Transmission mechanical
failure

failure

failure

failure
Shift solenoid circuit For transmission tests,

P0787
malfunction TCM/Control valve failure
Shift solenoid circuit For transmission tests,

P0788
plausibility error TCM/Control valve failure
For J-Gate module

Gear positions R, D J-Gate incorrectly adjusted
P0825 adjustment/replacement,
plausibility error

P0829 5-6 Gear load fault Transmission mechanical
failure
J-Gate module CAN CAN open circuit fault For CAN tests,
network malfunction. (J- Communications Network For J-
P0860
Gate module/CAN CAN short circuit fault Gate module,
monitored by the ECM) External Controls
J-Gate module failure
Carry out comprehensive
System checks not component monitor drive cycle.
OBD monitors have not
P1000 complete since last Refer to the DTC section of JTIS,
completed
memory clear accessed by the icon on the
opening page.
MAF sensor to ECM sensor

ground circuit; open
Mass air flow (MAF) high voltage, high
For MAF ground tests, GO to
P1104 sensor ground resistance
malfunction
MAF sensor failure

MAP sensor to ECM sensing
circuit; open circuit or
Manifold absolute short circuit to ground
For MAP sensor tests, GO to
P1107 pressure (MAP) sensor
MAP sensor supply circuit Pinpoint Test G258127p33.
sensing circuit low voltage
(to splice) open circuit
MAP sensor failure

MAP sensor ground circuit
Manifold absolute (to splice) open circuit
pressure (MAP) sensor For MAP sensor tests, GO to
P1108 MAP sensor to ECM sensing
sensing circuit high circuit; short circuit to Pinpoint Test G258127p33.
voltage high voltage
MAP sensor failure

System checks complete
P1111 OBD monitors have completed No action necessary.
since last memory clear
APP sensor to ECM sensing

circuit "1"; open circuit,
short circuit to ground For APP 1 sensor tests, GO to
P1122 (APP) sensor circuit low
or high resistance Pinpoint Test G258127p22.
voltage - APP1
APP sensor power supply
high resistance
APP sensor failure

Accelerator pedal position APP sensor to ECM sensing
(APP) sensor circuit high circuit(s) short circuit to
high voltage
voltage - APP1. Note: This For APP 1 sensor tests, GO to
P1123
DTC could be flagged by APP sensor ground circuit(s) Pinpoint Test G258127p22.
both sensor element open circuit
circuits having faults
APP sensor failure
circuit (APP2); open
Accelerator pedal position ground, high resistance
For APP 2 sensor tests, GO to
P1215 (APP) sensor sensing
circuit low voltage - APP2 APP sensor supply circuit (to Pinpoint Test G258127p23.
splice) open circuit, high
resistance
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APP sensor failure

Accelerator pedal position APP sensor to ECM sensing
(APP) sensor sensing circuit(s) short circuit to
circuit high voltage - high voltage
For APP 2 sensor tests, GO to
P1216 APP2. Note: This DTC
could be flagged by both APP sensor ground circuit(s) Pinpoint Test G258127p23.
sensor element circuits (to splice) open circuit
having faults
APP sensor failure
For throttle body,

Throttle control position Throttle motor failure
P1224 Range: G00442->G45703
error
Throttle body failure Fuel Charging and Controls - VIN
Range: G00442->G45703
Throttle motor
disconnected
For throttle motor to ECM circuit
Throttle motor to ECM drive tests, GO to Pinpoint Test
circuits; short circuit or G258127p24.
Throttle motor control open circuit For throttle body,
P1229
circuit malfunction Fuel Charging and Controls - VIN
ECM ground circuit fault(s) Range: G00442->G45703
(PI01-04, 05, 54)
Range: G00442->G45703
Throttle motor failure
Throttle body failure

ECM to fuel pump 2 module For fuel pump 2 module tests,
control drive circuit; Fuel Tank and Lines - 4.2L NA V8
Fuel pump 2 drive circuit
P1233 open circuit, short - AJV8/4.2L SC V8 - AJV8/3.0L NA
fault circuit, high resistance V6 - AJ27/3.5L NA V8 - AJV8, VIN
Range: G00442->G45703
Fuel pump 2 module failure
ECM to rear electronic For fuel pump module tests,
module (REM) drive
No fuel pump commands circuit; open circuit,
P1234 - AJV8/4.2L SC V8 - AJV8/3.0L NA
received by ECM short circuit, high
resistance V6 - AJ27/3.5L NA V8 - AJV8, VIN
Range: G00442->G45703
REM failure
ECM to rear electronic For fuel pump module tests,
module (REM) drive
Fuel pump not activated circuit; open circuit,
P1236 - AJV8/4.2L SC V8 - AJV8/3.0L NA
when requested by ECM short circuit, high
resistance V6 - AJ27/3.5L NA V8 - AJV8, VIN
Range: G00442->G45703
REM failure
voltage circuit(s); short
Sensor power supply For sensor supply tests, GO to
P1240 circuit to ground, short
circuit malfunction circuit to high voltage, Pinpoint Test G258127p25.
open circuit, high
resistance
Sensor power supply ECM to sensors supply For sensor supply tests, GO to
P1241
circuit low voltage voltage circuit(s); short Pinpoint Test G258127p25.
circuit to ground
Sensor power supply voltage circuit(s); open For sensor supply tests, GO to
P1242
circuit high voltage circuit, high resistance, Pinpoint Test G258127p25.
short circuit to high
voltage
Sensor ground circuits ECM to sensors ground For sensor ground tests, GO to
P1243
open circuit circuit; open circuit, Pinpoint Test G258127p26.
high resistance
Ignition switch to ECM
Engine crank signal low For crank signal tests, GO to
P1245 circuit; open circuit
voltage Pinpoint Test G258127p27.
Ignition switch to ECM
Engine crank signal high circuit; short circuit to For crank signal tests, GO to
P1246
voltage high voltage Pinpoint Test G258127p27.

P1250 Throttle valve return INSTALL a new throttle body.
Throttle return spring
spring malfunction failure (throttle body Fuel Charging and Controls - VIN
failure) Range: G00442->G45703
Range: G00442->G45703
Throttle motor relay coil

open circuit
For throttle motor relay tests,
Throttle motor relay OFF Throttle motor relay failure
failure
Throttle motor relay coil to G258127p36.
ECM ground circuit fault

(relay coil drive)
INSTALL a new throttle body,
Throttle Body - 4.2L NA V8 -
Throttle "limp-home" Throttle limp-home spring
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P1254 AJV8/3.5L NA V8 - AJV8, VIN

spring malfunction failure (throttle body
failure) Range: G00442->G45703
(19.70.04)
Security input Invalid ignition key code

malfunction. Note: This
PATS signal to instrument Contact dealer technical support
DTC can only be cleared
P1260 cluster missing or for information on security
following rectification corrupted system.
after an ignition OFF/ON
cycle Security message (PATS)
CAN failure
Misfire rate catalyst
damage, Right-hand
(Note; This DTC will flag
P1313 only when accompanied Refer to P0300 possible sources Refer to P0300 Actions.
by a random or individual
cylinder misfire DTC;
P0300, P0301 to P0308)
Misfire rate catalyst

damage, Left-hand (Note;
This DTC will flag only
P1314 when accompanied by a Refer to P0300 possible sources Refer to P0300 Actions.
random or individual
cylinder misfire DTC;
P0300 to P0308)
Misfire excess emission
(Note; This DTC will flag
only when accompanied
by an individual cylinder
misfire DTC; P0300 to
P0308)
REM to fuel pump drive

circuit; open circuit, For fuel pump module tests,
short circuit, high Fuel Tank and Lines - 4.2L NA V8
Fuel pump drive circuit
P1338 resistance - AJV8/4.2L SC V8 - AJV8/3.0L NA
low/high voltage
V6 - AJ27/3.5L NA V8 - AJV8, VIN
REM failure Range: G00442->G45703
Fuel pump failure

Fuel pump 2 module to fuel
pump drive circuit; open
high resistance For fuel pump 2 module tests,
Fuel pump 2 drive circuit Fuel pump 2 module to ECM
P1339 - AJV8/4.2L SC V8 - AJV8/3.0L NA
low/high voltage monitor circuit; open
circuit, short circuit, V6 - AJ27/3.5L NA V8 - AJV8, VIN
Fuel pump 2 module failure
Fuel pump 2 failure

CMP sensor gap

Left-hand camshaft on sensor face
P1340 position sensor (CMP)
sensor circuit malfunction CMP sensor sensing circuit; Pinpoint Test G258127p28.
open circuit, short
CMP sensor failure

Left-hand camshaft CMP sensor gap

incorrect/foreign matter For CMP sensor tests, GO to
on sensor face Pinpoint Test G258127p28.
range/performance
CMP sensor sensing circuit
open circuit, short
CMP sensor failure

circuits; short circuit, For APP sensor sensing circuit
open circuit, high tests, GO to Pinpoint Test
(APP) sensor sensing APP sensor supply circuits;
P1344 G258127p23.
circuits short circuit, open
range/performance circuit, high resistance For sensor ground tests, GO to
APP sensor ground circuits; For sensor supply tests, GO to
open circuit Pinpoint Test G258127p25.
APP sensor failure

between splice and
ECM; open circuit, short
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Right-hand cylinders circuit to ground or

ignition monitor fault short circuit to B+
voltage G00442->G45703
Ignition coil ground circuit

fault
between splice and
ECM; open circuit, short
Left-hand cylinders circuit to ground or
ignition monitor fault short circuit to B+
voltage G00442->G45703
Ignition coil ground circuit

fault
VCT solenoid to ECM PWM
drive circuit fault
VCT solenoid ground circuit

fault Check oil condition; For VCT
Right-hand variable
solenoid tests, GO to Pinpoint
camshaft timing (VCT) oil
P1384 VCT solenoid failure Test G258127p29.
control solenoid
malfunction Oil contamination Engine
VCT oil flow fault
VCT/camshaft mechanical
failure
VCT solenoid to ECM PWM
drive circuit fault
VCT solenoid ground circuit

fault Check oil condition; For VCT
Left-hand variable
solenoid tests, GO to Pinpoint
camshaft timing (VCT) oil
P1396 VCT solenoid failure Test G258127p30.
control solenoid
malfunction Oil contamination Engine
VCT oil flow fault
VCT/camshaft mechanical
failure
ECM to air cleaner solenoid
circuit; open circuit, For air cleaner solenoid circuit
Air cleaner solenoid valve
P1410 short circuit, high tests, GO to Pinpoint Test
drive circuit malfunction resistance G258127p38.
Air cleaner solenoid failure

For Intercooler coolant pump
Intercooler coolant pump
P1474 Intercooler coolant pump circuit tests, GO to Pinpoint Test
malfunction failure G258127p39.
ECM P/N circuit; short

circuit to high voltage,
high resistance
For P/N circuit tests and gear
Gear change Gear selector cable selector cable/J-Gate module
P1516 PARK/NEUTRAL driving adjustment incorrect adjustment,
malfunction External Controls For CAN tests,
J-Gate module adjustment Communications Network
incorrect
J-Gate module/ECM CAN

fault
ECM P/N circuit; short
resistance
For P/N circuit tests and gear
Gear change Gear selector cable selector cable/J-Gate module
P1517 PARK/NEUTRAL starting adjustment incorrect adjustment,
malfunction External Controls For CAN tests,
J-Gate module adjustment Communications Network
incorrect
J-Gate module/ECM CAN

fault
Brake ON/OFF switch to
ECM circuit; open
Brake ON/OFF switch power

Brake ON/OFF switch; circuit
brake CANCEL switch
malfunction. (Note: Brake Brake ON/OFF switch failure
ON/OFF switch - normally
Brake CANCEL switch to G00442->G45703
open; brake CANCEL
ECM circuit; open
switch - normally closed)
Brake CANCEL switch power

circuit
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Brake CANCEL switch failure

"Flight recorder" data is
stored if any one of five
conditions occur
Inertia switch If none of the five conditions

activated occur, check:
Check the five conditions, for
P1582 Throttle limp-home Inertia switch to ECM inertia switch circuit tests, GO to
mode activated circuit; short circuit to Pinpoint Test G258127p31.
B+ voltage
Engine starts and
stumbles Inertia switch failure
Engine fails to start
Engine stall
TCM internal For transmission tests,
P1603
communications error TCM/Control valve failure
Battery power supply

circuit; open circuit, For transmission tests,
P1605 TCM RAM error short circuit to ground

Engine management
ECM control relay failure For EMS control relay tests, GO
P1606 system (EMS) control
relay malfunction ECM control relay to ECM
circuit fault
ECM control relay coil

power supply open
circuit
ECM ground circuit fault

(relay coil drive)
ECM microprocessor-to- Contact dealer technical support
P1609 microprocessor for advice on possible ECM
ECM failure
communication failure failure.

P1611 ECM sub CPU failure for advice on possible ECM
ECM failure
failure.

open circuit
P1631 Throttle motor relay failure GO to Pinpoint Test
drive circuit OFF failure
G258127p36.
Throttle motor relay coil to
ECM drive circuit open
ground
ECM to generator
Generator charge system CHARGE/FAULT circuit;
short circuit, open
failure/generator For charging system tests,
CHARGE/FAULT circuit Generator
failure Generator regulator failure
Generator failure
P1633 ECM main CPU failure for advice on possible ECM
ECM failure
failure.

Throttle "watchdog"
P1634 for advice on possible ECM
circuit malfunction ECM failure
failure.
CAN open circuit fault - For CAN tests,

CAN ECM to DSCCM DSCCM to ECM Communications Network
P1637
network malfunction Contact dealer technical support
CAN short circuit fault
for advice on possible ECM
DSCCM failure failure.
ECM failure
CAN open circuit fault - IC to
ECM For CAN tests,
CAN ECM/IC network
P1638 CAN short circuit fault Contact dealer technical support
malfunction
IC failure failure.
ECM failure
For CAN tests,
P1642 CAN circuit malfunction Control module failure -
check for additional Communications Network
logged DTCs to locate
control module source
CAN open circuit fault - TCM For CAN tests,
to ECM
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Communications Network For

CAN ECM/TCM network transmission tests,
P1643 CAN short circuit fault
malfunction Contact dealer technical support
TCM failure for advice on possible ECM
failure.
ECM failure
HO2S heater failure For HO2S tests, GO to Pinpoint
Test G258127p6.
HO2S sensing circuit; short and GO to Pinpoint Test
Right-hand ECM HO2S circuit to ground, short
P1646 G258127p7.
control malfunction circuit to high voltage,
open circuit, high Contact dealer technical support
resistance for advice on possible ECM
failure.
ECM failure
HO2S heater failure
For HO2S tests, and GO to
HO2S sensing circuit; short Pinpoint Test G258127p11.
Left-hand ECM HO2S circuit to ground, short
P1647 Contact dealer technical support
control malfunction circuit to high voltage,
open circuit, high for advice on possible ECM
resistance failure.
ECM failure
ECM internal KS CPU self-
test failure ECM failure
failure.
TP sensor amplifier circuit
malfunction ECM failure
failure.

drive circuit ON failure Throttle motor relay coil to
ECM drive circuit; short G258127p36.
Throttle motor relay ON
failure Throttle motor relay coil to
ECM drive circuit; short G258127p36.
CAN open circuit fault -
ASCCM to ECM For CAN tests,
CAN ECM/ASCCM
network malfunction
ASCCM failure failure.
ECM failure
ground
Adaptive speed control Steering wheel cassette For speed control system,
P1697 HEADWAY switch(es) reel; short circuit to Speed Control - VIN Range:
circuit malfunction ground G00442->G45703

HEADWAY +/ - switch(es)
failure (stuck ON)
CAN open circuit fault -
A/CCM to ECM For CAN tests,
CAN ECM/A/CCM
network malfunction
A/CCM failure failure.
ECM failure
CAN TCM/J-Gate module CAN open circuit fault - TCM For CAN tests,
P1774 Communications Network For J-
network malfunction to J-Gate module
Gate module,
CAN short circuit fault External Controls
J-Gate module failure

Transmission fluid level low
Transmission fluid cooler

circuit;
Transmission over- obstructed/leaking For transmission information,
P1783
temperature shut-down
Transmission fluid cooler
fins blocked by debris
failure
Ignition switched power
supply fuse failure
TCM ignition switched
P1794 power supply circuit
Ignition switched power
malfunction supply circuit; short
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circuit to ground, open

circuit
For CAN tests,
CAN open circuit or short
Communications Network For
P1796 CAN network fault circuit fault
transmission tests,

to ECM Communications Network For
CAN TCM/ECM network transmission tests,
ECM failure for advice on possible ECM
failure
to IC Communications Network For
CAN TCM/IC network transmission tests,
IC failure for advice on possible ECM
failure
CAN TCM/DSCCM to DSCCM Communications Network For
P1799
network malfunction transmission tests,
DSCCM failure
Pinpoint Tests

P0101, P0102, P0103; MASS AIR FLOW
(MAF) SENSOR CIRCUIT
RANGE/PERFORMANCE, HIGH/LOW
VOLTAGE
RESISTANCE
Disconnect the MAF sensor electrical connector, PI14. 4. Measure the resistance between PI01, pin
44 (GW) and PI14, pin 03 (GW).
-> Yes
-> No
G258127t2 : CHECK THE MAF SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between the MAF sensor electrical connector, PI14, pin 03 (GW) and GROUND.
-> Yes
REPAIR the short circuit to high voltage. For additional information, refer to the wiring diagrams.
CLEAR the DTC. TEST the system for normal operation.
-> No
G258127t3 : CHECK THE MAF SENSOR SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI14, pin 03 (GW)
and GROUND.
-> Yes
DTC. TEST the system for normal operation
-> No
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1. Reconnect the ECM electrical connector, PI01. 2. Turn the ignition switch to the ON position. 3.
Measure the voltage between the MAF sensor electrical connector, PI14, pin 01 (GU) and GROUND.
-> Yes
Mass Air Flow (MAF) Sensor (18.30.15) CLEAR the DTC. TEST the system for normal operation.
-> No
REPAIR the circuit between the MAF sensor electrical connector, PI14, pin 01 (GU) and BATTERY. This
circuit includes the EMS control relay, fuse 14 of the front power distribution box, and the high
power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC.

P0111, P0112, P0113; INTAKE AIR
TEMPERATURE (IAT) SENSOR
CIRCUIT RANGE/PERFORMANCE,
HIGH/LOW VOLTAGE
RESISTANCE
Disconnect the MAF sensor electrical connector, PI14. 4. Measure the resistance between PI01, pin
71 (U) and PI14, pin 04 (U).
-> Yes
-> No
G258127t6 : CHECK THE IAT SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between PI14, pin 04 (U) and GROUND.
-> Yes
-> No
G258127t7 : CHECK THE IAT SENSOR SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI14, pin 04 (U)
and GROUND.
-> Yes
REPAIR the short circuit to GROUND. For additional information, refer to the wiring diagrams. CLEAR
the DTC. TEST the system for normal operation.
-> No
P0116*, P0117, P0118, P0125; ENGINE
SENSOR CIRCUIT
VOLTAGE
RESISTANCE
Disconnect the ECT sensor electrical connector, PI25. 4. Measure the resistance between PI01, pin 70
(UY) and PI25, pin 02 (UY).
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-> Yes
-> No
G258127t9 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between PI25, pin 02 (UY) and GROUND.
-> Yes
-> No
G258127t10 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT TO
GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI25, pin 02 (UY)
and GROUND.
-> Yes
-> No
Engine Coolant Temperature (ECT) Sensor - 4.2L NA V8 - AJV8 (18.30.10) CLEAR the DTC. TEST the

P0121, P0122, P0123; THROTTLE
POSITION (TP) SENSOR
VOLTAGE
RESISTANCE
Disconnect the TP sensor electrical connector, PI26. 4. Measure the resistance between PI01, pin 75
(R) and PI26, pin 03 (R).
-> Yes
-> No
G258127t12 : CHECK THE TP SENSOR SENSING CIRCUIT TP1 FOR SHORT TO
HIGH VOLTAGE
Measure the voltage between PI26, pin 03 (R) and GROUND.
-> Yes
-> No
G258127t13 : CHECK THE TP SENSOR SENSING CIRCUIT TP1 FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI26, pin 03 (R)
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and GROUND.
-> Yes
-> No
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G00442->G45703 (19.70.04) CLEAR

P0222, P0223; THROTTLE POSITION
(TP) SENSOR CIRCUIT TP2 HIGH/LOW
VOLTAGE
G258127t14 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the TP sensor electrical connector, PI26. 3.
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI01, pin 76 (Y)
and PI26, pin 02 (Y).
-> Yes
-> No
G258127t15 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between PI26, pin 02 (Y) and GROUND.
-> Yes
-> No
G258127t16 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR SHORT TO

GROUND
1. Measure the resistance between PI26, pin 02 (Y) and GROUND.
-> Yes
-> No

P0131, P0132, P0133, P1646; RIGHT-
HAND H02S SENSING CIRCUIT
LOW/HIGH CURRENT, SLOW
RESPONSE, ECM CONTROL
MALFUNCTION
1. Disconnect the battery negative terminal. 2. Disconnect the H02S electrical connector, PI10. 3.
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI10, pin 03 (R)
and PI01, pin 83 (R).
-> Yes
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-> No
G258127t18 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO HIGH

VOLTAGE
Measure the voltage between PI01, pin 83 (R) and GROUND.
-> Yes
-> No
G258127t19 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI01, pin 83 (R)
and GROUND.
-> Yes
-> No

1. Measure the resistance between PI10, pin 04 (Y) and PI01, pin 84 (Y).
-> Yes
-> No
G258127t21 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO HIGH

VOLTAGE
1. Measure the voltage between PI10, pin 04 (Y) and GROUND.
-> Yes
-> No

GROUND
1. Measure the resistance between PI10, pin 04 (Y) and GROUND.
-> Yes
-> No
INSTALL a new H02S.
CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, contact dealer
technical support for advice on possible ECM failure.
P0031, P0032; RIGHT-HAND H02S
HEATER CONTROL CIRCUIT
HIGH/LOW CURRENT
1. Disconnect the H02S electrical connector, PI10. 2. Turn the ignition switch to the ON position. 3.
Make sure the O2S heater relay is engaged. 4. Measure the voltage between PI10, pin 01 (WG) and
GROUND.
-> Yes
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-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the HO2S heater relay, fuse
34 of the front power distribution box, and the high power protection module. For additional

HIGH RESISTANCE
Measure the resistance between PI01, pin 01 (RU) and PI10, pin 02 (RU). 4. Measure the resistance
between PI01, pin 02 (RU) and EM21, pin 02 (RU).
-> Yes
-> No

Measure the voltage between PI10, pin 02 (RU) and GROUND.
-> Yes
-> No

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI10, pin 02 (RU)
and GROUND.
-> Yes
-> No
INSTALL a new H02S.

P0137, P0138, P0140; RIGHT-HAND
CATALYST MONITOR SENSOR
SENSING CIRCUIT LOW/HIGH
VOLTAGE, NO ACTIVITY
FOR HIGH RESISTANCE
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI11, pin 04 (N)
and PI01, pin 128 (N).
-> Yes
-> No

FOR SHORT TO HIGH VOLTAGE
Measure the voltage between PI11, pin 04 (N) and GROUND.
-> Yes
-> No
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FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI11, pin 04 (N)
and GROUND.
-> Yes
-> No

FOR HIGH RESISTANCE
1. Measure the resistance between PI11, pin 03 (B) and PI01, pin 130 (BW).
-> Yes
-> No

P0037, P0038; RIGHT-HAND CATALYST
MONITOR SENSOR HEATER CONTROL
CIRCUIT LOW/HIGH RESISTANCE
G258127t31 : CHECK THE POWER SUPPLY TO THE CATALYST MONITOR
HEATER
1. Disconnect the catalyst monitor sensor electrical connector, PI11. 2. Turn the ignition switch to the
ON position. 3. Make sure the O2S heater relay is engaged. 4. Measure the voltage between PI11, pin
01 (WG) and GROUND.
-> Yes
-> No
REPAIR the power supply circuit to the catalyst monitor sensor heater. This circuit includes the heater
relay, fuse 34 of the front power distribution box, and the high power protection module. For
operation.

FOR HIGH RESISTANCE
Measure the resistance between PI11, pin 02 (UY) and PI01, pin 92 (UY).
-> Yes
-> No
P0151, P0152, P0153; LEFT-HAND H02S
CURRENT, SLOW RESPONSE, ECM
CONTROL MALFUNCTION
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI12, pin 03 (G)
and PI01, pin 107 (G).
-> Yes
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-> No
G258127t34 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO HIGH

VOLTAGE
Measure the voltage between PI12, pin 03 (G) and GROUND.
-> Yes
-> No
G258127t35 : CHECK THE H02S VARIABLE CIRCUIT FOR SHORT TO GROUND

1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI12, pin 03 (G)
and GROUND.

-> Yes
-> No

1. Measure the resistance between PI12, pin 04 (N) and PI01, pin 108 (N).
-> Yes
-> No
G258127t37 : CHECK THE H02S CONSTANT CIRCUIT FOR SHORT TO HIGH

VOLTAGE
1. Measure the voltage between PI12, pin 04 (N) and GROUND.
-> Yes
-> No

GROUND
1. Measure the resistance between PI12, pin 04 (N) and GROUND.
-> Yes
-> No
INSTALL a new H02S.

P0051, P0052; LEFT-HAND H02S
HIGH/LOW CURRENT
1. Disconnect the H02S electrical connector, PI12. 2. Turn the ignition switch to the ON position. 3.
Measure the voltage between PI12, pin 01 (WR) and GROUND.

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-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the heater relay, fuse 33 of
the front power distribution box, and the high power protection module. For additional information,

HIGH RESISTANCE
Measure the resistance between PI12, pin 02 (RW) and PI01, pin 55 (RW). 4. Measure the resistance
between PI12, pin 02 (RW) and PI01, pin 56 (RW).
-> Yes
-> No
Measure the voltage between PI12, pin 02 (RW) and GROUND.
-> Yes
-> No

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI12, pin 02 (RW)
and GROUND.
-> Yes
-> No
INSTALL a new H02S.

P0057, P0058; LEFT-HAND CATALYST
MONITOR SENSOR HEATER CONTROL
CIRCUIT LOW/HIGH RESISTANCE
SENSOR HEATER
1. Disconnect the catalyst monitor sensor electrical connector, PI13. 2. Turn the ignition switch to the
ON position. 3. Make sure the O2S heater relay is engaged. 4. Measure the voltage between PI13, pin
01 (WR) and GROUND.
-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the heater relay, fuse 33 of
the front power distribution box, and the high power protection module. For additional information,

Measure the resistance between PI13, pin 02 (RW) and PI01, pin 93 (RW).

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-> Yes
-> No

P0196, P0197, P0198; ENGINE OIL
TEMPERATURE (EOT) SENSOR
VOLTAGE
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the EOT sensor electrical connector, PI24.
3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI24, pin 01 (Y)

-> Yes
-> No
G258127t46 : CHECK THE EOT SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
-> Yes
-> No
G258127t47 : CHECK THE EOT SENSOR SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI24, pin 01 (Y)
and GROUND.
-> Yes
-> No

RESISTANCE
1. Measure the resistance between PI24, pin 02 (BG) and PI01, pin 19 (BG).
-> Yes
REPAIR the high resistance circuit. This circuit includes harness splices, PIS1 and EMS2. For additional
-> No

P0157, P0158, P0160; LEFT-HAND
CATALYST MONITOR SENSOR
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FOR HIGH RESISTANCE

1. Disconnect the battery negative terminal. 2. Disconnect the catalyst monitor sensor electrical
connector, PI13. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance
between PI13, pin 04 (N) and PI01, pin 129 (N).
-> Yes
-> No

-> Yes
-> No

FOR SHORT TO GROUND
and GROUND.
-> Yes
-> No

FOR OPEN CIRCUIT
-> Yes
REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
-> No

P0327, P0328; RIGHT-HAND KNOCK
SENSOR (KS) HIGH/LOW VOLTAGE
1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI20. 3.

-> Yes
-> No
G258127t54 : CHECK KS SENSING CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3.
-> Yes
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-> No
G258127t55 : CHECK KS SENSING CIRCUIT FOR SHORT TO GROUND

and GROUND.
-> Yes
-> No

1. Measure the resistance between PI20, pin 01 (B) and PI01, pin 100 (BG).
-> Yes
-> No
INSTALL a new KS.

P0332, P0333; LEFT-HAND KNOCK
SENSOR (KS) HIGH/LOW VOLTAGE
1. Disconnect the battery negative terminal. 2. Disconnect the KS electrical connector, PI19. 3.
-> Yes
-> No
G258127t58 : CHECK KS SENSING CIRCUIT FOR SHORT TO HIGH VOLTAGE

1. Turn the ignition switch to the ON position. 2. Reconnect the battery negative terminal. 3.
-> Yes
-> No
G258127t59 : CHECK KS SENSING CIRCUIT FOR SHORT TO GROUND

and GROUND.
-> Yes
-> No

1. Measure the resistance between PI19, pin 02 (B) and PI01, pin 100 (BG).
-> Yes
-> No
INSTALL a new KS.
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P0335, P0336; CRANKSHAFT POSITION
(CKP) SENSOR CIRCUIT
RANGE/PERFORMANCE, CIRCUIT
MALFUNCTION
1. Turn the ignition switch to the OFF position. 2. Check the CKP sensor for correct installation.
-> Yes
-> No
Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.


-> Yes
-> No
Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.

RESISTANCE
Disconnect the CKP sensor electrical connector, PI21. 4. Measure the resistance between PI21, pin 02
(O) and PI01, pin 36 (O).
-> Yes
-> No
G258127t64 : CHECK THE CKP SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between PI21, pin 02 (O) and GROUND.
-> Yes
-> No
G258127t65 : CHECK THE CKP SENSOR SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI21, pin 02 (O)
and GROUND.

-> Yes
-> No

RESISTANCE
1. Measure the resistance between PI21, pin 01 (B) and PI01, pin 37 (B).
-> Yes
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-> No

P0340, P0341; RIGHT-HAND CAMSHAFT
POSITION (CMP) SENSOR CIRCUIT
MALFUNCTION
1. Turn the ignition switch to the OFF position. 2. Check the CMP sensor for correct installation.
-> Yes
-> No
-> Yes
-> No

RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the CMP sensor electrical connector, PI23.
3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI23, pin 02 (Y)
-> Yes
-> No
G258127t70 : CHECK THE CMP SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
-> Yes
-> No
GROUND
and GROUND.
-> Yes
-> No

RESISTANCE
1. Measure the resistance between PI23, pin 01 (R) and PI01, pin 95 (R).
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-> Yes
-> No

P0480; RADIATOR COOLING FAN
MODULE DRIVE CIRCUIT
MALFUNCTION
1. Disconnect the fan module electrical connector, GC04. 2. Measure the voltage between GC04 (NG)
and GROUND.
-> Yes
front power distribution box (80A), and the high power protection module. For additional
-> No
Reconnect electrical connector, GC04. GO to Pinpoint Test G258127t74.
G258127t74 : CHECK THE RADIATOR FAN MODULE GROUND

1. Disconnect the fan module electrical connector, GCU03. 2. Measure the resistance between
GCU03 (B) and GROUND.
-> Yes
-> No
Reconnect electrical connector, GCU03. GO to Pinpoint Test G258127t75.

1. Disconnect the fan module electrical connector, GC01. 2. Turn the ignition switch to the ON
position. 3. Make sure the EMS relay is engaged. 4. Measure the voltage between GC01, pin 02 (GU)
and GROUND.
-> Yes
REPAIR the circuit between the cooling fan module and battery. This circuit includes the front power
distribution box, (fuse 14) the EMS control relay, and the high power protection module. For
operation.
-> No
G258127t76 : CHECK THE ECM TO RADIATOR FAN MODULE CIRCUIT FOR

HIGH RESISTANCE
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between GC01, pin 01
(WU) and PI01, pin 51 (W).

-> Yes
-> No

Measure the voltage between GC01, pin 01 (WU) and GROUND.
-> Yes
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-> No

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between GC01, pin 01 (WU)
and GROUND.
-> Yes
-> No
INSTALL a new radiator cooling fan module. CLEAR the DTC. TEST the system for normal operation.

P0560; BATTERY POWER SUPPLY
VOLTAGE MALFUNCTION
1. Disconnect the ECM electrical connector, PI01. 2. Measure the voltage between PI01, pin 22 (NR)
and GROUND.
-> Yes
Recheck the DTCs.
-> No
box, and the high power protection module. For additional information, refer to the wiring diagrams.

P1104; MASS AIR FLOW (MAF) SENSOR
GROUND MALFUNCTION
G258127t80 : CHECK THE MAF SENSOR GROUND
1. Disconnect the MAF sensor electrical connector, PI14. 2. Turn the ignition switch to the ON
position. 3. Measure the resistance between PI14, pin 02 (BK) and GROUND.
-> Yes
-> No

RESISTANCE
Measure the resistance between PI14, pin 02 (BK) and PI01, pins 45 and 46 (BK).
-> Yes
-> No
G258127t82 : CHECK THE MAF SENSOR GROUND CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between PI14, pin 02 (BK) and GROUND.
-> Yes
-> No
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P1122, P1123*; ACCELERATOR PEDAL
POSITION (APP) SENSOR SENSING
CIRCUIT 1 HIGH/LOW VOLTAGE
RESISTANCE
Disconnect the APP sensor electrical connector, CR14. 4. Measure the resistance between CR14, pin
01 (Y) and PI01, pin 103 (Y).
-> Yes
-> No
G258127t84 : CHECK THE APP SENSOR SENSING CIRCUIT FOR SHORT TO
HIGH VOLTAGE
Measure the voltage between CR14, pin 01 (Y) and GROUND.
-> Yes
-> No

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between CR14, pin 01 (Y)
and GROUND.
-> Yes
-> No

Measure the voltage between CR14, pin 02 (OY) and GROUND.
-> Yes
-> No
Accelerator Pedal (19.20.01) CLEAR the DTC. TEST the system for normal operation.
G258127t87 : CHECK THE APP SENSOR SUPPLY VOLTAGE CIRCUIT FOR
HIGH RESISTANCE
1. Turn the ignition switch to the OFF position. 2. Disconnect the ECM electrical connector, PI01. 3.
Measure the resistance between PI01, pin 12 (OY) and CR14, pin 02 (OY).
-> Yes
-> No
Check the ECM power supplies (recheck DTCs. P1104 may be flagged).

P1215, P1216*; ACCELERATOR PEDAL
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POSITION (APP) SENSOR SENSING

CIRCUIT 2 HIGH/LOW VOLTAGE
G258127t88 : CHECK THE APP SENSOR SENSING CIRCUIT FOR HIGH
RESISTANCE
Disconnect the APP sensor electrical connector, CR14. 4. Measure the resistance between CR14, pin
04 (R) and PI01, pin 102 (R).
-> Yes
-> No

HIGH VOLTAGE
Measure the voltage between CR14, pin 04 (R) and GROUND.

-> Yes
-> No

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between CR14, pin 04 (R)
and GROUND.
-> Yes
-> No

Measure the voltage between CR14, pin 05 (Y) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
Measure the resistance between CR14, pin 05 (Y) and PI01, pin 13 (Y).
-> Yes
-> No

P1229; THROTTLE MOTOR CONTROL
CIRCUIT MALFUNCTION
G258127t93 : CHECK THE THROTTLE MOTOR - TO ECM CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the throttle motor electrical connector,
PI18. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI18, pin
01 (GW) and PI01, pin 80 (GW).
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-> Yes
-> No
G258127t94 : CHECK THE THROTTLE MOTOR + TO ECM CIRCUIT FOR HIGH

RESISTANCE
1. Measure the resistance between PI18, pin 02 (RW) and PI01, pin 106 (RW).
-> Yes
-> No

P1240, P1241, P1242; SENSOR SUPPLY
VOLTAGE MALFUNCTION, HIGH/LOW
VOLTAGE
G258127t95 : CHECK THE SUPPLY VOLTAGE AT THE APP SENSOR
1. Disconnect the APP sensor electrical connector, CR14. 2. Turn the ignition switch to the ON
position. 3. Measure the voltage between CR14, pin 02 (OY) and GROUND.
-> Yes
-> No

HIGH RESISTANCE
1. Disconnect the ECM electrical connector, PI01. 2. Measure the resistance between CR14, pin 02
(OY) and PI01, pin 12 (OY).
-> Yes
-> No

1. Turn the ignition switch to the ON position. 2. Measure the voltage between CR14, pin 02 (OY) and
GROUND.
-> Yes
-> No

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between CR14, pin 02 (OY)
and GROUND.
-> Yes
-> No
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G258127t99 : CHECK THE SUPPLY VOLTAGE AT THE TP SENSOR

1. Disconnect the throttle position sensor electrical connector, PI26. 2. Turn the ignition switch to the
ON position. 3. Measure the voltage between PI26, pin 04 (OY) and GROUND.
-> Yes
-> No
G258127t100 : CHECK THE TP SENSOR SUPPLY VOLTAGE CIRCUIT FOR

HIGH RESISTANCE
Measure the resistance between PI26, pin 04 (OY) and PI01, pin 12 (OY).
-> Yes
-> No
1. Turn the ignition switch to the ON position. 2. Measure the voltage between PI26, pin 04 (OY) and
GROUND.
-> Yes
-> No

SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI26, pin 04 (OY)
and GROUND.
-> Yes
-> No
G258127t103 : CHECK THE SUPPLY VOLTAGE AT THE FUEL TANK PRESSURE

SENSOR
1. Disconnect the fuel tank pressure sensor electrical connector, FP01. 2. Reconnect the ECM
electrical connector, PI01. 3. Turn the ignition switch to the ON position. 4. Measure the voltage
between FO01, pin 03 (OY) and GROUND.
-> Yes
-> No
G258127t104 : CHECK THE FUEL TANK PRESSURE SENSOR SUPPLY
VOLTAGE CIRCUIT FOR HIGH RESISTANCE
-> Yes
-> No

VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Turn the ignition switch to the ON position. 2. Measure the voltage between FP01, pin 03 (OY) and
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GROUND.
-> Yes
-> No

VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between FP01, pin 03 (OY)
and GROUND.
-> Yes
-> No
G258127t107 : CHECK THE SUPPLY VOLTAGE AT THE MANIFOLD ABSOLUTE
PRESSURE SENSOR
1. Disconnect the MAP sensor electrical connector, PI29. 2. Reconnect the ECM electrical connector,
PI01. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between PI29, pin 02
(OY) and GROUND.
-> Yes
-> No
G258127t108 : CHECK THE MANIFOLD ABSOLUTE PRESSURE SENSOR

SUPPLY VOLTAGE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connector, PI01. 2. Measure the resistance between PI29, pin 02
-> Yes
-> No

SUPPLY VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
GROUND.
-> Yes
-> No
SUPPLY VOLTAGE CIRCUIT FOR SHORT TO GROUND
and GROUND.
-> Yes
-> No
G258127t111 : CHECK THE SUPPLY VOLTAGE AT THE FUEL RAIL PRESSURE

(FRP) SENSOR
1. Disconnect the FRP sensor electrical connector, PI28. 2. Reconnect the ECM electrical connector,
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PI01. 3. Turn the ignition switch to the ON position. 4. Measure the voltage between PI28, pin 01
(OY) and GROUND.
-> Yes
-> No
G258127t112 : CHECK THE FUEL RAIL PRESSURE (FRP) SENSOR SUPPLY

VOLTAGE CIRCUIT FOR HIGH RESISTANCE
-> Yes
-> No
VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
GROUND.
-> Yes
-> No

VOLTAGE CIRCUIT FOR SHORT TO GROUND
and GROUND.
-> Yes
-> No
Check for DTCs relating to individual sensors, and/or sensor GROUND. Carry out pinpoint tests for
sensors indicated.

P1243; SENSOR GROUND CIRCUITS
OPEN CIRCUIT
G258127t115 : CHECK THE SENSOR GROUND AT THE THROTTLE POSITION
(TP) SENSORS
1. Disconnect the throttle sensor electrical connector, PI26. 2. Measure the resistance between PI26,
pin 01 (BG) and GROUND.
-> Yes
-> No
G258127t116 : CHECK THE THROTTLE POSITION (TP) SENSOR GROUND

(BG) and PI01, pin 19 (BG).
-> Yes
-> No
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G258127t117 : CHECK THE SENSOR GROUND AT THE ACCELERATOR PEDAL

POSITION (APP) SENSOR
1. Disconnect the APP sensor electrical connector, CR14. 2. Reconnect the ECM electrical connector,
PI01. 3. Measure the resistance between CR14, pin 06 (BG) and GROUND.
-> Yes
-> No
G258127t118 : CHECK THE ACCELERATOR PEDAL POSITION (APP) SENSOR

1. Disconnect the ECM electrical connector, PI01. 2. Measure the resistance between CR14, pin 06
-> Yes
-> No
G258127t119 : CHECK THE SENSOR GROUND AT THE FUEL TANK PRESSURE

(FTP) SENSOR
1. Disconnect the FTP sensor electrical connector, FP01. 2. Reconnect the ECM electrical connector,
PI01. 3. Measure the resistance between FP01, pin 01 (BG) and GROUND.
-> Yes
-> No
G258127t120 : CHECK THE FUEL TANK PRESSURE (FTP) SENSOR GROUND

-> Yes
-> No
G258127t121 : CHECK THE SENSOR GROUND AT THE ENGINE COOLANT

TEMPERATURE (ECT) SENSOR
1. Reconnect the ECM electrical connector, PI01. 2. Disconnect the ECT sensor electrical connector,
PI25. 3. Measure the resistance between PI25, pin 01 (BG) and GROUND.
-> Yes
-> No
G258127t122 : CHECK THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR

-> Yes
-> No
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G258127t123 : CHECK THE SENSOR GROUND AT THE MANIFOLD ABSOLUTE

PRESSURE (MAP) SENSOR
1. Disconnect the MAP sensor electrical connector, PI29. 2. Reconnect the ECM electrical connector,
-> Yes
-> No
G258127t124 : CHECK THE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

-> Yes
-> No
G258127t125 : CHECK THE SENSOR GROUND AT THE FUEL TEMPERATURE

(FT) SENSOR
1. Disconnect the FT sensor electrical connector, IL09. 2. Reconnect the ECM electrical connector,
PI01. 3. Measure the resistance between IL09, pin 02 (BG) and GROUND.
-> Yes
-> No
G258127t126 : CHECK THE FUEL TEMPERATURE (FT) SENSOR GROUND

1. Disconnect the ECM electrical connector, PI01. 2. Measure the resistance between IL09, pin 02
-> Yes
-> No
G258127t127 : CHECK THE SENSOR GROUND AT THE FUEL RAIL PRESSURE

(FRP) SENSOR
1. Disconnect the FRP sensor electrical connector, IL12. 2. Reconnect the ECM electrical connector,
PI01. 3. Measure the resistance between IL12, pin 02 (BG) and GROUND.
-> Yes
-> No
G258127t128 : CHECK THE FUEL RAIL PRESSURE (FRP) SENSOR GROUND

-> Yes
-> No
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G258127t129 : CHECK THE SENSOR GROUND AT THE ENGINE OIL

TEMPERATURE (EOT) SENSOR
1. Disconnect the EOT sensor electrical connector, PI38. 2. Reconnect the ECM electrical connector,
-> Yes
-> No
G258127t130 : CHECK THE ENGINE OIL TEMPERATURE (EOT) SENSOR

-> Yes
-> No
G258127t131 : CHECK THE SENSOR GROUND AT THE A/C PRESSURE

SENSOR
1. Disconnect the A/C pressure sensor electrical connector, EC11. 2. Reconnect the ECM electrical
connector, PI01. 3. Measure the resistance between EC11, pin 01 (BG) and GROUND.
-> Yes
-> No
Check for DTCs relating to individual sensors. Carry out pinpoint tests for sensors indicated.
G258127t132 : CHECK THE A/C PRESSURE SENSOR GROUND CIRCUIT FOR

HIGH RESISTANCE
1. Disconnect the ECM electrical connector, PI01. 2. Measure the resistance between EC11, pin 02
-> Yes
-> No
Check for DTCs relating to individual sensors. Carry out pinpoint tests for sensors indicated.

P1245, P1246; ENGINE CRANK SIGNAL
LOW/HIGH VOLTAGE
G258127t133 : CHECK THE IGNITION SWITCH TO ECM CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the ignition switch electrical connector,
IP34. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between IP34, pin
01 (Y) and PI01, pin 06 (Y).

-> Yes
-> No
G258127t134 : CHECK THE IGNITION SWITCH TO ECM CIRCUIT FOR SHORT

TO HIGH VOLTAGE
Measure the voltage between IP34, pin 01 (Y) and GROUND.
-> Yes
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-> No
INSTALL a new ignition switch. CLEAR the DTC. TEST the system for normal operation.

P1340, P1341; LEFT-HAND CAMSHAFT
POSITION (CMP) SENSOR CIRCUIT
MALFUNCTION
RANGE/PERFORMANCE
-> Yes
-> No
-> Yes
-> No

RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the CMP sensor electrical connector, PI56.
3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI01, pin 68 (N)
-> Yes
-> No

HIGH VOLTAGE
-> Yes
-> No
GROUND
and GROUND.
-> Yes
-> No

P0010, P1384; RIGHT-HAND VARIABLE
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CAMSHAFT TIMING (VCT) OIL

CONTROL SOLENOID MALFUNCTION,
CIRCUIT MALFUNCTION
G258127t140 : CHECK ECM TO VCT SOLENOID + CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the VCT electrical connector, PI16. 3.
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI16, pin 01 (Y)
-> Yes
-> No
G258127t141 : CHECK ECM TO VCT SOLENOID + CIRCUIT FOR SHORT TO

HIGH VOLTAGE
-> Yes
-> No

GROUND
and GROUND.
-> Yes
-> No
G258127t143 : CHECK VCT SOLENOID GROUND

1. Measure the resistance between PI16, pin 02 (B) and GROUND.
-> Yes
-> No
INSTALL a new VCT solenoid.

P1396; LEFT-HAND VARIABLE
CAMSHAFT TIMING (VCT) OIL
CONTROL SOLENOID MALFUNCTION,
CIRCUIT MALFUNCTION
G258127t144 : CHECK ECM TO VCT SOLENOID + CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the VCT electrical connector, PI17. 3.
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between PI17, pin 01 (YU)
and PI01, pin 110 (YU).
-> Yes
-> No
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HIGH VOLTAGE
Measure the voltage between PI17, pin 01 (YU) and GROUND.
-> Yes
-> No

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI17, pin 01 (YU)
and GROUND.
-> Yes
-> No
G258127t147 : CHECK VCT SOLENOID GROUND

1. Disconnect the battery negative terminal. 2. Measure the resistance between PI17, pin 02 (B) and
GROUND.
-> Yes
-> No

P1582; "FLIGHT RECORDER" DATA IS
STORED IF ANY ONE OF FIVE
CONDITIONS OCCUR
G258127t148 : CHECK THE INERTIA SWITCH TO ECM CIRCUIT FOR SHORT
CIRCUIT TO B+ VOLTAGE
1. Make sure the inertia switch is not tripped. 2. Disconnect the inertia switch electrical connector,
CR02. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the voltage between PI01, pin 10
(GU) and GROUND.
-> Yes
REPAIR the short circuit to B+. For additional information, refer to the wiring diagrams. CLEAR the
-> No
INSTALL a new inertia switch. CLEAR the DTC. CLEAR the flight recorder information. TEST the system
P1606; EMS CONTROL RELAY
MALFUNCTION
G258127t149 : CHECK THE EMS RELAY PERMANENT B+ SUPPLY
1. Remove the EMS relay. 2. Measure the voltage between the relay base, pins 02 and 03 and
GROUND.
-> Yes
-> No
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REPAIR the circuit between the relay base and battery. This circuit includes the high power
protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
G258127t150 : CHECK THE EMS RELAY TO ECM CIRCUIT FOR HIGH

RESISTANCE
Measure the resistance between the relay base, pin 05 and PI01, pins 23 (WR) and 24 (WR).
-> Yes
-> No

HIGH RESISTANCE
Measure the resistance between the relay base, pin 01 and PI01, pin 40 (U).
-> Yes
-> No
INSTALL a new EMS relay. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST G258127p33 : P0105,

P1107, P1108; MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR SENSING
CIRCUIT MALFUNCTION, HIGH/LOW
VOLTAGE
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the MAP sensor electrical connector, PI29.
(BK) and PI01, pin 127 (BK).
-> Yes
-> No
G258127t153 : CHECK THE MAP SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
1. Reconnect the battery negative terminal. 2. Measure the voltage between PI29, pin 01 (BK) and
GROUND.
-> Yes
REPAIR the short to high voltage. For additional information, refer to the wiring diagrams. CLEAR the
-> No
G258127t154 : CHECK THE MAP SENSOR SENSING CIRCUIT FOR SHORT TO
GROUND
1. Measure the resistance between PI29, pin 01 (BK) and GROUND.
-> Yes
-> No

P0181, P0182, P0183; ENGINE FUEL
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TEMPERATURE (EFT) SENSOR

RANGE/PERFORMANCE, LOW/HIGH
VOLTAGE
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the EFT sensor electrical connector, IL09.
(WU) and PI01, pin 50 (WU).
-> Yes
-> No
G258127t156 : CHECK THE EFT SENSOR SENSING CIRCUIT FOR SHORT TO

HIGH VOLTAGE
Measure the voltage between IL09, pin 01 (WU) and GROUND.
-> Yes
-> No
G258127t157 : CHECK THE EFT SENSOR SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between IL09, pin 01 (WU)
and GROUND.
-> Yes
-> No

P0532, P0533; AIR CONDITIONING
PRESSURE SENSOR CIRCUIT
LOW/HIGH VOLTAGE
HIGH RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the A/C pressure sensor electrical
connector, EC11. 3. Disconnect the ECM electrical connector, PI01. 4. Measure the resistance
between EC11, pin 02 (WU) and PI01, pin 121 (WU).
-> Yes
-> No

1. Reconnect the ECM electrical connector, PI01. 2. Reconnect the battery negative terminal. 3. Turn
the ignition switch to the ON position. 4. Measure the voltage between EC11, pin 02 (WU) and
GROUND.
-> Yes
-> No
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SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EC11, pin 02 (WU)
and GROUND.
-> Yes
-> No
(82.10.32)

P1631, P1657, P1658; THROTTLE
MOTOR RELAY CONTROL CIRCUIT
MALFUNCTION/OFF FAILURE/ON
FAILURE
G258127t161 : CHECK THE THROTTLE MOTOR RELAY POWER SUPPLIES
1. Remove the throttle motor relay. 2. Turn the ignition switch to the ON position. 3. Measure the
voltage between the relay base, pins 01 and 03 and GROUND.
Is either voltage less than 10 volts?
-> Yes
REPAIR the circuit between the relay base and battery. This circuit includes the front power
distribution box (fuse 14). For additional information, refer to the wiring diagrams. CLEAR the DTC.
-> No
G258127t162 : CHECK THE THROTTLE MOTOR RELAY COIL DRIVE CIRCUIT

FROM THE ECM FOR HIGH RESISTANCE
Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between the relay base, pin
02 and PI01, pin 52 (GR).
-> Yes
-> No
G258127t163 : CHECK THE THROTTLE MOTOR RELAY COIL DRIVE CIRCUIT

FROM THE ECM FOR SHORT TO B +
1. Reconnect the battery negative terminal. 2. Measure the voltage between the relay base, pin 02
and GROUND.
-> Yes
-> No
G258127t164 : CHECK THE POWER SUPPLY CIRCUIT FROM THE RELAY
BASE TO THE ECM FOR HIGH RESISTANCE
1. Measure the resistance between the relay base, pin 05 and PI01, pin 134 (GU).
-> Yes
REPAIR the high resistance circuit. This circuit includes the front power distribution box (fuse 24). For
operation.
-> No
G258127t165 : CHECK THE POWER SUPPLY CIRCUIT FROM THE RELAY

BASE TO THE ECM FOR SHORT TO B +
1. Measure the voltage between the relay base, pin 05 and GROUND.
www.JagDocs.com
-> Yes
-> No
INSTALL a new throttle motor relay. CLEAR the DTC. TEST the system for normal operation.

P0097, P0098; INTAKE AIR
TEMPERATURE (IAT) SENSOR 2
SENSING CIRCUIT
VOLTAGE
G258127t166 : CHECK IAT SENSOR 2 SENSING CIRCUIT FOR HIGH
RESISTANCE
1. Disconnect the battery negative terminal. 2. Disconnect the IAT sensor 2 electrical connector, PI43.
(YU) and PI01, pin 72 (YU).
-> Yes
-> No
G258127t167 : CHECK IAT SENSOR 2 SENSING CIRCUIT FOR SHORT TO HIGH

VOLTAGE
Measure the voltage between PI43, pin 01 (YU) and GROUND.
-> Yes
-> No
G258127t168 : CHECK IAT SENSOR 2 SENSING CIRCUIT FOR SHORT TO

GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between PI43, pin 01 (YU)
and GROUND.
-> Yes
-> No
INSTALL a new IATS 2.
PINPOINT TEST G258127p38 : P1410;

AIR CLEANER SOLENOID VALVE
DRIVE CIRCUIT MALFUNCTION
G258127t169 : CHECK THE POWER SUPPLY TO THE AIR CLEANER
SOLENOID VALVE
1. Disconnect the air cleaner solenoid valve electrical connector, EC37. 2. Turn the ignition switch to
the ON position. 3. Measure the voltage between EC37, pin 01 (GU) and GROUND.
-> Yes
-> No
REPAIR the circuit between the air cleaner solenoid valve and battery. This circuit includes the front
power distribution box (fuse 14), the EMS relay, and the high power protection module. For
operation.
G258127t170 : CHECK THE AIR CLEANER SOLENOID VALVE TO ECM CIRCUIT

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FOR HIGH RESISTANCE

Disconnect the ECM electrical connector, PI01. 4. Measure the resistance between EC37, pin 02 (U)
and PI01, pin 14 (U).
-> Yes
-> No

Measure the voltage between EC37, pin 02 (U) and GROUND.
-> Yes
-> No

FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between EC37, pin 02 (U)
and GROUND.
-> Yes
-> No
INSTALL a new air cleaner solenoid valve. CLEAR the DTC. TEST the system for normal operation.

P1474; CHECK INTERCOOLER
COOLANT PUMP FUNCTION
G258127t173 : CHECK POWER SUPPLY TO INTERCOOLER COOLANT PUMP
1. Disconnect the intercooler coolant pump electrical connector, CP02. 2. Turn the ignition switch to
the ON position. 3. Make sure the EMS relay is energized. 4. Measure the voltage between CP02, pin
02 (NG) and GROUND.
-> Yes
REPAIR the circuit between CP02, pin 02 and battery. This circuit includes the front power
distribution box (fuse 31), the ignition relay, and the high power protection module. For additional
-> No
G258127t174 : CHECK THE INTERCOOLER COOLANT PUMP GROUND

1. Measure the resistance between CP02, pin 01 (B) and GROUND.
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. TEST the
-> No
INSTALL a new intercooler coolant pump.
Water Pump CLEAR the DTC. TEST the system for normal operation.
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G45704->G99999
Overview
addition of secondary air injection and changes to evaporative emissions and exhaust gas
recirculation to comply with stage four emissions requirements.



retrieve the fault codes before proceeding to the DTC Index, or the symptom chart if no DTCs are set.
Symptom Chart
Symptom
(general)
Security system
/Immobilizer engaged
Check that the security system
Engine in shut-down
mode is disarmed. Check for DTCS. For
starting system,
ECM relay For ECM relay tests, GO to
Engine does not crank
Battery For battery information,
Battery For Park/Neutral tests,
Park/Neutral switch External Controls For engine
information,
Starting system
Engine
Harness
Engine seized
system,
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disconnected/restrict
ed
Non-Start ignition system tests,
G45704->G99999 For fuel
Engine cranks, but does
Fuel system system tests,
not fire
Harness Range: G45704->G99999 For
CKP tests, GO to Pinpoint Test
sensor G531332p17.
ECM fault procedures manual if an ECM is
suspect.

purge valve Evaporative Emissions - VIN
Fuel pump fuel system tests,
but will not start Spark plugs Range: G45704->G99999 For
G45704->G99999
Harness
Difficult to Check coolant anti-freeze For battery information,

Difficult to start cold content Battery For CKP sensor tests,
start
GO to Pinpoint Test
Battery G531332p17.
For EGR system tests,
CKP sensor Engine Emission Control - VIN
fuel system tests,
(EGR) valve stuck
open Fuel Charging and Controls - VIN
Fuel pump purge valve tests,
Evaporative emissions Range: G45704->G99999
purge valve
Injector leak
For fuel system tests,
(EFT) sensor
Intake air temperature EFT sensor tests, GO to Pinpoint
(IAT) sensor Test G531332p34.
Mass air flow (MAF) Pinpoint Test G531332p2.
sensor For MAF sensor tests, GO to
purge valve
Fuel pump Range: G45704->G99999
Ignition system
Injector leak For fuel system tests,
EFT sensor Range: G45704->G99999 For
EFT sensor tests, GO to Pinpoint
Difficult to start after IAT sensor Test G531332p34.
hot soak (vehicle
standing after engine MAF sensor
Evaporative emissions For MAF sensor tests, GO to
temperature)
purge valve Pinpoint Test G531332p1.
Fuel pump Evaporative Emissions - VIN
Range: G45704->G99999
Ignition system
Check compressions,
Compressions high/low Engine For battery information,
Engine cranks too
Battery For starting system
fast/slow Battery
tests,
Starting system
system,
Breather system ECM relay tests, GO to Pinpoint
disconnected/restrict Test G531332p32.
ed
ECM relay
MAF sensor Engine Ignition - VIN Range:
G45704->G99999 For air filter
Ignition system information,
start
Air filter restricted Filtering - VIN Range: G45704-
>G99999 For fuel system,
Fuel lines
Fuel rail pressure (FRP) Range: G45704->G99999 For
www.JagDocs.com
sensor FRP sensor tests, GO to Pinpoint

Test G531332p40.
Air leakage For intake system information,
Engine
stalls
>G99999

Engine stalls on overrun and GO to Pinpoint Test
Throttle position (TP) G531332p5.
sensors For fuel system tests,
Range: G45704->G99999

For fuel system,
ECM relay Fuel Charging and Controls - VIN
Engine stalls at steady Range: G45704->G99999 For
speed CKP sensor
CKP sensor tests, GO to Pinpoint
TP sensors Test G531332p17.
G531332p5.
Engine stalls with speed For ECM relay tests, GO to

control enabled ECM relay Pinpoint Test G531332p32.

ECM relay
TP sensors and GO to Pinpoint Test
G531332p5.
Engine stalls when Additional engine loads For accessory drive information,
maneuvering (PAS, air conditioning, Accessory Drive Belt - 4.2L NA
etc) V8 - AJV8/4.2L SC V8 -
AJV8/3.5L NA V8 - AJV8
(12.10.40) For transmission
CAN malfunction information,
For CAN network tests,
For fuel pump and fuel line

Fuel pump
tests,
Fuel lines Fuel Tank and Lines - 4.2L NA V8
- AJV8/4.2L SC V8 - AJV8/3.0L
Injector leak NA V6 - AJ27/3.5L NA V8 - AJV8,
Fuel pressure For injector tests,
Air leakage
intake system,
TP sensors
Poor Engine hesitates/poor Throttle motor Filtering - VIN Range: G45704-
driveability acceleration >G99999 For TP sensor tests,
Ignition system GO to Pinpoint Test
G531332p4.
EGR valve stuck and GO to Pinpoint Test
G531332p5.
HO2 sensors
Transmission malfunction Pinpoint Test G531332p24.
Restricted pedal travel Engine Ignition - VIN Range:
(carpet, etc) G45704->G99999 For EGR
tests,
Accelerator pedal Engine Emission Control - VIN
position (APP) sensor
Range: G45704->G99999 Check
for DTCs relating to HO2
sensors, refer to the DTC index.
Check the accelerator pedal
travel. For APP sensor tests, GO
G531332p23.
For fuel pump and lines tests,

- AJV8/4.2L SC V8 - AJV8/3.0L
NA V6 - AJ27/3.5L NA V8 - AJV8,
Fuel pump VIN Range: G45704->G99999
For intake system,
Fuel lines Intake Air Distribution and
Air leakage
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>G99999 For MAF sensor tests,

GO to Pinpoint Test
MAF sensor
G531332p1.
Engine backfires
sensors, refer to the DTC index.
Ignition system For ignition system,
Sticking variable camshaft G45704->G99999 For VCT
timing (VCT) hub information,
APP sensor
GO to Pinpoint Test
G531332p22.
G531332p23.
Check the fuel pressure and fuel

Fuel pump lines.
Fuel lines
- AJV8/4.2L SC V8 - AJV8/3.0L
MAF sensor NA V6 - AJ27/3.5L NA V8 - AJV8,
Engine surges For MAF sensor tests, GO to
Harness
Throttle motor
G531332p5.
Ignition system
G45704->G99999

G531332p16.
Knock sensor (KS)/circuit
Check the fuel pressure and fuel
malfunction
lines.
Fuel pump Fuel Tank and Lines - 4.2L NA V8
- AJV8/4.2L SC V8 - AJV8/3.0L
Fuel lines NA V6 - AJ27/3.5L NA V8 - AJV8,
Fuel quality For FRP sensor tests, GO to
Engine FRP sensor
detonates/knocks
HO2 sensors sensors, refer to the DTC index.
For intake system,
Air leakage Intake Air Distribution and
Sticking VCT hub
>G99999 Check DTCs for VCT
range/performance fault. For
(internal ECM fault) VCT information,
Engine Refer to the warranty
policy and procedures manual if
an ECM is suspect.
GO to Pinpoint Test
G531332p4.
APP sensor malfunction G531332p5.
Speed control inhibited Check message center for

Default mode enabled
or disabled default message. For speed
control switches,
Speed control switch Speed Control - VIN Range:
G45704->G99999 For TP sensor
TP sensors tests, GO to Pinpoint Test
G531332p4.
Brake pedal switch switch
CAN fault G531332p5.
For brake pedal switch tests, GO
For CAN tests,

APP sensor malfunction and GO to Pinpoint Test
G531332p23.
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ECT sensor and GO to Pinpoint Test

G531332p5.
MAF sensor For ECT sensor tests, GO to
Poor throttle response Pinpoint Test G531332p3.
Traction control event Pinpoint Test G531332p1.
For transmission information.
Air leakage For intake system,
Breather system Filtering - VIN Range: G45704-
disconnected/restrict >G99999 For breather system
ed
information,
For Park/Neutral tests,

Park/Neutral switch External Controls For TP sensor
Engine defaults, TP sensors G531332p4.
warning light and and GO to Pinpoint Test
messages. Refer to the MAF sensor G531332p5.
owner handbook For MAF sensor tests, GO to
Harness
DTC index
NOTE:
Left front wheel speed Invalid data received from Anti-Lock Control -
C003100
sensor ABS: left front wheel Stability Assist - VIN
Right front wheel speed Invalid data received from Anti-Lock Control -
C003400
sensor ABS: right front wheel Stability Assist - VIN
Invalid data received from Anti-Lock Control -

C003700 Left rear wheel speed sensor
ABS: left rear wheel Stability Assist - VIN
Right rear wheel speed Invalid data received from Anti-Lock Control -
C003A00
sensor ABS: right rear wheel Stability Assist - VIN
Check the engine timing.

Intake (A) camshaft position Cam timing has not been set Timing Drive
P001100 timing - over-advanced (right up correctly Components - VIN Range:
hand bank) G45704->G99999
Timing chain has slipped (12.65.13)

Intake (A) camshaft position Cam timing has not been set Timing Drive
P001200 timing - over-retarded (right up correctly Components - VIN Range:
The relative positions of the

P001600 Crankshaft position Reset the sensor
CKP and CMP teeth are
(CKP)/Camshaft position positions.
not correct Sensors
(CMP) sensor correlation, incorrectly aligned on Camshaft Position (CMP)
right hand bank rebuild Sensor LH (18.31.12)
Camshaft Position (CMP)
Sensor RH (18.31.11)
Sensor (18.30.12)
Reset the sensor

positions.
P001800
(CMP) sensor correlation, left not correct Sensors Camshaft Position (CMP)
hand bank incorrectly aligned on Sensor RH (18.31.11)
rebuild
Sensor (18.30.12)

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Intake camshaft position Cam timing has not been set Timing Drive
P002100 timing - over-advanced (left up correctly Components - VIN Range:

Intake camshaft position Cam timing has not been set Timing Drive
P002200 timing - over-retarded (left up correctly Components - VIN Range:
Oil contamination
Variable camshaft timing Check the oil condition
(VCT) control solenoid circuit VCT oil flow fault and flow. For right hand
P002672 range/performance (right bank VCT solenoid circuit
hand bank) - actuator stuck VCT solenoid fault tests, GO to Pinpoint
open Test G531332p29.
failure
Oil contamination
(VCT) control solenoid circuit VCT oil flow fault and flow. For right hand
P002677 range/performance (right bank VCT solenoid circuit
hand bank) - commanded VCT solenoid fault tests, GO to Pinpoint
position not reachable Test G531332p29.
failure
P002872 Variable camshaft timing Oil contamination Check the oil condition
(VCT) control solenoid circuit and flow. For left hand
range/performance (left VCT oil flow fault bank VCT solenoid circuit
hand bank) - actuator stuck tests, GO to Pinpoint
open VCT solenoid fault Test G531332p30.
failure
Oil contamination
(VCT) control solenoid circuit VCT oil flow fault and flow. For left hand
P002877 range/performance (left bank VCT solenoid circuit
hand bank) - commanded VCT solenoid fault tests, GO to Pinpoint
position not reachable Test G531332p30.
failure
For right hand bank HO2S
HO2S heater control circuit heater circuit tests, GO
low (right hand bank) to Pinpoint Test
fault
HO2S heater failure

For right hand bank HO2S
high (right hand bank) to Pinpoint Test
fault
HO2S heater failure

short circuit to ground For right hand bank
Catalyst monitor heater catalyst monitor heater
P003600 control circuit (right hand Catalyst monitor sensor circuit tests, GO to
bank) heater control circuit: Pinpoint Test

heater failure
P005100 circuit: open circuit
low (left hand bank) to Pinpoint Test
HO2S heater control circuit: G531332p11.
high resistance

fault
HO2S heater failure

high (left hand bank) to Pinpoint Test
fault
HO2S heater failure

short circuit to ground For left hand bank
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Catalyst monitor heater catalyst monitor heater

P005600 control circuit (left hand Catalyst monitor sensor circuit tests, GO to
bank) heater control circuit: Pinpoint Test

heater failure
tests, vehicles without
supercharger, GO to
Pinpoint Test
G531332p33.
Manifold absolute pressure MAP sensor failure
tests, vehicles with
P006900 (MAP) - Barometric pressure
correlation BARO sensor failure (internal supercharger, GO to
ECM fault) Pinpoint Test
G531332p36.
manual if an ECM is
suspect.

P007100 Ambient temperature value
sensor range/performance missing from CAN bus Control Components

P007200 Ambient air temperature
sensor circuit low sensor circuit: high Control Components
resistance

circuit to ground
Ambient air temperature Ambient air temperature
P007300
sensor circuit high sensor circuit: short Control Components
circuit to power
VCT solenoid valve
P007500 (VCT) control circuit (right VCT solenoid valve to ECM
hand bank)

VCT solenoid valve
(right hand bank)

VCT solenoid valve
(right hand bank)

VCT solenoid valve
P008100 (VCT) control circuit (left VCT solenoid valve to ECM
hand bank)

VCT solenoid valve
P008200 (VCT) control circuit low (left VCT solenoid valve to ECM
hand bank)

VCT solenoid valve
P008300 (VCT) control circuit high (left VCT solenoid valve to ECM
hand bank)

sensor disconnected
Fuel rail pressure (FRP) For FRP sensor circuit

sensor to ECM sensing
circuit: open circuit or
short circuit to ground Test G531332p40.
For fuel pump circuit and
Fuel rail pressure (FRP) fuel line tests,
Fuel rail/system pressure -
P008700 sensor supply circuit: high Fuel Tank and Lines - 4.2L
too low resistance NA V8 - AJV8/4.2L SC V8 -
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AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
sensor failure
VIN Range: G45704-
Fuel pump failure >G99999
Fuel line leak

(supply/sense): short For FRP sensor circuit
circuit to each other tests, GO to Pinpoint
Test G531332p40.
FRP sensor to ECM sense and GO to Pinpoint Test
circuit: short circuit to G531332p25.
high voltage
For fuel pump circuit and
Fuel rail/system pressure -
P008800 fuel line tests,
too high FRP sensor ground circuit:
high resistance Fuel Tank and Lines - 4.2L
FRP sensor failure AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
Restricted fuel line VIN Range: G45704-
>G99999
Fuel pump short circuit to
battery
MAPT intake air temperature
Manifold absolute sensor circuit: short For MAPT intake air
P009700 pressure/temperature temperature sensor
circuit to ground
(MAPT) sensor intake air tests, GO to Pinpoint
MAPT intake air temperature
temperature low input sensor circuit: high Test G531332p37.
resistance
Manifold absolute For MAPT intake air
pressure/temperature MAPT intake air temperature temperature sensor
P009800
(MAPT) sensor intake air sensor circuit: short tests, GO to Pinpoint
temperature high input circuit to power Test G531332p37.
Blocked air cleaner

For intake system
Air intake leak information,
Engine breather leak and Filtering - VIN Range:
G45704->G99999 Check
Mass air flow (MAF) sensor to the engine breather
Mass or volume air flow A ECM sensing circuit: high
P010100 system,
circuit range/performance resistance, intermittent
short circuit to ground Engine Emission Control -
VIN Range: G45704-
MAF sensor supply circuit: >G99999 For MAF
high resistance sensor circuit tests, GO
to Pinpoint Test
Throttle adaption fault (check G531332p1.
at Ignition ON)
MAF sensor supply circuit:
high resistance, short For MAF sensor circuit
circuit to ground tests, GO to Pinpoint
P010200 Test G531332p1.
circuit low input MAF sensor ground circuit: and GO to Pinpoint Test
MAF sensor failure

circuit: short circuit to For MAF sensor circuit
battery
P010300 Test G531332p1.
circuit high input MAF sensor to ECM sensor
ground circuit: high and GO to Pinpoint Test
MAF sensor failure

Intake manifold air leak For intake system
(loose or missing information,
Manifold absolute pressure component) Intake Air Distribution
P010600 (MAP)/BARO sensor and Filtering - VIN Range:
range/performance MAP sensor to ECM circuit(s)
G45704->G99999 For
fault
MAP sensor circuit tests,
Throttle adaption fault (check vehicles without
throttle position voltage supercharger, GO to
at Ignition ON) Pinpoint Test
G531332p33.
MAP sensor failure For MAP sensor circuit
tests, vehicles with
supercharger, GO to
Pinpoint Test
G531332p36.

MAP sensor to ECM circuit: supercharger, GO to
high resistance, short Pinpoint Test
Manifold absolute pressure circuit to ground
G531332p33.
P010700 (MAP)/BARO sensor low
MAP sensor sensor supply For MAP sensor circuit
input
circuit: open circuit tests, vehicles with
supercharger, GO to
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MAP sensor failure Pinpoint Test

G531332p36.

MAP sensor sensor ground supercharger, GO to
circuit: high resistance Pinpoint Test
G531332p33.
P010800 (MAP)/BARO sensor high MAP sensor to ECM sense
circuit: short circuit to For MAP sensor circuit
input
high voltage tests, vehicles with
supercharger, GO to
MAP sensor failure Pinpoint Test
G531332p36.

sensor circuit
P011123 high resistance tests, GO to Pinpoint
Test G531332p2.
stuck low IAT sensor failure

sensor circuit
P011124 high resistance tests, GO to Pinpoint
Test G531332p2.
stuck high IAT sensor failure
Intake air temperature (IAT) IAT sensor to ECM wiring: For IAT sensor circuit
P011129 sensor circuit high resistance tests, GO to Pinpoint
range/performance - signal Test G531332p2.
IAT sensor failure
invalid

P011200 IAT sensor to ECM wiring: tests, GO to Pinpoint
sensor circuit low input high resistance Test G531332p2.
IAT sensor failure

IAT sensor to ECM wiring:
P011300 IAT sensor to ECM sensing tests, GO to Pinpoint
sensor circuit high input circuit: short circuit to Test G531332p2.
battery
IAT sensor failure

Low coolant level
Check the coolant level,
Engine coolant temperature ECT sensor to ECM sensing
etc. For ECT sensor
(ECT) sensor circuit circuit: intermittent high
P011623 circuit tests, GO to
Pinpoint Test
stuck low
Engine thermostat failure G531332p3.
ECT sensor failure

Low coolant level
ECT sensor to ECM sensing Check the coolant level,

Engine coolant temperature
circuit: intermittent high etc. For ECT sensor
(ECT) sensor circuit
P011624 resistance circuit tests, GO to
Pinpoint Test
stuck high Engine coolant thermostat G531332p3.
failure
ECT sensor failure

Low coolant level
ECT sensor to ECM sensing Check the coolant level,

circuit: intermittent high etc. For ECT sensor
(ECT) sensor circuit
P011629 resistance circuit tests, GO to
Pinpoint Test
invalid Engine coolant thermostat G531332p3.
failure
ECT sensor failure

ECT sensor disconnected For ECT sensor circuit
P011700 tests, GO to Pinpoint
(ECT) sensor circuit low input ECT sensor to ECM sensing Test G531332p3.
to battery
ECT sensor failure

Engine overheat For cooling fan circuit
condition/cooling fan tests, GO to Pinpoint
Engine coolant temperature failure
Test G531332p19.
P011800 (ECT) sensor 1 circuit high
ECT sensor to ECM wiring: For ECT sensor circuit
input
short circuit to ground tests, GO to Pinpoint
Test G531332p3.
ECT sensor failure
For throttle position
TP sensor to ECM wiring: high sensor circuit 1 tests, GO
resistance to Pinpoint Test
G531332p4.
P012100 circuit range/performance, TP sensor to ECM sensing
circuits: (TP 1 or TP 2) For throttle position
circuit 1 and 2
short circuit to battery sensor circuit 2 tests, GO
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to Pinpoint Test
TP sensor failure G531332p5.
TP sensor to ECM sensing For throttle position

Throttle position (TP) sensor circuit 1: short circuit to sensor circuit 1 tests, GO
P012200 ground, high resistance
circuit 1 low input to Pinpoint Test
G531332p4.
TP sensor failure
TP sensor to ECM sensing For throttle position
Throttle position (TP) sensor circuit (TP1): short circuit sensor circuit 1 tests, GO
P012300
circuit 1 low input to high voltage to Pinpoint Test
G531332p4.
TP sensor failure
Low coolant level
Check the coolant level,
etc. For ECT sensor
Insufficient coolant temp for circuit: intermittent high
P012500 circuit tests, GO to
closed loop fuel control resistance
Pinpoint Test
Engine thermostat failure G531332p3.
ECT sensor failure

Contaminated coolant Check the coolant level,
Coolant thermostat (coolant etc. Check the
P012800 temp below thermostat thermostat condition and
failure
regulating temperature) function. Check for ECT
ECT sensor failure ECT sensor sensor DTCs.
DTC may also be flagged
H02S disconnected
H02S to ECM variable current For right hand bank HO2

H02 sensor circuit low circuit fault sensor circuit tests, GO
P01311A
voltage (right hand bank) to Pinpoint Test
ECM to HO2S constant G531332p6.
H02S failure
H02S disconnected
H02S to ECM variable current For right hand bank HO2

H02 sensor circuit high circuit fault sensor circuit tests, GO
P01321B
voltage (right hand bank) to Pinpoint Test
ECM to HO2S constant G531332p6.
H02S failure
HO2S to ECM wiring shield
high resistance For right hand bank HO2
HO2 sensor circuit slow sensor circuit tests, GO
P013300 Exhaust leak
response (right hand bank) to Pinpoint Test
Fuel control system fault G531332p6.
HO2 sensor failure

HO2 sensor circuit no activity sensor circuit tests, GO
P013400
detected (right hand bank) HO2S slow activation to Pinpoint Test
G531332p6.

disconnected
Catalyst monitor sensor to For right hand bank

ECM wiring: high
Catalyst monitor circuit low catalyst monitor circuit
P013700 resistance
voltage (right hand bank) tests, GO to Pinpoint
Catalyst monitor sensor: Test G531332p8.

failure
sensing circuit: short
Catalyst monitor circuit high catalyst monitor circuit
voltage (right hand bank) tests, GO to Pinpoint
ground braided shield:
high resistance

failure
For right hand bank
P013900 circuit slow response (right Catalyst monitor sensor slow
response tests, GO to Pinpoint
hand bank)
Test G531332p8.
Catalyst monitor
disconnected
Catalyst monitor mechanical

damage
Catalyst monitor to ECM

wiring: high resistance For right hand bank
Catalyst monitor circuit no
P014000 activity detected (right hand
Catalyst monitor sensing tests, GO to Pinpoint
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bank) circuit: short circuit to Test G531332p8.

power
Catalyst monitor: short circuit

to ground
Catalyst monitor ground (BRD

braided shield) high
resistance
Catalyst monitor heater catalyst monitor circuit
circuit (right hand bank) tests, GO to Pinpoint
heater failure
H02 sensor circuit low HO2 sensing circuit: short For left hand bank HO2S
voltage (left hand bank) - circuit tests, GO to
P01511A circuit to high voltage,
circuit resistance below high resistance Pinpoint Test
threshold G531332p10.
HO2S failure
H02 sensor circuit low H02S sensing circuit: short For left hand bank HO2S
voltage (left hand bank) - circuit tests, GO to
P01521B circuit to high voltage,
circuit resistance above high resistance Pinpoint Test
threshold G531332p10.
H02S failure
P015300 H02S circuit slow response For left hand bank HO2S
H02S to ECM wiring shield
(left hand bank) high resistance Pinpoint Test
G531332p10.
Exhaust leak
Fuel control system fault
H02S failure
H02S circuit no activity circuit tests, GO to
P015400
detected (left hand bank) H02S slow activation Pinpoint Test
G531332p10.

disconnected

ECM wiring high For left hand bank
P015700 circuit low voltage (left hand
bank) Catalyst monitor sensor short tests, GO to Pinpoint
circuit to ground Test G531332p14.
Fuel control system lean fault

failure
circuit to high voltage For left hand bank
P015800 circuit high voltage (left hand Catalyst monitor sensor
ground (BRD braided tests, GO to Pinpoint
bank)
shield) high resistance Test G531332p14.

failure
For left hand bank
P015900 circuit slow response (left Catalyst monitor sensor slow
response tests, GO to Pinpoint
hand bank)
Test G531332p14.

disconnected For left hand bank
P016000 circuit no activity detected
Catalyst monitor sensor tests, GO to Pinpoint
(left hand bank) mechanical damage Test G531332p14.

ECM wiring high
resistance

Catalyst monitor sensor short

circuit to ground

ground (BRD braided
shield) high resistance
For left hand bank
Catalyst monitor sensor catalyst monitor circuit
P016100 heater circuit (left hand
heater control circuit tests, GO to Pinpoint
bank) malfunction Test G531332p14.
For intake system

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information,
G45704->G99999 For
fuel line and fuel
pressure tests,
Air intake leak between MAF Fuel Tank and Lines - 4.2L
sensor and cylinder head NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
Fuel filter/system restriction AJ27/3.5L NA V8 - AJV8,
System too lean (right hand
P017100 VIN Range: G45704-
>G99999 For fuel
MAF sensor fault (low intake injector information,
air flow) Fuel Injectors (18.10.02)
Exhaust leak (before catalyst) tests, GO to Pinpoint
Test G531332p1.
Check the exhaust
system (before catalyst)
for condition and
security,

System too rich (right hand information,
P017200
bank) Leaking fuel injector(s) Intake Air Distribution
Oil contaminated with fuel G45704->G99999 For
(too many cold starts fuel injector information,
with vehicle subsequentlyFuel Injectors (18.10.02)
not getting hot enough
Check oil condition, if
for long enough)
contamination is present,
MAF sensor fault (high intake renew engine oil and
Pinpoint Test
G531332p1.
For intake system

information,
G45704->G99999 For
fuel line and pressure
tests,
Air intake leak between MAF Fuel Tank and Lines - 4.2L
sensor and cylinder head NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
Fuel filter/system restriction AJ27/3.5L NA V8 - AJV8,
System too lean (left hand
P017400 VIN Range: G45704-
>G99999 For fuel
MAF sensor fault (low intake injector information,
air flow) Fuel Injectors (18.10.02)
Exhaust leak (before catalyst) tests, GO to Pinpoint
Test G531332p1.
Check the exhaust
system (before catalyst)
for condition and
security,

information,
System too rich (left hand Oil contaminated with fuel and Filtering - VIN Range:
P017500 G45704->G99999 For
bank) (too many cold starts
with vehicle subsequently fuel injector information,
not getting hot enough Fuel Injectors (18.10.02)
for long enough) Check oil condition, if
contamination is present,
MAF sensor fault (high intake
air flow) renew engine oil and
filter. For MAF sensor
Pinpoint Test
G531332p1.

short circuit to high For EFT sensor circuit
(EFT) sensor A circuit
P018123 voltage tests, GO to Pinpoint
Test G531332p34.
stuck low EFT sensor ground circuit:
high resistance
EFT sensor failure

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(EFT) sensor circuit
Test G531332p34.
stuck high EFT sensor ground circuit:
high resistance
EFT sensor failure

(EFT) sensor A circuit
Test G531332p34.
invalid EFT sensor ground circuit:
high resistance
EFT sensor failure

ground
(EFT) sensor circuit low input EFT sensor to splice sensor
ground circuit: short Test G531332p34.
circuit
EFT sensor failure

Engine fuel temperature For EFT sensor circuit
P018300
(EFT) sensor circuit high input EFT sensor to ECM sensing tests, GO to Pinpoint
short circuit to high Test G531332p34.
voltage

ground circuit: high
resistance
EFT sensor failure

Fuel rail pressure (FRP) For FRP sensor circuit
P019100 sensor circuit FRP sensor range and tests, GO to Pinpoint
range/performance performance Test G531332p40.

circuit: high resistance or For FRP sensor circuit
P019200 short circuit to ground tests, GO to Pinpoint
sensor circuit low input
Test G531332p40.
FRP sensor to supply circuit:
high resistance
FRP sensor failure

(supply, sense): short
FRP sensor to ECM sense For FRP sensor circuit

P019300 circuit: short circuit to tests, GO to Pinpoint
sensor circuit high input high voltage Test G531332p40.
FRP sensor ground circuit:

high resistance
FRP sensor failure

Engine oil temperature (EOT) EOT sensor to ECM sensing
sensor circuit circuit: intermittent high
Test G531332p13.
stuck low
EOT sensor failure
sensor circuit circuit: intermittent high
Test G531332p13.
stuck high
EOT sensor failure
Engine oil temperature (EOT) EOT sensor to ECM sensing For EOT sensor circuit
P019629 sensor circuit circuit: intermittent high tests, GO to Pinpoint
resistance Test G531332p13.
invalid EOT sensor failure

Engine oil temperature (EOT) circuit: short circuit to
sensor circuit low input ground
Test G531332p13.
EOT sensor failure
sensor circuit high input circuit: high resistance,
short circuit to battery Test G531332p13.
EOT sensor failure

P020100
ground G45704->G99999
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Injector failure
P020200
ground G45704->G99999
Injector failure
P020300
ground G45704->G99999
Injector failure
P020400
ground G45704->G99999
Injector failure
Injector disconnected For injector circuit tests,
Cylinder 5 injector Fuel Charging and
P020500 Injector harness wiring: high
ground G45704->G99999
Injector failure
P020600
ground G45704->G99999
Injector failure
P020700
ground G45704->G99999
Injector failure
P020800
ground G45704->G99999
Injector failure
circuit 2 low input TP sensor circuit 2 low input
Test G531332p5.

circuit 2 high input TP sensor circuit 2 high input
Test G531332p5.

Accelerator pedal position For APP sensor circuit 1
P022700 (APP) sensor circuit 1 low tests, GO to Pinpoint
input Accelerator pedal position Test G531332p22.
high resistance
Accelerator pedal position For APP sensor circuit 1
P022800 (APP) sensor circuit 1 high tests, GO to Pinpoint
input short circuit to power Test G531332p22.
MAPT pressure sensor to

ECM circuit: short circuit For MAPT pressure
Manifold absolute
to ground sensor tests, GO to
P023700 pressure/temperature
Pinpoint Test
(MAPT) sensor pressure low MAPT pressure sensor to G531332p41.
ECM circuit: high
resistance
For MAPT pressure
Manifold absolute
MAPT pressure sensor to sensor tests, GO to
P023800 pressure/temperature
ECM circuit: short circuit Pinpoint Test
(MAPT) sensor pressure high to power G531332p41.
For auxiliary coolant

Charge air cooler coolant Charge air cooler coolant pump tests, GO to
P023B13
pump control circuit low pump circuit low (short Pinpoint Test
circuit) G531332p39.

Charge air cooler coolant Charge air cooler coolant pump tests, GO to
P023C12
pump control circuit high pump circuit (open Pinpoint Test
circuit) G531332p39.

circuit faults (cylinder
misfire detected DTCs
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also logged)
For ignition coil and
Ignition coil failure spark plug tests,
Spark plug Range: G45704->G99999
failure/fouled/incorrect For fuel pressure test,
gap
(low/high) AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
Fuel injector circuit fault(s) VIN Range: G45704-
Random/multiple cylinder
P030000 (injector DTCs also >G99999 For fuel
misfire detected logged) injector circuit tests,
Fuel Charging and
Fuel injectors
restricted/leaking
G45704->G99999 Check
Fuel injectors continuously compressions, valve gear,
open etc,
Fuel contamination AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
springs

P030100 Cylinder 1 misfire detected Refer to P030000 possible Refer to P030000 actions
sources

sources

sources

sources

sources

sources

sources

sources
Check for fuel level

Misfire detected with low sensor codes, add fuel.
P031300 Misfire detected during low
fuel fuel level condition Clear the DTC and test
Misfire detected on first 1000 Carry out the tests

Engine misfire detected on revs indicated for a normal
P031600
startup misfire code, but on a
Refer to P030000 possible cold engine.
sources
P032700
low input (right hand bank) KS to ECM sense circuit: short Pinpoint Test
KS failure
Poor sensor contact with the For right hand bank KS
Knock sensor (KS) 1 circuit cylinder block circuit tests, GO to
P032800
high input (right hand bank) Pinpoint Test
KS to ECM sense circuit: high G531332p15.
power
KS failure
P033200
low input (left hand bank) KS to ECM sense circuit: short Pinpoint Test
KS failure
high input (left hand bank) resistance, short circuit to Pinpoint Test
power G531332p16.
KS failure
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CKP Sensor gap incorrect/

Crankshaft position (CKP) face /damaged teeth on
sensor A circuit - rotor
CKP sensor sensing circuit: Test G531332p17.
operation
circuit to power
CKP sensor failure


Crankshaft position (CKP) For CKP sensor circuit
rotor
P033594 sensor A circuit - unexpected tests, GO to Pinpoint
operation CKP sensor sensing circuit: Test G531332p17.
circuit to power
CKP sensor failure

Crankshaft position (CKP) For CKP sensor circuit
P033600 sensor A circuit tests, GO to Pinpoint
range/performance rotor Test G531332p17.
CKP sensor sensing circuit:
intermittent high
power
CKP sensor failure


sensor A circuit (right hand face /damaged rotor
P034092 bank or single sensor) -
operation
circuit to power


face /damaged rotor
sensor A circuit (right hand circuit tests, GO to
P034094
bank or single sensor) - CMP sensor sensing circuit: Pinpoint Test
unexpected operation high resistance, short G531332p18.
circuit to power


face /damaged rotor
sensor A circuit circuit tests, GO to
P034100
range/performance (right CMP sensor sensing circuit: Pinpoint Test
hand bank or single sensor) high resistance, short G531332p18.
circuit to power
Camshaft position (CMP) CMP sensor disconnected For left hand bank CMP
sensor A circuit (left hand circuit tests, GO to
P034592 CMP sensor gap incorrect/
bank) - performance or foreign matter on sensor Pinpoint Test
incorrect operation face /damaged rotor G531332p28.
CMP sensor sensing circuit:
circuit to power


Camshaft position (CMP) face /damaged rotor
P034594 sensor A circuit (left hand
bank) - unexpected operation
high resistance short G531332p28.
circuit to power

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Camshaft position (CMP) foreign matter on sensor For left hand bank CMP
face /damaged rotor
sensor A circuit circuit tests, GO to
P034600
range/performance (left CMP sensor sensing circuit: Pinpoint Test
hand bank) high resistance, short G531332p28.
circuit to power

drive circuit: high
ground
Ignition coil 1
P035100 Ignition module/coil ground Engine Ignition - VIN
primary/secondary circuit circuit: high resistance Range: G45704->G99999
Ignition module/coil battery

relay, if fitted)
drive circuit: short circuit For ignition coil tests,
Ignition coil 2
P035200 to ground, high Engine Ignition - VIN
primary/secondary circuit resistance Range: G45704->G99999


relay, if fitted)
to ground, high
resistance
Ignition coil 3

relay, if fitted)
to ground, high
resistance
Ignition coil 4

relay, if fitted)
to ground, high
resistance
Ignition coil 5

relay, if fitted)
drive circuit: short circuit For ignition coil tests,
Ignition coil 6
P035600 to ground, high Engine Ignition - VIN
primary/secondary circuit resistance Range: G45704->G99999


relay, if fitted)
to ground, high
resistance
Ignition coil 7

relay, if fitted)
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to ground, high
resistance
Ignition coil 8

relay, if fitted)
EGR valve incorrectly fitted or
loose
For EGR tests,
EGR pipe blocked Engine Emission Control -
P040100 (EGR) flow insufficient
VIN Range: G45704-
detected EGR valve stuck closed, >G99999
blocked
EGR valve failure

For secondary air
injection tests,
P041300 Secondary air check valve Engine Emission Control -
switching valve A circuit open control circuit high VIN Range: G45704-
>G99999
For secondary air

P041400 Secondary air injection Secondary air check valve
injection tests,
switching valve A circuit control circuit low
shorted VIN Range: G45704-
>G99999

overheating damage
Catalyst system efficiency lean combustion
condition/level. Check
P042000 below threshold (right hand
the catalysts for damage.
poisoning caused by
excessive oil
consumption and/or
contaminated fuel
overheating damage
Catalyst system efficiency lean combustion
condition/level. Check
P043000 below threshold (left hand
the catalysts for damage.
poisoning caused by
excessive oil
consumption and/or
contaminated fuel
For evaporative
emissions tests,
P044100 Purge valve range Evaporative Emissions -
system incorrect purge flow performance VIN Range: G45704-
>G99999
For evaporative
Evaporative emission (EVAP) emissions tests,
P044700 system vent control circuit DMTL COV circuit ground Evaporative Emissions -
open short VIN Range: G45704-
>G99999
EVAP canister close valve

power supply circuit: high
resistance, short circuit For evaporative
EVAP canister close valve to
P044800 system vent control circuit Evaporative Emissions -
ECM drive circuit: high
shorted resistance, short circuit to VIN Range: G45704-
battery >G99999
EVAP canister close valve

failure
P045600 Evaporative emission (EVAP) DMTL system has detected a For evaporative
system leak detected (very leak emissions tests,
small leak) Evaporative Emissions -
VIN Range: G45704-
>G99999

short circuit to ground For evaporative
circuit low high resistance VIN Range: G45704-
>G99999
failure
For evaporative
circuit high short circuit to power VIN Range: G45704-
>G99999
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P046129 range/performance - signal resistance
AJV8/3.0L NA V6 -
invalid
VIN Range: G45704-
data)
P04612F range/performance - signal resistance
AJV8/3.0L NA V6 -
erratic
VIN Range: G45704-
data)
short circuit to ground or
Fuel level sensor A circuit low NA V8 - AJV8/4.2L SC V8 -
input AJV8/3.0L NA V6 -
VIN Range: G45704-
data)
short circuit to high
Fuel level sensor A circuit NA V8 - AJV8/4.2L SC V8 -
P046300 voltage
high input AJV8/3.0L NA V6 -
VIN Range: G45704-
data)
Electric fan control circuit:
P048023 Fan 1 control circuit low tests, GO to Pinpoint
Electric fan control circuit: Test G531332p19.
high resistance
P048024 Fan 1 control circuit high Electric fan control circuit: tests, GO to Pinpoint
short circuit to battery Test G531332p19.

Cooling fan difficult to turn
Fan/Motor damaged necessary.
Check the battery

Fan control module reports condition. Check the
battery voltage less than charging system and fan
9 volts circuits.
Fan control module reports Check the charging

battery voltage greater system and fan circuits.
than 18 volts
Cooling fan jammed
necessary.
EGR valve power supply For EGR tests,

Exhaust gas recirculation Engine Emission Control -
P048900
(EGR) control circuit low EGR valve power supply VIN Range: G45704-
circuit: short circuit to >G99999
ground
For EGR tests,
Exhaust gas recirculation EGR valve to ECM drive Engine Emission Control -
P049000
(EGR) control circuit high circuit: short circuit to VIN Range: G45704-
battery >G99999
Vehicle speed sensor Check for TCM DTCs.
P050082 Vehicle speed: invalid signal
malfunction received over CAN
Vehicle speed sensor Check for TCM DTCs.

P050086 Vehicle speed: invalid signal
malfunction received over CAN

Check the brake switch

function. GO to Pinpoint
Test G531332p42.
The brake pressure reading
does not agree with the
brake light switch value Anti-Lock Control -
Stability Assist - VIN
Range: G45704->G99999
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Brake switch high fault: Brake

lights stuck on Gearshift
interlock inoperative For brake switch and
Speed control inoperative circuit tests, GO to
Pinpoint Test
Brake switch low fault: Brake G531332p42.
lights inoperative
Gearshift stuck in Park
Reduced engine braking
For brake switch and
Brake switch A/B correlation circuit tests, GO to
P050464
- signal plausibility failure Brake switch malfunction Pinpoint Test
G531332p42.

system.
G45704->G99999 Check
P050600 the accessory drive belt
(defective/seized and components.
component) Accessory Drive Belt -
4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8/3.5L NA V8 -
AJV8 (12.10.40)
P050624 Idle air control system RPM Air intake restriction

lower than expected Accessory drive overload system.
(defective/seized Intake Air Distribution
component) and Filtering - VIN Range:
G45704->G99999 Check
the accessory drive belt
and components.
Accessory Drive Belt -
4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8/3.5L NA V8 -
AJV8 (12.10.40)

system,
Intake air leak between MAF Intake Air Distribution
sensor and throttle and Filtering - VIN Range:
Idle air control system RPM G45704->G99999
higher than expected throttle and engine Inspect the engine
breather system,
>G99999

system,
Intake air leak between MAF Intake Air Distribution
sensor and throttle and Filtering - VIN Range:
Idle air control system RPM G45704->G99999
higher than expected throttle and engine Inspect the engine
breather system,
>G99999

P050B84
timing too retarded Range: G45704->G99999

P050B85
timing too advanced Range: G45704->G99999
P05120C Starter request circuit Crank request circuit: high For starter request circuit
input tests, GO to Pinpoint
Test G531332p27.
For starter request circuit

P05120E Starter request circuit Crank request circuit: low tests, GO to Pinpoint
input Test G531332p27.
Programme keys using

P051300 Incorrect immobilizer key the Jaguar approved
diagnostic system.
Air conditioning (A/C) For A/C pressure sensor

P053200 refrigerant pressure sensor A A/C refrigerant pressure tests, GO to Pinpoint
circuit low input sensor circuit low input Test G531332p35.
For A/C pressure sensor

P053300 A/C Refrigerant pressure tests, GO to Pinpoint
sensor A circuit high input sensor circuit high input Test G531332p35.
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For battery back-up tests,

P056013 System voltage GO to Pinpoint Test
Battery back-up malfunction
G531332p20.

to Pinpoint Test
G531332p40.
to Pinpoint Test
P056100 System voltage unstable G531332p33.
System voltage comparison
For TP sensor tests, GO
to Pinpoint Test
G531332p4.
G531332p5.

to Pinpoint Test
G531332p40.
ECM to sensor supply voltage to Pinpoint Test
circuit(s): short circuit to
G531332p33.
ground
For TP sensor tests, GO
to Pinpoint Test
G531332p4.
G531332p5.

to Pinpoint Test
G531332p40.
ECM to sensors supply to Pinpoint Test
P056300 System voltage high voltage circuit(s): high G531332p33.
resistance, short circuit to For TP sensor tests, GO
power to Pinpoint Test
G531332p4.
G531332p5.
For speed control,

Speed control cancel button
P057501 Speed control cancel button Speed Control - VIN
fault fault Range: G45704->G99999
For speed control,

low Speed control low input
Range: G45704->G99999
For speed control,

high Speed control high input
Range: G45704->G99999
For speed control,

Speed control multi-function
input A circuit stuck Speed switch stuck fault
Range: G45704->G99999
Speed control multi-function For speed control,

P05791C input A circuit Speed control switch Speed Control - VIN
range/performance deadband detection Range: G45704->G99999
For speed control,

Speed control multi-function
input B circuit stuck Active speed limiter fault
Range: G45704->G99999

P060143 memory check sum error -
CPU communication. - sub manual if an ECM is
special memory failure
suspect.
P060145 Internal control module Refer to the warranty

CPU communication
memory check sum error - policy and procedures
program memory failure manual if an ECM is
suspect.

P060442
(RAM) error - general Initial RAM test manual if an ECM is

P060443
(RAM) error - special Shut off RAM test manual if an ECM is

P060444
(RAM) error - data memory RAM check sum manual if an ECM is
failure suspect.
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P060445
(RAM) error - program ECM failure manual if an ECM is

Internal control module read using the Jaguar
P060500 EEPROM/flash checksum
only memory (ROM) error error approved diagnostic
system.

Internal control module read policy and procedures
P060529
only memory (ROM) error ROM error manual if an ECM is
suspect.

Internal control module read
P060542 only memory (ROM) error -
ROM check sum manual if an ECM is
general memory failure
suspect.

Shut off ROM test manual if an ECM is
special memory failure
suspect.
P060544 Internal control module read Refer to the warranty

Initial ROM test
only memory (ROM) error - policy and procedures
data memory failure manual if an ECM is
suspect.

Continuous ROM test manual if an ECM is
program memory failure
suspect.

P060546
only memory (ROM) error Continuous ROM test manual if an ECM is
suspect.

Shut off ROM test manual if an ECM is
supervision software failure
suspect.

P060564
only memory (ROM) error ROM error - sub manual if an ECM is
suspect.

P060600 ECM/PCM processor fault
Watchdog error manual if an ECM is
suspect.

P060601
general electrical failure Controller test - sub manual if an ECM is
suspect.

P060604 ECM/PCM processor
System internal failures manual if an ECM is
suspect.

ECM/PCM processor - system policy and procedures
P060605 Throttle return spring failure
programming failures (throttle body failure) manual if an ECM is
suspect.
P060641 ECM/PCM processor - Refer to the warranty

Watch dog timer fault - sub
general checksum failure manual if an ECM is
suspect.

P060642
general memory failure Error capturing instructions manual if an ECM is
suspect.

ECM/PCM processor - special policy and procedures
P060643
memory failure Duplication memory fault manual if an ECM is
suspect.

ECM/PCM processor - data policy and procedures
P060644 Duplication memory fault -
memory failure sub manual if an ECM is
suspect.
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P060645 Detection of write to internal
program memory failure ROM manual if an ECM is
suspect.

ECM/PCM processor -
using the Jaguar
P060646 calibration/parameter Detection of write to internal
ROM - sub approved diagnostic
memory failure
system.

using the Jaguar
P060647 ECM/PCM processor fault
Watch dog timer fault approved diagnostic
system.

ECM/PCM processor - using the Jaguar
P060648
supervision software failure Scheduling sequence check approved diagnostic
system.

P060649
internal electronic failure Controller test manual if an ECM is
suspect.
P060700 Control module performance Refer to the warranty

Sub - CPU watch dog
manual if an ECM is
suspect.

APS Communication manual if an ECM is
performance
suspect.

throttle position Throttle motor amplifier policy and procedures
P060E62
performance - signal failure for valve sensor manual if an ECM is
compare failure malfunction suspect.

throttle position policy and procedures
P060E64
performance - signal TPS Communication manual if an ECM is

ECM is suspect.

ECM is suspect.

Control module vehicle using the Jaguar
P061043
options error VID block fault approved diagnostic
system.

short circuit to ground.
For starter relay tests,
P06160E Starter relay circuit low GO to Pinpoint Test

Starter relay drive circuit: For starter relay tests,
P06170C Starter relay circuit high short circuit to battery GO to Pinpoint Test
G531332p27.
Internal control module policy and procedures
P061A00
torque performance Pedal follower error manual if an ECM is
suspect.

Absolute engine torque policy and procedures
P061A29 torque performance - signal
calculation failure - sub- manual if an ECM is
invalid processor suspect.

calculation failure manual if an ECM is
suspect.

P061B29 torque calculation Absolute and dynamic engine
torque calculation failure manual if an ECM is
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performance - signal invalid

suspect.

torque calculation policy and procedures
P061B64 Absolute and dynamic engine
performance - signal torque calculation failure manual if an ECM is

Fuel pump A control
P062700 Invalid fuel pump duty AJV8/3.0L NA V6 -
circuit/open requested by the ECM AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
>G99999

Fuel pump A control circuit
P062A00 Fuel pump circuit fault (FPDM AJV8/3.0L NA V6 -
range/performance to fuel pump) AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
>G99999
VIN not programmed or Configure the module

P063000 using the Jaguar
incompatible - ECM/PCM CCF to CAN VIN mismatch
approved diagnostic
system.
For EMS relay tests, GO

ECM power relay control
P068773 EMS control relay to Pinpoint Test
circuit high malfunction G531332p32.
Output speed sensor circuit For transmission tests.

P072186 TCM Output shaft speed
range/performance sensor error received

P08510E Park/Neutral switch input tests,
circuit low circuit low External Controls

P08520C Park/Neutral switch input tests,
circuit high circuit high External Controls

P114600 Generator load low
Generator - C line circuit low
Manifold absolute
pressure/temperature For MAPT tests, GO to
P114723 (MAPT) intake air MAPT intake air temperature Pinpoint Test
temperature sensor circuit stuck low at engine start G531332p37.
range/performance
Manifold absolute
temperature sensor circuit stuck high at engine start G531332p37.
range/performance
Manifold absolute
temperature sensor circuit stuck G531332p37.
range/performance
Generator load high input For generator tests,

P124400
(see P062600) Generator - C line circuit high
Immobilizer to PCM signal Configure the system

P125900 Incorrect ID received from
error using the Jaguar
instrument pack
approved diagnostic
system.

tests,
circuit fault (cylinder Engine Ignition - VIN
misfire detected DTC also Range: G45704->G99999
flagged) Check the fuel pressure,
Fuel delivery pressure low NA V8 - AJV8/4.2L SC V8 -
AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8,
P131500 Persistent misfire (injector DTCs also
flagged) VIN Range: G45704-
Ignition coil failure circuit tests,
Fuel Charging and
Spark plug Controls - VIN Range:
failure/fouled/incorrect G45704->G99999 For
gap
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spark plug tests,

Range: G45704->G99999
Check for associated

Injector driver misfire -
P131600 Injector driver module codes DTCs and refer to the
emissions damage detected DTC index.

P136700 Ignition amplifier group A short circuit to power Engine Ignition - VIN
Range: G45704->G99999
circuit fault, right hand
bank
P136800 Ignition amplifier group B short circuit to power Engine Ignition - VIN
Range: G45704->G99999
circuit fault left hand
bank
P160300 EEPROM error
ECM fault manual if an ECM is
suspect.
ECM electronic throttle
Dynamic torque monitoring policy and procedure
P162600 monitoring / self test -
error torque monitoring manual if an ECM is
problem suspect.

P162900 Internal voltage regulator
Generator - F line failure
Smart alternator faults For generator tests,

P163200
sensor/circuit Generator - L line failure

Fuel trim too lean, right hand
P209600 codes. Check for air
intake faults

Fuel trim too rich, right hand
intake faults

Fuel trim too lean, left hand
intake faults

Fuel trim too rich, left hand
intake faults

Replace the throttle
body.
Throttle Body - 4.2L NA
Throttle actuator control V8 - AJV8/3.5L NA V8 -
P210129 motor circuit Jammed throttle blade, AJV8, VIN Range:
range/performance gearing or motor G45704->G99999
(19.70.04) or
Throttle Body - 4.2L SC
V8 - AJV8, VIN Range:
G45704->G99999
(19.70.04)
Throttle actuator control Check for a message in

P210162 motor circuit Jammed throttle blade, the instrument cluster.
range/performance gearing or motor Replace the throttle
body.
V8 - AJV8/3.5L NA V8 -
AJV8, VIN Range:
G45704->G99999
(19.70.04) or
G45704->G99999
(19.70.04)

body.
P210164 motor circuit Jammed throttle blade, AJV8, VIN Range:
gearing or motor
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range/performance G45704->G99999
(19.70.04) or
G45704->G99999
(19.70.04)
Check for throttle related

DTCs. Check the intake
control circuit
Throttle blade stuck open system for leaks.
(commanded position not Intake air system leak and Filtering - VIN Range:
reachable)
G45704->G99999

Fuel Charging and
Control circuit: short circuit
Throttle actuator motor Controls - VIN Range:
P210329 to power
control circuit high G45704->G99999 Refer
ECM fault to the warranty policy
and procedures manual if
an ECM is suspect.

Throttle actuator motor Control circuit: short circuit motor circuit tests,
P210364 control circuit high - signal to power
Fuel Charging and
plausibility failure Controls - VIN Range:
ECM fault
G45704->G99999 Refer
to the warranty policy
an ECM is suspect.

the reason for the fuel
P210500 system - forced engine Throttle MIL request due to
fuel cut cut. Follow the action
shutdown
indicated for those DTCs.

body.
P210629 system - forced limited AJV8, VIN Range:
Signal invalid
power G45704->G99999
(19.70.04) or
G45704->G99999
(19.70.04)

body.
P210664 system - forced limited AJV8, VIN Range:
Signal plausibility failure
power G45704->G99999
(19.70.04) or
G45704->G99999
(19.70.04)

Control circuit: short circuit motor circuit tests,
to power, short circuit to Fuel Charging and
P211800 control current ground, high resistance Controls - VIN Range:
range/performance G45704->G99999 Refer
ECM fault to the warranty policy
an ECM is suspect.

body.
P211900 throttle body AJV8, VIN Range:
Throttle spring faulty
(19.70.04) or
G45704->G99999
(19.70.04)
For APP sensor tests, GO

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P212200 (APP) sensor D circuit low G531332p22.
APP sensor circuit 2 low input
input and GO to Pinpoint Test
G531332p23.
For APP sensor tests, GO

P212300 (APP) sensor D circuit high APP sensor: circuit 2 high G531332p22.
G531332p23.

clear the DTCs and
P213528 (APP) sensor 1 and 2 voltage APP sensor: incorrect start
value (not zero) retest. If the code resets,
correlation
replace the APP sensor.

Accelerator pedal position APP sensor: excessive
clear the DTCs and
P213529 (APP) sensor 1 and 2 voltage difference between raw
correlation values of circuit 1 and 2 - retest. If the code resets,
sub-processor replace the APP sensor.

APP sensor: incorrect start clear the DTCs and
P213562 (APP) sensor 1 and 2 voltage
value (not zero) sub- retest. If the code resets,
correlation processor replace the APP sensor.
P213564 Accelerator pedal position APP sensor: excessive Check connections, etc,
(APP) sensor 1 and 2 voltage difference between raw clear the DTCs and
correlation values of circuit 1 and 2 retest. If the code resets,
replace the APP sensor.

low input ECM fault) manual if an ECM is
suspect.

high input ECM fault) manual if an ECM is
suspect.
For evaporative
P240100 system leak detection pump DMTL pump circuit(s): short Evaporative Emissions -
control circuit low circuit to ground VIN Range: G45704-
>G99999
For evaporative
Evaporative emission system
emissions tests,
diagnostic monitoring of tank
P240200 DMTL pump circuit(s): short Evaporative Emissions -
leakage (DMTL) pump circuit to power VIN Range: G45704-
control circuit high
>G99999
DMTL reference leak For evaporative

emissions tests,
DMTL pump sense circuit DMTL pump circuit: short
range/performance - signal circuit, high resistance
VIN Range: G45704-
invalid
blocked/leaking
DMTL reference leak For evaporative
emissions tests,
DMTL pump sense circuit DMTL pump circuit: short
P24042F Evaporative Emissions -
range/performance - signal circuit, high resistance
VIN Range: G45704-
erratic
blocked/leaking
For evaporative
emissions tests,
DMTL pump sense circuit low circuit, high resistance VIN Range: G45704-
>G99999
For evaporative
Evaporative emission system emissions tests,
P240600 DMTL pump sense circuit DMTL pump circuit: short Evaporative Emissions -
high circuit, high resistance VIN Range: G45704-
>G99999
For evaporative
P240B00 DMTL pump heater circuit DMTL heater control circuit Evaporative Emissions -
low low VIN Range: G45704-
>G99999
For evaporative
P240C00 DMTL pump heater circuit DMTL heater control circuit Evaporative Emissions -
high high VIN Range: G45704-
>G99999
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Secondary air injection For secondary air

Secondary air injection pump/valve/pipework
injection tests,
system air flow/pressure leaks
sensor circuit
range/performance Secondary air injection pump VIN Range: G45704-
>G99999
For secondary air
injection tests,
sensor circuit low input, right system MAP sensor
circuit low VIN Range: G45704-
hand bank
>G99999
For secondary air

injection tests,
sensor circuit high input, system MAP sensor
circuit high VIN Range: G45704-
right hand bank
>G99999
For secondary air

Secondary air injection injection tests,
P244400 system pump stuck ON, right Engine Emission Control -
system pump control
hand bank circuit low VIN Range: G45704-
>G99999
P244500 Secondary air injection Secondary air pump control For secondary air
system pump stuck OFF, right circuit high injection pump circuit
hand bank tests,
VIN Range: G45704-
>G99999
For evaporative
emissions tests,
system change-over valve
(COV) performance/stuck circuit, high resistance VIN Range: G45704-
open
>G99999
For evaporative
Evaporative emission control emissions tests,
P245100 system COV valve stuck DMTL pump circuit: short Evaporative Emissions -
closed circuit, high resistance VIN Range: G45704-
>G99999
Generator - For charging system

P250300 Charging system voltage low range/performance - tests,
output voltage low when
high requested
Generator - For charging system
P250400 Charging system voltage high range/performance - tests,
output voltage high when
low requested
Coolant pump control circuit pump tests, GO to
P260100 Coolant pump control circuit
range/performance range/performance Pinpoint Test
G531332p39.
ECT sensor fault

ECM/PCM Internal engine off fault
P261064 components listed.
timer performance
Body processor module fault Follow the action listed
(time) for those DTCs.
CAN error
ECT sensor fault Check for DTCs indicating
ECM/PCM Internal engine off
P261087 Ambient temperature sensor components listed.
timer performance fault Follow the action listed
for those DTCs.
Body processor module fault
(time)
CAN error
For REM drive circuit
ECM to rear electronic tests,
Fuel pump A low module (REM) drive Fuel Tank and Lines - 4.2L
circuit; open circuit, short
flow/performance (fuel NA V8 - AJV8/4.2L SC V8 -
pump not activated when AJV8/3.0L NA V6 -
requested by ECM) Fuel pump module failure AJ27/3.5L NA V8 - AJV8,
VIN Range: G45704-
REM failure >G99999
Supercharger intake flap

control circuit: short For air cleaner solenoid
Air cleaner inlet control circuit to ground valve tests, GO to
P267600
circuit low Pinpoint Test
Supercharger intake flap G531332p38.
control circuit: high
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resistance
For air cleaner solenoid
Air cleaner inlet control Supercharger intake flap valve tests, GO to
P267700
circuit high control circuit: short Pinpoint Test
Control module For network tests,

U007300
communication bus off CAN Link circuit malfunction

U010100 CAN Link ECM/TCM network
TCM malfunction


U010400 CAN Link ECM/ACC module
speed control module network malfunction

For network tests,
U012100 anti-lock brake system (ABS) CAN Link ECM/ABSCM
control module network malfunction
Lost communication with CAN Link ECM/Electric park For network tests,
U012800
park brake control module brake signal missing
network malfunction
CAN Link ECM/suspension
U013200 Lost communication with For network tests,
control module network
malfunction
suspension control module

U015100 Lost comms - CAN or
restraints control module hardwired

For network tests,

For network tests,
U016400 heating ventilation and air CAN Link ECM/HEVAC
conditioning control module network malfunction
Programme the keys

using the Jaguar
U016700 vehicle immobilizer control Security challenge response
timeout approved diagnostic
module
system.

U040264
transmission control module Actual gear position status

U040267
transmission control module Gear shift position status

U040281
transmission control module Output shaft speed

For network tests,
MSR monitoring - plausibility
control module

For network tests,
MSR monitoring - rationality
control module

instrument panel control For network tests,
U042381 External ambient
module - invalid serial data temperature
received

For network tests,
U042386 instrument panel control
Battery voltage level
module - signal invalid
using the Jaguar
U042600 vehicle immobilizer control
Security code mismatch approved diagnostic
module
system.
Warning indicator requested For network tests,

U206400
by another control module Crash event has occurred
Pinpoint Tests
PINPOINT TEST G531332p1 : MASS AIR

FLOW (MAF) SENSOR CIRCUIT
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VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the MAF sensor electrical
ECM connector PI300, harness side MAF connector PI14, harness side
Pin 70 Pin 03
-> Yes
-> No

CIRCUIT TO POWER
MAF connector PI14, harness side Battery
-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
TEST the system for normal operation
-> No

1. Reconnect the ECM electrical connector, PI300. 2. Key on, engine off. 3. Measure the voltage
between:

-> Yes
-> No
REPAIR the circuit between the MAF sensor electrical connector, PI14, pin 01 (GU) and BATTERY. This
circuit includes the EMS control relay, fuse 14 of the front power distribution box, and the high
power protection module. For additional information, refer to the wiring diagrams. CLEAR the DTC.

CIRCUIT RANGE/PERFORMANCE,
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HIGH/LOW VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the MAF sensor electrical
ECM connector PI300, harness side MAF connector PI14, harness side
Pin 66 Pin 04
-> Yes
-> No
TO POWER
-> Yes
-> No
TO GROUND
-> Yes
-> No

SENSOR CIRCUIT
VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the ECT sensor electrical
ECM connector PI300, harness side ECT sensor connector PI25, harness side
Pin 68 Pin 02
-> Yes
-> No
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G531332t9 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT CIRCUIT
TO POWER
-> Yes
-> No
G531332t10 : CHECK THE ECT SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO GROUND
1. Turn the ignition switch to the OFF position. 2. Measure the resistance between:
-> Yes
-> No
Engine Coolant Temperature (ECT) Sensor - 4.2L SC V8 - AJV8 (18.30.10)
Engine Coolant Temperature (ECT) Sensor - 4.2L NA V8 - AJV8 (18.30.10) CLEAR the DTC. TEST the

THROTTLE POSITION (TP) SENSOR
VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the TP sensor electrical
ECM connector PI300, harness side TP sensor connector PI26, harness side
Pin 65 Pin 06
-> Yes
-> No
CIRCUIT TO POWER
-> Yes
-> No
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CIRCUIT TO GROUND
-> Yes
-> No
THROTTLE POSITION (TP) SENSOR
CIRCUIT TP2 HIGH/LOW VOLTAGE
G531332t14 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR HIGH
RESISTANCE
1. Key off. 2. Disconnect the TP sensor electrical connector, PI26. 3. Disconnect the ECM electrical
ECM connector PI300, harness side TP sensor connector PI26, harness side
Pin 67 Pin 04
-> Yes
-> No
G531332t15 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR SHORT CIRCUIT

TO POWER
-> Yes
-> No
G531332t16 : CHECK TP SENSOR SENSING CIRCUIT TP2 FOR SHORT CIRCUIT
TO GROUND
-> Yes
-> No
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MALFUNCTION
1. Key off. 2. Disconnect the H02S electrical connector, PI10. 3. Disconnect the ECM electrical
ECM connector PI300, harness side HO2S connector PI10, harness side
Pin 28 Pin 04
-> Yes
-> No

POWER
HO2S connector PI10, harness side Battery
-> Yes
-> No

GROUND
-> Yes
-> No
ECM connector PI300, harness side HO2S connector PI10, harness side
Pin 29 Pin 03
-> Yes
-> No
www.JagDocs.com

TO POWER
-> Yes
REPAIR the short circuit For additional information, refer to the wiring diagrams. CLEAR the DTC.
-> No

TO GROUND

-> Yes
-> No
INSTALL a new H02S.
Heated Oxygen Sensor (HO2S) CLEAR the DTC. TEST the system for normal operation. If the DTC is

HAND H02S HEATER CONTROL
CIRCUIT HIGH/LOW CURRENT
1. Key off. 2. Disconnect the H02S electrical connector, PI10. 3. Key on, engine off. 4. Make sure the
O2S heater relay is engaged. 5. Measure the voltage between:
-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the HO2S heater relay, fuse
34 of the front power distribution box, and the high power protection module. For additional

HIGH RESISTANCE
HO2S connector PI10, harness side ECM connector PI300, harness side
Pin 02 Pin 76
-> Yes
-> No

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-> Yes
-> No


-> Yes
-> No
INSTALL a new H02S.

FOR HIGH RESISTANCE
1. Key off. 2. Disconnect the catalyst monitor sensor electrical connector, PI11. 3. Disconnect the
ECM electrical connector, PI300. 4. Measure the resistance between:
Catalyst monitor sensor connector PI11, harness side ECM connector PI300, harness side
Pin 04 Pin 40
-> Yes
-> No

Catalyst monitor sensor connector PI11, harness side Battery

-> Yes
-> No

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-> Yes
-> No

FOR HIGH RESISTANCE
Pin 03 Pin 22

-> Yes
-> No
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC. TEST the system for normal operation.

LOW/HIGH RESISTANCE
HEATER
1. Key off. 2. Disconnect the catalyst monitor sensor electrical connector, PI11. 3. Key on, engine off.
4. Make sure the O2S heater relay is engaged. 5. Measure the voltage between:
-> Yes
-> No
REPAIR the power supply circuit to the catalyst monitor sensor heater. This circuit includes the heater
diagrams. CLEAR the DTC. TEST the system for normal operation.

FOR HIGH RESISTANCE
Pin 02 Pin 88
-> Yes
-> No
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC. TEST the system for normal operation. If the DTC
is repeated, refer to the warranty policy and procedures manual if an ECM is suspect.

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MALFUNCTION
1. Key off. 2. Disconnect the H02S electrical connector, PI12. 3. Disconnect the ECM electrical
Pin 04 Pin 26
-> Yes
-> No
POWER
-> Yes
-> No

GROUND
-> Yes
-> No

Pin 03 Pin 27
-> Yes
-> No

TO POWER
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-> Yes
-> No

TO GROUND

-> Yes
-> No
INSTALL a new H02S.

HAND H02S HEATER CONTROL
CIRCUIT HIGH/LOW CURRENT
1. Key off. 2. Disconnect the H02S electrical connector, PI12. 3. Key on, engine off. 4. Measure the
voltage between:
-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the heater relay and fuse 34
of the front power distribution box. For additional information, refer to the wiring diagrams. CLEAR

HIGH RESISTANCE
Pin 02 Pin 77
-> Yes
-> No


www.JagDocs.com
-> Yes
-> No

-> Yes
-> No
INSTALL a new H02S.

LOW/HIGH RESISTANCE
SENSOR HEATER
sure the catalyst monitor sensor heater relay is engaged. 4. Measure the voltage between:
-> Yes
-> No
REPAIR the power supply circuit to the H02S heater. This circuit includes the heater relay and fuse 34
of the front power distribution box. For additional information, refer to the wiring diagrams. CLEAR

Pin 01 Pin 89

-> Yes
-> No
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC. TEST the system for normal operation. If the DTC

VOLTAGE
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RESISTANCE
1. Key off. 2. Disconnect the EOT sensor electrical connector, PI24. 3. Disconnect the ECM electrical
Pin 02 Pin 23
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

RESISTANCE
Pin 01 Pin 10

-> Yes
-> No
Oil Temperature Sensor (18.31.01) CLEAR the DTC. TEST the system for normal operation. If the DTC

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FOR HIGH RESISTANCE

1. Key off. 2. Disconnect the catalyst monitor sensor electrical connector, PI13. 3. Disconnect the
ECM electrical connector, PI300. 4. Measure the resistance between:
Catalyst monitor sensor PI13, harness side ECM connector PI300, harness side
Pin 04 Pin 41
-> Yes
-> No

Catalyst monitor sensor PI13, harness side Battery

-> Yes
-> No

Catalyst monitor sensor PI13, harness side Battery
-> Yes
-> No

FOR HIGH RESISTANCE
Catalyst monitor sensor PI13, harness side ECM connector PI300, harness side
Pin 03 Pin 45

-> Yes
-> No
Catalyst Monitor Sensor (18.30.66) CLEAR the DTC. TEST the system for normal operation.

HAND KNOCK SENSOR (KS)
HIGH/LOW VOLTAGE
1. Key off. 2. Disconnect the KS electrical connector, PI19. 3. Disconnect the ECM electrical
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Pin 04 Pin 42
-> Yes
-> No


-> Yes
-> No

-> Yes
-> No

Pin 03 Pin 19
-> Yes
-> No
INSTALL a new KS.
Knock Sensor (KS) LH (18.30.92) CLEAR the DTC. TEST the system for normal operation.
HAND KNOCK SENSOR (KS)
HIGH/LOW VOLTAGE
1. Key off. 2. Disconnect the KS electrical connector, PI19. 3. Disconnect the ECM electrical
Pin 02 Pin 43

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-> Yes
-> No

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

Pin 01 Pin 20
-> Yes
-> No
INSTALL a new KS.
Knock Sensor (KS) LH (18.30.92) CLEAR the DTC. TEST the system for normal operation.

SENSOR CIRCUIT
MALFUNCTION
1. Key off. 2. Check the CKP sensor for correct installation.
-> Yes
-> No
Crankshaft Position (CKP) Sensor (18.30.12) Reconnect the sensor. CLEAR the DTCs. TEST the system
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-> Yes
-> No
Crankshaft Position (CKP) Sensor (18.30.12) Reconnect the sensor. CLEAR the DTCs. TEST the system

RESISTANCE
1. Disconnect the ECM electrical connector, PI300. 2. Disconnect the CKP sensor electrical connector,
PI21. 3. Measure the resistance between:
Pin 02 Pin 30

-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

RESISTANCE
Pin 01 Pin 06
-> Yes
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-> No
Crankshaft Position (CKP) Sensor (18.30.12) CLEAR the DTC. TEST the system for normal operation.

SENSOR CIRCUIT
MALFUNCTION
1. Key off. 2. Check the CMP sensor for correct installation.
-> Yes
-> No
Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTCs. TEST the system for normal
operation.
-> Yes
-> No
Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTCs. TEST the system for normal
operation.

RESISTANCE
1. Disconnect the CMP sensor electrical connector, PI23. 2. Disconnect the ECM electrical connector,
PI300. 3. Measure the resistance between:
Pin 02 Pin 34
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO GROUND

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-> Yes
-> No

RESISTANCE
Pin 01 Pin 07
-> Yes
-> No
Camshaft Position (CMP) Sensor RH (18.31.11) CLEAR the DTC. TEST the system for normal
operation.

RADIATOR COOLING FAN MODULE
DRIVE CIRCUIT MALFUNCTION
1. Disconnect the fan module electrical connector, GCU04. 2. Measure the voltage between:
Fan module connector GCU04, harness side Battery
Single pin Negative terminal
-> Yes
front power distribution box (80A). For additional information, refer to the wiring diagrams. CLEAR
-> No
G531332t74 : CHECK THE RADIATOR FAN MODULE GROUND

1. Disconnect the fan module electrical connector, GCU03. 2. Measure the resistance between:
Single pin Negative terminal
-> Yes
-> No

1. Disconnect the fan module electrical connector, GCU01. 2. Key on, engine off. 3. Make sure the
EMS relay is engaged. 4. Measure the voltage between:
-> Yes
REPAIR the circuit between the cooling fan module and battery. This circuit includes the front power
distribution box, (fuse 14) and the EMS control relay. For additional information, refer to the wiring
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-> No

HIGH RESISTANCE
Fan module connector GCU01, harness side ECM connector PI300, harness side
Pin 01 Pin 49
-> Yes
-> No
-> Yes
-> No

-> Yes
-> No
INSTALL a new radiator cooling fan module. CLEAR the DTC. TEST the system for normal operation.

BATTERY POWER SUPPLY VOLTAGE
MALFUNCTION
1. Disconnect the ECM electrical connector, PI300. 2. Measure the voltage between:
ECM connector PI300, harness side Battery
-> Yes
Recheck the DTCs.
-> No
box. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
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PINPOINT TEST G531332p21 : MASS

AIR FLOW (MAF) SENSOR GROUND
MALFUNCTION
G531332t80 : CHECK THE MAF SENSOR GROUND
1. Disconnect the MAF sensor electrical connector, PI14. 2. Key on, engine off. 3. Measure the
resistance between:
-> Yes
-> No
RESISTANCE
Pin 02 Pin 18
-> Yes
-> No
G531332t82 : CHECK THE MAF SENSOR GROUND CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
Refer to the warranty policy and procedures manual if an ECM is suspect.

(APP) SENSOR SENSING CIRCUIT 1
HIGH/LOW VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the APP sensor electrical
connector, CR14. 4. Measure the resistance between:
ECM connector PI300, harness side APP sensor connector CR14, harness side
Pin 01 Pin 38
-> Yes
-> No
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G531332t84 : CHECK THE APP SENSOR SENSING CIRCUIT FOR SHORT

CIRCUIT TO POWER
1. Key on, ignition off. 2. Measure the voltage between:
-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

1. Reconnect the ECM electrical connector, PI300. 2. Key on, ignition off. 3. Measure the voltage
between:
-> Yes
-> No

HIGH RESISTANCE
APP sensor connector CR14, harness side ECM connector PI300, harness side
Pin 02 Pin 32
-> Yes
-> No

(APP) SENSOR SENSING CIRCUIT 2
HIGH/LOW VOLTAGE
G531332t88 : CHECK THE APP SENSOR SENSING CIRCUIT FOR HIGH
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RESISTANCE
1. Key off. 2. Disconnect the APP sensor electrical connector, CR14. 3. Disconnect the ECM electrical
Pin 04 Pin 24
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No

1. Reconnect the ECM electrical connector, PI300. 2. Key on, engine off. 3. Measure the voltage
between:
-> Yes
-> No

HIGH RESISTANCE
Pin 05 Pin 19
-> Yes
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-> No

THROTTLE MOTOR CONTROL
CIRCUIT MALFUNCTION
G531332t93 : CHECK THE THROTTLE MOTOR - TO ECM CIRCUIT FOR HIGH
RESISTANCE
1. Key off. 2. Disconnect the throttle motor electrical connector, PI26. 3. Disconnect the ECM
electrical connector, PI300. 4. Measure the resistance between:
Throttle motor connector PI26, harness side ECM connector PI300,harness side
Pin 02 Pin 74
-> Yes
-> No
G531332t94 : CHECK THE THROTTLE MOTOR + TO ECM CIRCUIT FOR HIGH

RESISTANCE
Throttle motor connector PI26, harness side ECM connector PI300,harness side
Pin 01 Pin 75
-> Yes
-> No
Throttle Body - 4.2L NA V8 - AJV8/3.5L NA V8 - AJV8, VIN Range: G45704->G99999 (19.70.04)
Throttle Body - 4.2L SC V8 - AJV8, VIN Range: G45704->G99999 (19.70.04) CLEAR the DTC. TEST the
PINPOINT TEST G531332p25 : SENSOR

SUPPLY VOLTAGE MALFUNCTION,
HIGH/LOW VOLTAGE
G531332t95 : CHECK THE SUPPLY VOLTAGE AT THE MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR
1. Disconnect the MAP sensor electrical connector, PI301. 2. Key on, engine off. 3. Measure the
voltage between:

-> Yes
REPAIR the circuit between the MAP sensor and battery. This circuit includes splice PIS84. For
operation.
-> No
G531332t96 : CHECK THE SUPPLY VOLTAGE AT THE FUEL RAIL PRESSURE

(FRP) SENSOR
1. Disconnect the FRP sensor electrical connector, PI28. 2. Measure the resistance between:
FRP sensor connector PI28, harness side Battery

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-> Yes
REPAIR the circuit between the FRP sensor and battery. This circuit includes splice PIS84. For
operation.
-> No
CHECK for DTCs indicating a sensor fault. Refer to the DTC index.
PINPOINT TEST G531332p26 : SENSOR

GROUND CIRCUITS OPEN CIRCUIT
G531332t115 : CHECK THE SENSOR GROUND AT THE MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR (VEHICLES WITH SUPERCHARGER)
1. Key off. 2. Disconnect the ECM electrical connector, PI300. 3. Disconnect the MAP sensor electrical
MAP sensor electrical connector PI301, harness side ECM connector PI300, harness side
Pin 04 Pin 12

-> Yes
-> No
G531332t116 : CHECK THE SENSOR GROUND AT THE ENGINE COOLANT

TEMPERATURE (ECT) SENSOR
1. Disconnect the ECT sensor electrical connector, PI25. 2. Measure the resistance between:
ECT sensor electrical connector PI25, harness side ECM connector PI300, harness side
Pin 01 Pin 12
-> Yes
-> No
G531332t117 : CHECK THE SENSOR GROUND AT THE MASS AIR FLOW (MAF)
SENSOR
1. Disconnect the MAF sensor electrical connector, PI14. 2. Measure the resistance between:
MAF sensor electrical connector PI14, harness side ECM connector PI300, harness side
Pin 05 Pin 12
-> Yes
-> No
CHECK for DTCs indicating a sensor fault. Refer to the warranty policy and procedures manual if an
ECM is suspect.

STARTER RELAY SIGNAL
CIRCUIT TO GROUND
1. Key off. 2. Remove the starter relay. 3. Measure the resistance between:

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-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No
G531332t133 : CHECK THE STARTER RELAY TO ECM CIRCUIT FOR HIGH

RESISTANCE
Starter relay base ECM connector EC300, harness side
Pin 02 Pin 51
-> Yes
-> No
INSTALL a new starter relay. Clear the DTC and test the system for normal operation. If the DTC
resets, refer to the warranty policy and procedures manual if an ECM is suspect.

SENSOR CIRCUIT MALFUNCTION
RANGE/PERFORMANCE
-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTCs. TEST the system for normal
operation.
-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTCs. TEST the system for normal
operation.

RESISTANCE
1. Key off. 2. Disconnect the CMP sensor electrical connector, PI22. 3. Disconnect the ECM electrical
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Pin 01 Pin 33
-> Yes
-> No

CIRCUIT TO POWER

-> Yes
-> No

CIRCUIT TO GROUND
-> Yes
-> No
Camshaft Position (CMP) Sensor LH (18.31.12) CLEAR the DTC. TEST the system for normal
operation.

MALFUNCTION, CIRCUIT
MALFUNCTION
G531332t140 : CHECK ECM TO VCT SOLENOID CIRCUIT FOR HIGH
RESISTANCE
1. Key off. 2. Disconnect the VCT electrical connector, PI16. 3. Disconnect the ECM electrical
VCT connector PI16, harness side ECM connector PI300, harness side
Pin 01 Pin 86
-> Yes
-> No
G531332t141 : CHECK ECM TO VCT SOLENOID CIRCUIT FOR SHORT CIRCUIT

TO POWER
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VCT connector PI16, harness side Battery
-> Yes
-> No

TO GROUND

-> Yes
-> No
G531332t143 : CHECK VCT SOLENOID POWER

-> Yes
REPAIR the circuit between the VCT solenoid and battery. This circuit includes splices PIS11 and
ECS72, and fuse 12 of the front power distribution box. For additional information, refer to the wiring
-> No
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90) CLEAR the DTC. TEST the system for
normal operation.

MALFUNCTION, CIRCUIT
MALFUNCTION
G531332t144 : CHECK ECM TO VCT SOLENOID CIRCUIT FOR HIGH
RESISTANCE
1. Key off. 2. Disconnect the VCT electrical connector, PI17. 3. Disconnect the ECM electrical
VCT connector PI17, harness side ECM connector PI300, harness side
Pin 01 Pin 87
-> Yes
-> No

TO POWER
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-> Yes
-> No

TO GROUND

-> Yes
-> No
G531332t147 : CHECK VCT SOLENOID POWER

-> Yes
REPAIR the circuit between the VCT solenoid and battery. This circuit includes splices PIS11 and
ECS72, and fuse 12 of the front power distribution box. For additional information, refer to the wiring
-> No
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90) CLEAR the DTC. TEST the system for
normal operation.
PINPOINT TEST G531332p31 : "FLIGHT

RECORDER" DATA IS STORED IF ANY
ONE OF FIVE CONDITIONS OCCUR
CIRCUIT TO POWER VOLTAGE
1. Make sure the inertia switch is not tripped. 2. Disconnect the inertia switch electrical connector,
CR02. 3. Disconnect the ECM electrical connector, EC300. 4. Measure the voltage between:
Inertia switch connector CR02, harness side ECM connector EC300, harness side
Pin 03 Pin 42
-> Yes
-> No
INSTALL a new inertia switch. CLEAR the DTC. CLEAR the flight recorder information. TEST the system

CONTROL RELAY MALFUNCTION
G531332t149 : CHECK THE EMS RELAY PERMANENT SUPPLY
1. Key off. 2. Remove the EMS relay. 3. Measure the voltage between:
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Relay base Battery
Pin 01
Negative terminal
Pin 05
-> Yes
-> No
REPAIR the circuit between the relay base and battery. For additional information, refer to the wiring

HIGH RESISTANCE
Relay base ECM connector EC300, harness side
Pin 02 Pin 16

-> Yes
-> No
G531332t151 : CHECK THE EMS RELAY TO ECM SUPPLY CIRCUIT FOR HIGH
RESISTANCE
Relay base ECM connector EC300, harness side
Pin 04
Pin 03
Pin 06
-> Yes
-> No
INSTALL a new EMS relay. CLEAR the DTC. TEST the system for normal operation.

(MAP) SENSOR SENSING CIRCUIT
MALFUNCTION, HIGH/LOW VOLTAGE
(VEHICLES WITHOUT
SUPERCHARGER)
RESISTANCE
1. Key off. 2. Disconnect the MAP sensor electrical connector, PI29. 3. Disconnect the ECM electrical
Pin 01 Pin 69
-> Yes
-> No

CIRCUIT TO POWER
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-> Yes
-> No

CIRCUIT TO GROUND

-> Yes
-> No
Manifold Absolute Pressure (MAP) Sensor - 4.2L NA V8 - AJV8 (18.30.86) CLEAR the DTC. TEST the
system for normal operation. If the DTC is repeated, refer to the warranty policy and procedures

FUEL TEMPERATURE (EFT) SENSOR
RANGE/PERFORMANCE, LOW/HIGH
VOLTAGE
RESISTANCE
1. Key off. 2. Disconnect the EFT sensor electrical connector, PI27. 3. Disconnect the ECM electrical
EFT sensor connector PI27, harness side ECM connector PI300, harness side
Pin 02 Pin 46
-> Yes
-> No

CIRCUIT TO POWER
EFT sensor connector PI27, harness side Battery
-> Yes
-> No

CIRCUIT TO GROUND
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EFT sensor connector PI27, harness side Battery
-> Yes
-> No
Fuel Temperature Sensor (18.30.99) CLEAR the DTC. TEST the system for normal operation.

SENSOR CIRCUIT LOW/HIGH
VOLTAGE
HIGH RESISTANCE
1. Key off. 2. Disconnect the A/C pressure sensor electrical connector, EC11. 3. Disconnect the ECM
A/C pressure sensor connector EC11, harness side ECM connector PI300, harness side
Pin 02 Pin 12
-> Yes
-> No

-> Yes
-> No

-> Yes
-> No
(82.10.32)

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SENSOR/TEMPERATURE (MAPT)
SENSOR, INTAKE AIR TEMPERATURE
(IAT2) SENSING CIRCUIT
G531332t166 : CHECK THE MAPT SENSOR IAT2 SENSING CIRCUIT FOR HIGH
RESISTANCE
1. key off. 2. Disconnect the MAPT sensor electrical connector, PI301. 3. Disconnect the ECM
MAPT sensor connector PI301, harness side ECM connector PI300, harness side
Pin 03 Pin 39
-> Yes
-> No
G531332t167 : CHECK THE MAPT SENSOR IAT2 SENSING CIRCUIT FOR

MAPT sensor connector PI301, harness side Battery
-> Yes
-> No
G531332t168 : CHECK THE MAPT SENSOR IAT2 SENSING CIRCUIT FOR

MAPT sensor connector PI301, harness side Battery
-> Yes
-> No
INSTALL a new MAPT sensor. CLEAR the DTC. TEST the system for normal operation.
CLEANER SOLENOID VALVE DRIVE
CIRCUIT MALFUNCTION
G531332t169 : CHECK THE POWER SUPPLY TO THE AIR CLEANER
SOLENOID VALVE
1. Key off. 2. Disconnect the air cleaner solenoid valve electrical connector, EC37. 3. Key on, engine
off. 4. Make sure the EMS relay is engaged. 5. Measure the voltage between:
Air cleaner solenoid valve connector EC37, harness side Battery

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-> Yes
-> No
REPAIR the circuit between the air cleaner solenoid valve and battery. This circuit includes splice
ECS20, fuse 14 of the front power distribution box and the EMS relay. For additional information,

FOR HIGH RESISTANCE
Air cleaner solenoid valve connector EC37, harness side ECM connector PI300, harness side
Pin 02 Pin 49
-> Yes
-> No

-> Yes
-> No

-> Yes
-> No
INSTALL a new air cleaner solenoid valve. CLEAR the DTC. TEST the system for normal operation.
THE AUXILIARY COOLANT PUMP
FUNCTION
G531332t173 : CHECK THE POWER SUPPLY TO THE AUXILIARY COOLANT
PUMP
1. Key off. 2. Disconnect the auxiliary coolant pump electrical connector, CP02. 3. Key on, engine off.
4. Make sure the EMS relay is engaged. 5. Make sure the auxiliary coolant pump relay is engaged. 6.
Auxiliary coolant pump connector CP02, harness side Battery

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-> Yes
REPAIR the circuit between CP02, pin 02 and battery. This circuit includes fuse 17 of the front power
distribution box, the auxiliary coolant pump relay and the EMS relay. For additional information,
-> No
G531332t174 : CHECK THE AUXILIARY COOLANT PUMP GROUND

Auxiliary coolant pump connector CP02, harness side Battery
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. TEST the
-> No
INSTALL a new auxiliary coolant pump.
Water Pump CLEAR the DTC. TEST the system for normal operation.

RAIL PRESSURE (FRP) SENSOR
CIRCUIT
G531332t175 : CHECK THE FRP SENSOR SUPPLY CIRCUIT VOLTAGE
1. Key off. 2. Disconnect the FRP sensor electrical connector, PI28. 3. Key on, engine off. 4. Measure
-> Yes
REPAIR the 5 volt supply circuit between the FRP sensor and the ECM. For additional information,
-> No

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER
-> Yes
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-> No

RESISTANCE
1. Disconnect the ECM sensor electrical connector, PI300. 2. Measure the resistance between:
FRP sensor connector PI28, harness side ECM connector PI300, harness side
Pin 03 Pin 71
-> Yes
-> No
G531332t180 : CHECK THE FRP SENSOR GROUND CIRCUIT FOR HIGH

RESISTANCE
FRP sensor connector PI28, harness side ECM connector PI300, harness side
Pin 02 Pin 10
-> Yes
REPAIR the high resistance circuit. This circuit includes splice PIS49. For additional information, refer
to the wiring diagrams. CLEAR the DTC and test the system for normal operation.
-> No
INSTALL a new FRP sensor.
Fuel Rail Pressure (FRP) Sensor (18.30.98) CLEAR the DTC and test the system for normal operation.

(MAP) SENSOR SENSING CIRCUIT
MALFUNCTION, HIGH/LOW VOLTAGE
(VEHICLES WITH SUPERCHARGER)
RESISTANCE
1. Key off. 2. Disconnect the MAP sensor electrical connector, PI301. 3. Disconnect the ECM electrical
Pin 01 Pin 38
-> Yes
-> No
CIRCUIT TO POWER
-> Yes
-> No
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CIRCUIT TO GROUND
-> Yes
-> No
Manifold Absolute Pressure (MAP) Sensor - 4.2L SC V8 - AJV8 (18.30.86) CLEAR the DTC. TEST the
system for normal operation. If the DTC is repeated, refer to the warranty policy and procedures

MANIFOLD ABSOLUTE
PRESSURE/TEMPERATURE (MAPT)
SENSOR PRESSURE SENSING CIRCUIT
G531332t101 : CHECK THE POWER SUPPLY TO THE MAPT SENSOR
1. Key off. 2. Disconnect the MAPT connector, PI310. 3. Key on, engine off. 4. Measure the voltage
between:
MAPT sensor connnector PI310, harness side Battery
-> Yes
-> No
CHECK the circuit between the MAPT sensor, pin 02 and the ECM. Refer to the warranty policy and
procedures manual if an ECM is suspect.
G531332t102 : CHECK THE GROUND TO THE MAPT SENSOR

-> Yes
REPAIR the high resistance circuit. This circuit includes splice PIS49 and the ECM. For additional
Refer to the warranty policy and procedures manual if an ECM is suspect.
-> No
G531332t100 : CHECK THE MAPT PRESSURE SENSING CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Disconnect the ECM connector, PI300. 2. Measure the resistance between:
-> Yes
-> No
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G531332t103 : CHECK THE MAPT PRESSURE SENSING CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G531332t104 : CHECK THE MAPT PRESSURE SENSING CIRCUIT FOR HIGH

RESISTANCE
MAPT sensor connnector PI310, harness side ECM connector PI300, harness side
Pin 01 Pin 69
-> Yes
DTC. TEST the system for normal operation. Refer to the warranty policy and procedures manual if an
ECM is suspect.
-> No
INSTALL a new MAPT sensor. CLEAR the DTC. TEST the system for normal operation.

SWITCH
RELEASED)
1. Key off. 2. Disconnect the brake switch electrical connector, CR78. 3. Make sure the brake pedal is
not pressed. 4. Measure the resistance between:
Pin 01 Pin 02
-> Yes
-> No

PRESSED)
Pin 01 Pin 02
-> Yes
-> No


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-> Yes
-> No

CIRCUIT TO GROUND

-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

RESISTANCE
Pin 02 Pin 41
-> Yes
-> No
REFER to the warranty policy and procedures manual if an ECM is suspect.

Removal

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Installation
1
procedure.


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Camshaft Position (CMP) Sensor LH
(18.31.12)
Removal

All vehicles
5 NOTE:
.
Vehicles with supercharger shown, vehicles with 3.5L or 4.2L engine without
supercharger similar.
NOTE:
Remove the engine compartment supports.

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6 . Loosen the throttle body intake pipe retaining clip.
7 . Detach the air filter outlet pipe

1) Detach the throttle body intake pipe.
2) Remove the throttle body intake pipe.
All vehicles
9 . NOTE:
Right-hand drive vehicles shown, left-hand drive vehicles similar.
Remove the engine compartment outer panel insulation.

10 . Remove the engine compartment outer panel.

11 . Remove the engine compartment outer access panel.
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All vehicles
12 . NOTE:
Remove the cabin air filter.

13 . NOTE:
Remove the cabin filter housing.
1) Remove the cabin filter housing retaining nuts.
2) Remove the cabin filter housing.
14 . NOTE:
Detach the engine compartment outer panel.
1) Remove the engine compartment outer panel retaining bolt.
2) Detach the engine compartment outer panel.

Detach the hood release cable.

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16 . Remove the engine compartment supports spacing plate.
17 NOTE:
.
Detach the engine compartment inner panel insulation.

18 NOTE:
.
NOTE:
Remove the left-hand engine compartment inner panel.
19 NOTE:
.
NOTE:
Left-hand drive vehicles shown, right-hand drive vehicles similar.
Remove the right-hand engine compartment inner panel.

20 . Detach the camshaft position (CMP) sensor electrical connector.
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21 . Disconnect the CMP sensor electrical connector.

Installation
Tighten to 7 Nm.
2 NOTE:
.
NOTE:
Tighten to 25 Nm.
Camshaft Position (CMP) Sensor RH
(18.31.11)
Removal
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All vehicles
5 NOTE:
.
NOTE:



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All vehicles
9 . NOTE:


All vehicles
12 . NOTE:

13 . NOTE:

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14 . NOTE:

16 . Remove the engine compartment support spacing plate.
17 NOTE:
.
Detach the engine compartment inner panel insulation.

18 NOTE:
.
NOTE:
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19 NOTE:
.
NOTE:

20 . Detach the camshaft position (CMP) sensor electrical connector.
21 . Disconnect the CMP sensor electrical connector.

Installation
Tighten to 7 Nm.
2 NOTE:
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.
NOTE:
Tighten to 25 Nm.
Removal
2 . Detach the catalyst monitor sensor electrical connector.
3 . Disconnect the catalyst monitor sensor electrical connector.
4 Detach the catalyst monitor sensor wiring harness from the retaining clip on the automatic
. transmission.
5
. CAUTION: Do not twist the catalyst monitor sensor wiring harness on removal.

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Installation
1
. CAUTION: Do not twist the catalyst monitor sensor wiring harness on installation.
Tighten to 40 Nm.
2 NOTE:
.

Test
(18.30.12)
Removal
Installation
1 . To install, reverse removal procedure.
Tighten to 7 Nm.
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5 Point Security Torx Bit

418-535
Removal

1) Remove the engine compartment panel retaining bolt.
2) Remove the engine compartment panel.

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6 NOTE:
.
the electrical connector.
Using the special tool, loosen the ECM electrical connector retaining bolt.
7 . Disconnect the ECM electrical connector.
8 . Remove the instrument panel lower trim panel.
1) Remove the retaining clips.
2) Remove the instrument panel lower trim panel.
9 . Remove the ECM retaining bracket.
1) Detach the retaining clips.

2) Remove the ECM.
Installation
1
. CAUTION: Make sure that the electrical connector is located correctly in the ECM.
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Do not force or overtighten the electrical connector. Failure to follow this instruction may
CAUTION: Make sure the ECM support bracket is located correctly.
Tighten to 5 Nm.
- 4.2L SC V8 - AJV8 (18.30.10)
Removal
1
personal injury.
injury.


Remove and discard the ECT sensor O-ring seal.
Installation
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Install a new ECT sensor O-ring seal.
Tighten to 17 Nm.
- 4.2L NA V8 - AJV8 (18.30.10)
Removal
1
personal injury.
injury.
2 . Remove the air cleaner outlet pipe. <<303-12B>>
3 . Remove the engine coolant temperature (ECT) sensor electrical connector.
1) Disconnect the ECT sensor electrical connector.
2) Remove the ECT sensor.

Installation
Tighten to 17 Nm.
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Removal
All vehicles
1
. WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
Depressurize the fuel system. <<310-00>>


All vehicles
5 NOTE:
.
Vehicles with 3.5L or 4.2L engine without supercharger shown, vehicles with
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Disconnect the fuel rail pressure (FRP) sensor vacuum hose.
1) Disconnect the FRP sensor electrical connector.
2) Disconnect the FRP sensor vacuum hose.
6 NOTE:
.
Vehicles with 3.5L or 4.2L engine without supercharger shown, vehicles with
Remove the FRP sensor.

Installation
1
. WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
Install a new O-ring seals.
Tighten to 5 Nm.
Removal

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All vehicles
5 . Remove the fuel temperature sensor.
Installation
Tighten to 7 Nm.
Removal
2 . Detach the heated oxygen sensor (HO2S) electrical connector.

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3 . Disconnect the HO2S electrical connector.
4
. CAUTION: Do not twist the H02S wiring harness on removal. Failure to follow this
Remove the HO2S.

Installation
1
. CAUTION: Do not twist the H02S wiring harness on installation. Failure to follow this
Tighten to 40 Nm.
Intake Air Temperature (IAT) Sensor - 4.2L
SC V8 - AJV8 (18.30.52)
Removal
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3 . Remove the IAT sensor.
Remove and discard the IAT sensor sealing washer.

Installation
Install a new IAT sensor sealing washer.
Tighten to 35 Nm.
Removal
2 . Remove the noise isolator.

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All vehicles
4 . Remove the knock sensor (KS).
Installation
Tighten to 25 Nm.
Manifold Absolute Pressure (MAP) Sensor -
4.2L SC V8 - AJV8 (18.30.86)
Removal
All vehicles
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3 . NOTE:

7 . NOTE:

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All vehicles
10 . NOTE:

11 . NOTE:
12 . NOTE:


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14 . Remove the engine compartment supports spacing plate.
15 . Detach the engine compartment inner panel insulation.

16 . NOTE:
17 . NOTE:

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Installation
Tighten to 10 Nm.
2 . NOTE:
Tighten to 25 Nm.
3 NOTE:
.

Test
Manifold Absolute Pressure (MAP) Sensor -
4.2L NA V8 - AJV8 (18.30.86)
Removal
2 . Remove the manifold absolute pressure (MAP) sensor.

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Installation
Tighten to 10 Nm.
2 . NOTE:

Removal
1 . Remove the mass airflow (MAF) sensor.
1) Disconnect the MAF sensor electrical connector.
2) Remove the mass airflow MAF sensor.
Installation
Tighten to 2 Nm.
2 NOTE:
.

Test
Removal

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Installation
1 NOTE:
.
Apply a small bead of sealant meeting Jaguar specification on the first three threads of
the oil temperature sensor.
To install, reverse the removal procedure
Tighten to 15 Nm.
Variable Camshaft Timing (VCT) Oil
Control Solenoid (18.30.90)
Removal
2 . Remove the variable camshaft timing (VCT) oil control solenoid.

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Installation
Tighten to 10 Nm.
2 NOTE:
.
Test
303-14C : Electronic Engine Controls – 2.7L V6 – TdV6
Specifications
Specifications

Engine control module (ECM) retaining bolt 6 - 53
Engine control module (ECM) retaining nuts 3 - 26
Engine oil pressure (EOP) sensor 15 11 -
Knock sensor (KS) Left-Hand retaining bolt 20 15 -
Knock Sensor (KS) Right-Hand retaining bolt 20 15 -
Manifold absolute pressure (MAP) sensor 3 - 26
Mass air flow (MAF) sensor retaining screws 2 - 18
General procedures

Adjustment
No Data Available
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1 Mass air flow (MAF) sensor(s)
2 Knock sensor (KS) Right-hand

3 Manifold absolute pressure (MAP) sensor
4 Fuel temperature sensor
5 Knock sensor (KS) Left-hand
6 Camshaft position (CMP) sensor
7 Crankshaft position (CKP) sensor
8 Engine oil pressure (EOP) sensor
9 Engine coolant temperature (ECT) sensor
10 Charge air temperature sensor

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1 Engine control module (ECM)
System Components
All engine functions are controlled by the Siemens common rail ECM.
ECM
The ECM is a high capacity processor which employs advanced software strategies that continuously
control the engines operating parameters. It gathers information from a number of sensors and
provides output to the actuators. The ECM also operates a port deactivation system, which closes or
opens flaps in the inlet system to provide the optimum swirl and flow conditions throughout the
operating range of the engine.
In addition, the ECM controls the actuation of the exhaust gas recirculation (EGR) system, the
variable geometry turbochargers and the throttle, giving faster and more accurate response. A full
torque-based strategy supports multiple injection control and integration with transmission and
braking controllers. Transient torque and boost control enables vehicle performance to be optimised
without compromising engine durability.
CKP Sensor
The CKP sensor signal is used to determine:
the quantity of fuel to be injected
the start of fuel delivery
the quantity of exhaust gases to be recirculated
The CKP sensor is located at the rear of the crankshaft behind the flywheel.
The CKP sensor is a Hall effect sensor which scans a magnetic disc on the crankshaft. The air gap
between the magnetic disc and the CKP is predetermined by the mounting of the sensor.
CMP Sensor
The CMP is located on the cylinder head behind the left-hand camshaft timing belt pulley.
The CMP sensor is Hall effect type and is required to identify cylinder number 1. (This is to
synchronise engine to camshaft timing). The sensor scans a web incorporated into the left- hand
camshaft timing belt pulley. The air gap between the magnetic ring and the CMP sensor is
predetermined by the mounting of the sensor.
ECT Sensor
The ECT sensor is a NTC type sensor and is fitted into the top water outlet hose. The sensor has a
bayonet type fitting.
KS
The KS registers increased vibrations which occur due to increased combustion noise. The ECM uses
the signal as a correction factor for calculating the quantity and timing of the fuel to be injected
during the injection phase.
There are two KS fitted to each bank of the cylinder block.

MAF Sensor
The MAF sensor is used to calculate the air mass. The MAF sensor is capable of detecting the mass air
flow extremely precisely.
On engines with a variable turbocharger, the MAF sensor is used solely to control the EGR and not
the fuel metering. The MAF sensor also incorporates the intake air temperature (IAT) sensor.
MAP Sensor
The MAP sensor is located in the top of the throttle valve.
The MAP sensor measures the charging pressure in the intake pipe and sends the ECM an analog
voltage signal.
Charge Air Temperature Sensor

The charge air temperature sensor measures the intake air or the charge air temperature and
supplies the ECM with an analog signal.
The charge air temperature sensor is located in the air intake plenum chamber.
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Intake Air Temperature (IAT) Sensor

The IAT sensor measures the intake air temperature and supplies the ECM with an analog signal.
There are two IAT sensors incorporated into the MAF sensor, the Left-hand bank IAT sensor is not
monitored by the ECM.

The FRP sensor measures the instantaneous fuel pressure in the fuel rail very precisely within a very
short time and supplies a voltage signal according to the pressure. The FRP is located on the the fuel
diverter rail and must not be removed from the diverter rail. For additional information, refer to Fuel
Charging and Controls (303-04C Fuel Charging and Controls - 2.7L Diesel)
Fuel Temperature Sensor

The fuel temperature sensor measures the temperature of the fuel in the low-pressure system. Air
and excessive heat in the fuel system can have an adverse effect on the operation of the sensor.
The fuel temperature sensor is located in the low-pressure side return line behind the throttle body
housing.
EOP Sensor
The engine oil pressure (EOP) sensor is located in the left-hand cylinder head. The EOP is connected
to the instrument cluster and is not directly part of the electronic engine control system.

Overview
2006MY sees the introduction of diesel to X350 and is accompanied by a diesel particulate filter
(DPF) system to comply with strict stage four emissions requirements. Active engine mounts are also
fitted and reduce transmitted vibration from the engine to the chassis when operating between 600
and 850rpm.

Exhaust System and
Engine
The engine management system (EMS) on 2006MY diesel makes use of 7-digit diagnostic trouble
codes (DTCs) rather than the familiar 5-digit.

Battery charge and condition
Fuel contamination/grade/quality 5 volt sensor supply
Fuel leaks Sensor(s)
Accessory drive belt Engine control module (ECM)
Symptom Chart
Inertia fuel shutoff (IFS) switch
Low/contaminated fuel
Air leakage Check that the inertia switch has not tripped.
Check the fuel level/condition,
Fuel system low pressure Fuel Charging and Controls For air intake
circuit fault
system,
Intake Air Distribution and Filtering Check
Fuel pump module fault
the fuel pump module operation, check the
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Blocked fuel filter fuel system low pressure circuit for

Engine cranks, leaks/damage,
but does not start Fuel volume control valve Fuel Tank and Lines - 2.7L V6 - TdV6 Check
(FVCV) the fuel filter, check the FVCV and FPCV,
blocked/contaminated Fuel Charging and Controls Check the fuel
injection pump,
(FPCV) Fuel Injection Pump For CKP sensor cicuit
blocked/contaminated tests, GO to Pinpoint Test G549822p14.
Refer to the warranty policy and procedures
Fuel injection pump failure manual if an ECM is suspect.

sensor
ECM fault
Glow plug system fault (very Check the glow plug circuits,
cold conditions) Glow Plug System Check the fuel
level/condition,
Fuel Charging and Controls For air intake
Air leakage system,
Difficult to start Intake Air Distribution and Filtering Check
Fuel pump module fault the fuel pump module operation, check the
fuel system low pressure circuit for
Fuel system low pressure leaks/damage,
circuit fault Fuel Tank and Lines - 2.7L V6 - TdV6 Check
the fuel filter, check the FVCV and FPCV,
Blocked fuel filter
Fuel Charging and Controls For EGR tests,
Fuel volume control valve Engine Emission Control
(FVCV)
blocked/contaminated

(FPCV)

valve(s) fault
Air ingress
Fuel system low pressure Check the air intake system,

circuit fault Intake Air Distribution and Filtering Check
the fuel level/condition,
Blocked fuel filter Fuel Charging and Controls Check the fuel
Rough idle system low pressure circuit for leaks/damage,
(FVCV) Fuel Tank and Lines - 2.7L V6 - TdV6 Check
blocked/contaminated the fuel filter, check the FVCV and FPCV,
Fuel pressure control valve Engine Emission Control
(FPCV)

valve(s) fault
Air intake system fault
Check the air intake system,
Diesel particulate fliter (DPF) Intake Air Distribution and Filtering Check for
blocked/restricted a blocked DPF or catalytic converter, install
new components as necessary.
Restricted exhaust system
Lack of power Diesel Particulate Filter (DPF) or
when Catalytic Converter - 2.7L V6 - TdV6
Low fuel pressure
accelerating (17.50.05) Check the fuel pressure,
Exhaust gas recirculation (EGR) Fuel Charging and Controls For EGR tests,
valve(s) fault Engine Emission Control For VGT actuator
tests,
Variable geometry Turbocharger
turbocharger (VGT)
actuator fault
Low/contaminated fuel Check the fuel level/condition,

Engine Fuel Charging and Controls Check the fuel
stops/stalls Air ingress system low pressure circuit for leaks/damage,
Fuel Tank and Lines - 2.7L V6 - TdV6 Check
Fuel system low pressure for fuel system leaks, check the FVCV and
circuit fault FPCV,
Fuel volume control valve Engine Emission Control
(FVCV)

(FPCV)
High pressure fuel leak

valve(s) fault
Air ingress
Fuel system low pressure

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circuit fault
Check the fuel level/condition,
Fuel metering valve Fuel Charging and Controls Check the fuel
blocked/contaminated system low pressure circuit for leaks/damage,
Fuel Tank and Lines - 2.7L V6 - TdV6 Check for
Engine judders
Fuel volume control valve fuel system leaks, check the FVCV and FPCV,
(FVCV) Fuel Charging and Controls Check the fuel
injection pump,
Fuel Injection Pump
(FPCV)

Fuel system low pressure
circuit fault
Check the fuel system low pressure circuit for
Fuel volume control valve leaks/damage,
(FVCV) Fuel Tank and Lines - 2.7L V6 - TdV6 Check
blocked/contaminated the FVCV and FPCV,
Excessive fuel Fuel Charging and Controls Check the fuel
consumption Fuel pressure control valve temperature sensor, fuel injection pump, etc
(FPCV) for leaks,
Fuel Charging and Controls Check for injector
DTCs. For EGR tests,
Fuel temperature sensor leak
Injector(s) failure

valve(s) fault
DTC index
NOTE:
FVCV circuit: high

resistance For FVCV and circuit tests,
ECM failure
FVCV circuit: high
resistance
FVCV circuit: short circuit For FVCV and circuit tests,

Fuel volume control valve to ground Fuel Charging and Controls
FVCV failure
ECM failure
FVCV circuit: high
resistance For FVCV and circuit tests,
ECM failure
P000400 Fuel volume control valve
FVCV circuit: short circuit For FVCV and circuit tests,
(FVCV) control circuit high to power Fuel Charging and Controls
FVCV failure and procedures manual if an
ECM is suspect.
ECM failure
Variable geometry actuator circuit tests,
turbocharger (VGT) Turbocharger Refer to the
P004500 short circuit to
actuator open circuit (right ground warranty policy and
hand bank) procedures manual if an ECM is
VGT actuator failure suspect.
ECM failure
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actuator circuit low (right ground warranty policy and
ECM failure
Variable geometry short circuit to actuator circuit tests,
turbocharger (VGT) power Turbocharger Refer to the
P004800
actuator circuit high (right warranty policy and
hand bank) VGT actuator failure procedures manual if an ECM is
suspect.
ECM failure
P004A00 short circuit to
actuator open circuit (left ground warranty policy and
ECM failure
Variable geometry VGT actuator circuit: For left hand bank VGT
turbocharger (VGT) high resistance actuator circuit tests,
P004C00 Turbocharger Refer to the
actuator circuit low (left
hand bank) VGT actuator circuit: warranty policy and
short circuit to procedures manual if an ECM is
ground suspect.
ECM failure
P004D00
actuator circuit high (left warranty policy and
hand bank) VGT actuator failure procedures manual if an ECM is
suspect.
ECM failure
Air leakage in intake path
between
turbocharger and
engine
MAP sensor circuit: high For MAP sensor tests, GO to

resistance
(MAP) sensor correlation MAP sensor circuit: short
ECM is suspect.
MAP sensor circuit: short
circuit to power
MAP sensor failure
ECM failure
Air leakage in intake path
between
turbocharger and
engine For air intake system
information,
MAP sensor circuit: high Intake Air Distribution and
resistance
Manifold absolute pressure Filtering For MAP sensor tests,
P006A00 (MAP) - mass or volume air MAP sensor circuit: short
GO to Pinpoint Test
flow correlation circuit to ground G549822p12.
MAP sensor circuit: short and procedures manual if an
MAP sensor failure
ECM failure
Fuel rail/system pressure Fuel rail pressure (FRP) For FRP sensor circuit tests,
P008700
too low sensor disconnected
FRP sensor to ECM Check the fuel lines, check the
sensing circuit: short fuel pressure and check the
circuit to ground fuel pump module circuits,
Fuel Tank and Lines - 2.7L V6 -
FRP sensor supply circuit:
TdV6
high resistance
FRP sensor failure
Fuel line leak
Fuel pump module

circuit: high
resistance
Fuel pump module

to ground
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Fuel pump module

failure
sensor to ECM wiring
(supply/sense): short
FRP sensor to ECM sense

circuit: short circuit For FRP sensor circuit tests and
to power FPCV tests,
Fuel rail/system pressure Fuel Charging and Controls For
P008800 FRP sensor failure
too high fuel pump module circuit tests,
Fuel pressure control Fuel Tank and Lines - 2.7L V6 -
valve (FPCV) fault TdV6
Fuel pump module

to power
Fuel pump module

failure
FPCV circuit: high For FPCV tests,
resistance Fuel Charging and Controls
(FPCV) control circuit open FPCV circuit: short circuit and procedures manual if an
to ground ECM is suspect.
FPCV failure
ECM failure
FPCV circuit: high
resistance For FPCV tests,
ECM failure
FPCV circuit: short circuit For FPCV tests,
to power Fuel Charging and Controls
ECM is suspect.
ECM failure
ACT sensor circuit: high
resistance For ACT sensor circuit tests, GO
Air charge temperature to Pinpoint Test G549822p6.
ACT sensor circuit: short
P009700 (ACT) sensor circuit low Refer to the warranty policy
circuit to ground
input and procedures manual if an
ACT sensor failure ECM is suspect.
ECM failure
ACT sensor circuit: short For ACT sensor circuit tests, GO
Air charge temperature circuit to power to Pinpoint Test G549822p6.
P009800 (ACT) sensor circuit high Refer to the warranty policy
input ACT sensor failure and procedures manual if an
ECM is suspect.
ECM failure
ACT sensor circuit: high
resistance
ACT sensor circuit: short For ACT sensor circuit tests, GO

Air charge temperature circuit to ground to Pinpoint Test G549822p6.
P009900 (ACT) sensor circuit Refer to the warranty policy
intermittent/erratic ACT sensor circuit: short and procedures manual if an
ACT sensor failure
ECM failure
MAF sensor circuit: high For right hand bank MAF
P010000 Mass air flow (MAF) sensor
resistance
range/performance (right sensor circuit tests, GO to
hand bank) MAF sensor circuit: short Pinpoint Test G549822p10.
circuit to ground Refer to the warranty policy
MAF sensor circuit: short ECM is suspect.
circuit to power
MAF sensor failure
ECM failure
For air intake system
Filtering For right hand bank
resistance
MAF sensor circuit tests, GO to
MAF sensor circuit: short Pinpoint Test G549822p10.
circuit to ground For EGR valve tests,
Mass air flow (MAF) too low Engine Emission Control Check
P010200
(right hand bank) MAF sensor failure for DTCs indicating VGT
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actuator, EGR, cylinder balance

Exhaust gas recirculation or ECU piezo injector drive
(EGR) valve stuck
faults. Refer to the DTC index
open/closed
VGT actuator fault Refer to the warranty policy
ECM failure ECM is suspect.

information,
Filtering For right hand bank
Air leakage
circuit to power Check for DTCs indicating VGT
P010300 actuator, EGR, cylinder
high (right hand bank) MAF sensor failure balance, fuel system or ECU
piezo injector drive faults.
VGT actuator fault
Refer to the DTC index for
pinpoint tests for DTC set.
ECM failure
ECM is suspect.
Mass air flow (MAF) sensor For air intake system

Air leakage
P010400 circuit intermittent/erratic information,
(right hand bank) MAF sensor circuit: high Intake Air Distribution and
resistance Filtering For right hand bank
MAF sensor circuit: short
MAF sensor failure
ECM failure
MAP sensor circuit: high
resistance
MAP sensor circuit: short For MAP sensor tests, GO to

Manifold absolute pressure circuit to ground Pinpoint Test G549822p12.
P010600 (MAP) sensor Refer to the warranty policy
range/performance MAP sensor circuit: short and procedures manual if an
MAP sensor failure
ECM failure
resistance For MAP sensor tests, GO to
Manifold absolute pressure Pinpoint Test G549822p12.
P010700 (MAP) sensor circuit low Refer to the warranty policy
circuit to ground
MAP sensor failure ECM is suspect.
ECM failure
MAP sensor circuit: short For MAP sensor tests, GO to
Manifold absolute pressure circuit to power Pinpoint Test G549822p12.
P010800 (MAP) sensor circuit high Refer to the warranty policy
input MAP sensor failure and procedures manual if an
ECM is suspect.
ECM failure
resistance
For MAP sensor tests, GO to
Manifold absolute pressure Pinpoint Test G549822p12.
circuit to ground
P010900 (MAP) sensor circuit Refer to the warranty policy
intermittent MAP sensor circuit: short and procedures manual if an
MAP sensor failure

ECM failure
resistance
For left hand bank MAF sensor
MAF sensor circuit: short circuit tests, GO to Pinpoint
Mass air flow (MAF) sensor circuit to ground
Test G549822p11.
P010A00 range/performance (left
hand bank) MAF sensor circuit: short Refer to the warranty policy
ECM is suspect.
MAF sensor failure
ECM failure
Filtering For left hand bank
resistance
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circuit to ground For EGR valve tests,
Mass air flow (MAF) too low Engine Emission Control Check
P010C00
(left hand bank) MAF sensor failure for DTCs indicating VGT
actuator, EGR, cylinder balance
Exhaust gas recirculation or ECU piezo injector drive
(EGR) valve stuck
faults. Refer to the DTC index
open/closed
VGT actuator fault Refer to the warranty policy

information,
Filtering For left hand bank
Air leakage
circuit to power Check for DTCs indicating VGT
P010D00 actuator, EGR, cylinder
high (left hand bank) MAF sensor failure balance, fuel system or ECU
piezo injector drive faults.
VGT actuator fault
Refer to the DTC index for
pinpoint tests for DTC set.
ECM failure
ECM is suspect.
Air leakage
resistance information,
Mass air flow (MAF) sensor MAF sensor circuit: short Filtering For left hand bank
P010E00 intermittent/erratic (left circuit to ground MAF sensor circuit tests, GO to
hand bank) Pinpoint Test G549822p11.
MAF sensor circuit: short Refer to the warranty policy
circuit to power
MAF sensor failure ECM is suspect.
ECM failure
Air leakage (post
turbocharger)

high resistance

short circuit to For air intake system
ground
information,
short circuit to Filtering For MAF sensor
power circuit tests, GO to Pinpoint
Mass air flow (MAF) sensor Test G549822p10.
P010F00 left and right hand bank MAF sensor failure and GO to Pinpoint Test
correlation G549822p11.
VGT actuator(s) circuit: For VGT actuator circuit tests,
high resistance
VGT actuator(s) circuit: warranty policy and
ground suspect.
VGT actuator(s) circuit:

short circuit to
power
ECM failure
IAT sensor circuit: high
resistance For IAT sensor circuit tests, GO
Intake air temperature (IAT) to Pinpoint Test G549822p9.
P011200
sensor circuit low input IAT sensor circuit: short Refer to the warranty policy
IAT sensor failure ECM is suspect.
ECM failure
IAT sensor circuit: short For IAT sensor circuit tests, GO
circuit to power to Pinpoint Test G549822p9.
sensor circuit high input IAT sensor failure and procedures manual if an
ECM is suspect.
ECM failure
resistance
IAT sensor circuit: short For IAT sensor circuit tests, GO

circuit to ground to Pinpoint Test G549822p9.
sensor intermittent/erratic IAT sensor circuit: short and procedures manual if an
IAT sensor failure

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ECM failure
ECT sensor circuit: high
resistance
For ECT sensor and circuit
ECT sensor circuit: short tests, GO to Pinpoint Test
Engine coolant temperature circuit to ground
G549822p1.
P011600 (ECT) sensor circuit
range/performance ECT sensor circuit: short Refer to the warranty policy
ECM is suspect.
ECT sensor failure
ECM failure
resistance For ECT sensor and circuit
ECT sensor circuit: short G549822p1.
P011700 (ECT) sensor circuit low
input
ECT sensor failure
ECM is suspect.
ECM failure
ECT sensor circuit: short For ECT sensor and circuit
Engine coolant temperature circuit to power tests, GO to Pinpoint Test
P011800 (ECT) sensor circuit high G549822p1.
input ECT sensor failure
ECM failure and procedures manual if an
ECM is suspect.

resistance
For ECT sensor and circuit
ECT sensor circuit: short tests, GO to Pinpoint Test
Engine coolant temperature circuit to ground
G549822p1.
P011900 (ECT) sensor circuit
intermittent/erratic ECT sensor circuit: short Refer to the warranty policy
ECM is suspect.
ECT sensor failure
ECM failure
circuit: high
resistance

circuit: short circuit and circuit tests, GO to
to ground
Fuel temperature sensor Pinpoint Test G549822p2.
P018100
circuit range/performance Fuel temperature sensor Refer to the warranty policy
circuit: short circuit and procedures manual if an

failure
ECM failure
circuit: high
resistance For fuel temperature sensor
and circuit tests, GO to
P018200 circuit: short circuit
circuit low input to ground Refer to the warranty policy
Fuel temperature sensor ECM is suspect.
failure
ECM failure
Fuel temperature sensor to power Pinpoint Test G549822p2.
P018300
circuit high input Refer to the warranty policy
Fuel temperature sensor and procedures manual if an
failure
ECM is suspect.
ECM failure
circuit: high
resistance

to ground
P018400
circuit: short circuit and procedures manual if an

failure
ECM failure
resistance
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For FRP sensor and circuit

FRP sensor circuit: short tests,
Fuel rail pressure (FRP) circuit to ground
P019100 sensor circuit
range/performance FRP sensor circuit: short Refer to the warranty policy
ECM is suspect.
FRP sensor failure
ECM failure
resistance For FRP sensor and circuit
tests,
Fuel rail pressure (FRP) FRP sensor circuit: short Fuel Charging and Controls
P019200
sensor circuit low input circuit to ground Refer to the warranty policy
FRP sensor failure
ECM is suspect.
ECM failure
For FRP sensor and circuit
FRP sensor circuit: short tests,
circuit to power
Fuel rail pressure (FRP) Fuel Charging and Controls
P019300
sensor circuit high input FRP sensor failure Refer to the warranty policy
FRP sensor circuit: high For FRP sensor and circuit

P019400 Fuel rail pressure (FRP) tests,
resistance
sensor circuit
intermittent/erratic FRP sensor circuit: short Refer to the warranty policy
ECM is suspect.
circuit to power
FRP sensor failure
ECM failure
EOT sensor circuit: high
resistance
Engine oil temperature EOT sensor circuit: short For EOT sensor circuit tests, GO
circuit to ground to Pinpoint Test G549822p3.
(EOT) sensor circuit, no
synchronization of PWM EOT sensor circuit: short and procedures manual if an
signal/PWM signal time out circuit to power ECM is suspect.
EOT sensor failure
ECM failure
resistance
EOT sensor circuit: short For EOT sensor circuit tests, GO

Engine oil temperature circuit to ground to Pinpoint Test G549822p3.
P019600 (EOT) sensor circuit Refer to the warranty policy
range/performance EOT sensor circuit: short and procedures manual if an
EOT sensor failure
ECM failure
resistance For EOT sensor circuit tests, GO
Engine oil temperature to Pinpoint Test G549822p3.
EOT sensor circuit: short
P019700 (EOT) sensor circuit low circuit to ground
EOT sensor failure ECM is suspect.
ECM failure
Engine oil temperature circuit to power to Pinpoint Test G549822p3.
P019800 (EOT) sensor circuit high Refer to the warranty policy
input EOT sensor failure and procedures manual if an
ECM is suspect.
ECM failure
resistance

Engine oil temperature circuit to ground to Pinpoint Test G549822p3.
P019900 (EOT) sensor circuit Refer to the warranty policy
intermittent EOT sensor circuit: short and procedures manual if an
EOT sensor failure
ECM failure
resistance
For fuel injector circuit tests,
Fuel injector circuit: Fuel Charging and Controls
Fuel injector open circuit,
P020100 short circuit to Refer to the warranty policy
cylinder 1 ground and procedures manual if an
ECM is suspect.
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ECM failure
resistance
ECM is suspect.
ECM failure
resistance
ECM is suspect.
ECM failure
Fuel injector circuit: high For fuel injector circuit tests,
resistance
cylinder 4 Fuel injector circuit:
ground ECM is suspect.
ECM failure
resistance
ECM is suspect.
ECM failure
resistance
ECM is suspect.
ECM failure
resistance
Fuel injector circuit:

short circuit to For fuel injector circuit tests,
ground Fuel Charging and Controls
Fuel injection timing,
P020A00 Refer to the warranty policy
cylinder 1 Fuel injector circuit: and procedures manual if an
short circuit to ECM is suspect.
power
ECM failure
resistance
Fuel injection timing, short circuit to
P020B00 Refer to the warranty policy
cylinder 2 ground
Fuel injector circuit: ECM is suspect.
short circuit to
power
ECM failure
resistance

P020C00 Refer to the warranty policy
power
ECM failure
resistance
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P020D00 Refer to the warranty policy
power
ECM failure
resistance

P020E00 Refer to the warranty policy
power
ECM failure
Fuel injector circuit: high For fuel injector circuit tests,
Fuel injection timing, Fuel Charging and Controls
P020F00 resistance
cylinder 6 Refer to the warranty policy
Fuel injector circuit: and procedures manual if an
ground

short circuit to
power
ECM failure
CKP sensor circuit: high
resistance
CKP sensor circuit: short

circuit to ground

circuit to power
For CKP and CMP sensor circuit
CMP sensor circuit: high tests, GO to Pinpoint Test
Crankshaft/Camshaft
P021900 position (CKP/CMP) sensor,
engine overspeed CMP sensor circuit: short and procedures manual if an
circuit to ground
ECM is suspect.
CMP sensor circuit: short
circuit to power
CKP sensor failure
CMP sensor failure
ECM failure
Air leakage For air intake system
information,
MAP sensor circuit: high Intake Air Distribution and
resistance Filtering For MAP sensor
circuit tests, GO to Pinpoint
Turbocharger overboost MAP sensor circuit: short Test G549822p12.
circuit to ground
condition, manifold For EGR valve tests,
P023400
absolute pressure (MAP) MAP sensor circuit: short Engine Emission Control Check
sensor control deviation circuit to power for DTCs indicating EGR or VGT
actuator faults. Refer to the
MAP sensor failure DTC index for pinpoint tests for
DTC set. Refer to the warranty
Air leakage policy and procedures manual
(EGR) fault
VGT actuator fault
ECM failure
high resistance

turbocharger (VGT) ground
P023600 actuator circuit
VGT actuator circuit: warranty policy and
range/performance (right
hand bank)
power suspect.
ECM failure
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actuator reached minimum ground warranty policy and
threshold (right hand bank) procedures manual if an ECM is
ECM failure
P023800
actuator reached maximum warranty policy and
threshold (right hand bank) VGT actuator failure procedures manual if an ECM is
suspect.
ECM failure
high resistance

Variable geometry
short circuit to actuator circuit tests,
turbocharger (VGT)
ground Turbocharger Refer to the
P024000 actuator circuit
warranty policy and
range/performance (left VGT actuator circuit: procedures manual if an ECM is
hand bank) short circuit to
suspect.
power

ECM failure
actuator reached minimum ground warranty policy and
threshold (left hand bank) procedures manual if an ECM is
ECM failure
P024200
actuator reached maximum warranty policy and
threshold (left hand bank) VGT actuator failure procedures manual if an ECM is
suspect.
ECM failure
Temperature sensor -
catalyst downstream
circuit: high
resistance
Diesel particulate filter catalyst downstream For temperature sensor -
(DPF) temperature sensor - circuit: short circuit
catalyst downstream circuit
P024B00 catalyst downstream circuit to ground
tests,
range/performance (right
Temperature sensor - Exhaust System
hand bank)
catalyst downstream
to power
catalyst downstream
failure
Air leakage For air intake system
information,
resistance
Turbocharger underboost Filtering For MAP sensor
condition, manifold MAP sensor circuit: short circuit tests, GO to Pinpoint
P029900 circuit to ground Test G549822p12.
absolute pressure (MAP)
sensor control deviation For EGR valve tests,
MAP sensor circuit: short Engine Emission Control Check
circuit to power for DTCs indicating EGR or VGT
actuator faults. Refer to the
MAP sensor failure
DTC index for pinpoint tests for
Exhaust gas recirculation DTC set. Refer to the warranty
(EGR) fault policy and procedures manual
VGT fault
ECM failure
resistance

short circuit to
ground For fuel injector tests,
Fuel trim maximum limit
P029A00 Fuel injector circuit: Refer to the warranty policy
reached, cylinder 1 short circuit to and procedures manual if an
Fuel injector leaking

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ECM failure
resistance

short circuit to
Fuel trim minimum limit
P029B00 Fuel injector circuit: Refer to the warranty policy
ECM failure
resistance
For fuel injector tests,
Fuel trim maximum limit short circuit to
P029E00 Refer to the warranty policy
reached, cylinder 2 ground
Fuel injector circuit: ECM is suspect.
short circuit to
power
ECM failure
resistance

short circuit to
P029F00 Fuel injector circuit: Refer to the warranty policy
ECM failure
resistance

short circuit to
ECM failure
resistance
Fuel injector circuit: For fuel injector tests,

short circuit to
Fuel trim minimum limit ground
P02A300 Refer to the warranty policy
reached, cylinder 3
Fuel injector circuit: and procedures manual if an
power

ECM failure
resistance

short circuit to
ECM failure
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resistance

short circuit to
ECM failure
resistance

short circuit to For fuel injector tests,
ground
P02AA00 Refer to the warranty policy
reached, cylinder 5 Fuel injector circuit:

ECM failure
resistance

short circuit to
P02AB00 Fuel injector circuit: Refer to the warranty policy
ECM failure
resistance

short circuit to
P02AE00 Fuel injector circuit: Refer to the warranty policy
ECM failure
resistance

short circuit to
P02AF00 Fuel injector circuit: Refer to the warranty policy
ECM failure
KS circuit: high resistance
KS circuit: short circuit to For right hand bank KS circuit

ground tests, GO to Pinpoint Test
G549822p7.
P032600 range/performance (right
KS circuit: short circuit to Refer to the warranty policy
hand bank) power and procedures manual if an
ECM is suspect.
KS failure
ECM failure
KS circuit: high resistance
KS circuit: short circuit to For left hand bank KS circuit

ground tests, GO to Pinpoint Test
G549822p8.
P033100 range/performance (left
KS circuit: short circuit to Refer to the warranty policy
hand bank) power and procedures manual if an
ECM is suspect.
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KS failure
ECM failure
CKP sensor gap
incorrect/ foreign
matter on sensor
face /damaged teeth
on rotor
CKP sensor circuit: high For CKP sensor tests, GO to

Crankshaft position (CKP) resistance Pinpoint Test G549822p14.
P033500 sensor synchronisation Refer to the warranty policy
failure CKP sensor circuit: short and procedures manual if an

circuit to power
CKP sensor failure
ECM failure
CKP sensor gap
incorrect/ foreign
matter on sensor For CKP sensor tests, GO to
Crankshaft position (CKP) face /damaged teeth Pinpoint Test G549822p14.
P033600 sensor circuit on rotor Refer to the warranty policy
range/performance and procedures manual if an
CKP sensor circuit: high ECM is suspect.
resistance

circuit to ground

circuit to power
CKP sensor failure
ECM failure
CKP sensor gap
incorrect/ foreign
matter on sensor
face /damaged teeth
on rotor For CKP sensor tests, GO to
Crankshaft position (CKP) CKP sensor circuit: high
P033700 resistance Refer to the warranty policy
CKP sensor circuit: short ECM is suspect.
circuit to ground
CKP sensor failure
ECM failure
CMP sensor gap
incorrect/ foreign
matter on sensor
face /damaged rotor
CMP sensor circuit: high For CMP sensor tests, GO to

resistance
Camshaft position (CMP) Pinpoint Test G549822p15.
range/performance circuit to ground and procedures manual if an
ECM is suspect.
circuit to power
CMP sensor failure
ECM failure
CMP sensor gap
incorrect/ foreign For CMP sensor tests, GO to
matter on sensor
Camshaft position (CMP) face /damaged rotor
CMP sensor circuit: high and procedures manual if an
resistance ECM is suspect.

circuit to ground
CMP sensor failure
ECM failure
Glow plug control circuit:
high resistance

short circuit to
ground
Glow plug monitor

For glow plug system circuit
Glow plug control module circuit: high
P038000 tests,
on, glow plugs not powered resistance
Glow Plug System
Glow plug monitor
to ground
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Glow plug failure
Glow plug control

module failure
short circuit to
power
Glow plug monitor For glow plug system circuit

Glow plug control module
P038200 circuit: short circuit tests,
off, glow plugs powered to power Glow Plug System
Glow plug failure
Glow plug control

module failure
Glow plug control
module, control
circuit: high
resistance
Glow plug control module -
P038300 Glow plug control tests,
control circuit low module, control Glow Plug System
to ground
Glow plug control

module failure
Glow plug control
module, control
Glow plug control module - circuit: short circuit
P038400 tests,
control circuit high to power
Glow Plug System
Glow plug control
module failure
EGR valve incorrectly
fitted or loose
EGR pipe blocked For EGR system,

EGR valve stuck closed, MAF sensor circuit tests, GO to
P040100 (EGR) insufficient flow
blocked Pinpoint Test G549822p10.
detected
EGR coolers blocked
G549822p11.
EGR valve failure
MAF sensor fault

EGR valve incorrectly
fitted or loose
EGR pipe blocked For EGR system,

EGR valve stuck closed, MAF sensor circuit tests, GO to
P040200 (EGR) excessive flow
blocked Pinpoint Test G549822p10.
detected
EGR coolers blocked
G549822p11.
EGR valve failure
MAF sensor fault

EGR valve circuit(s): high
resistance
EGR valve circuit(s): For right hand bank EGR valve

short circuit to and circuit tests,
Exhaust gas recirculation ground
Engine Emission Control Refer
P040300 (EGR) valve H-bridges (right
EGR valve circuit(s): to the warranty policy and
hand bank)
power suspect.
EGR valve failure
ECM failure
P040400 Exhaust gas recirculation IAT sensor fault For IAT sensor circuit tests, GO
(EGR) control circuit to Pinpoint Test G549822p9.
range/performance (right MAP sensor fault For MAP sensor circuit tests,
hand bank) GO to Pinpoint Test
MAF sensor fault G549822p12.
EGR valve stuck closed,
GO to Pinpoint Test
blocked
G549822p10.
EGR valve circuit(s): high and GO to Pinpoint Test
For right hand bank EGR valve
EGR valve circuit(s): and circuit tests,
short circuit to Engine Emission Control
ground

short circuit to
power
EGR valve failure

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resistance
Exhaust gas recirculation For right hand bank EGR valve
P040500 (EGR) valve circuit low (right EGR valve circuit(s): and circuit tests,
hand bank) short circuit to Engine Emission Control
ground
EGR valve failure

Exhaust gas recirculation For right hand bank EGR valve
short circuit to
P040600 (EGR) valve circuit high and circuit tests,
power
(right hand bank) Engine Emission Control
EGR valve failure
Intake air shut off
throttle circuit(s):
high resistance
Exhaust gas recirculation For intake air shut off throttle
Intake air shut off
P040700 (EGR) - intake air shut off and circuit tests,
throttle circuit low short circuit to Engine Emission Control
ground
Intake air shut off

throttle failure
Intake air shut off
Exhaust gas recirculation throttle circuit(s): For intake air shut off throttle
P040800 (EGR) - intake air shut off short circuit to and circuit tests,
throttle circuit high power Engine Emission Control
Intake air shut off

throttle failure
catalyst upstream
circuit: high
resistance
Diesel particulate filter catalyst upstream
(DPF) temperature sensor - circuit: short circuit For temperature sensor -
P042600 catalyst upstream circuit to ground catalyst upstream circuit tests,
range/performance (right Exhaust System
hand bank) Temperature sensor -
catalyst upstream
to power
catalyst upstream
failure
catalyst upstream
circuit: high
resistance
Diesel particulate filter
For temperature sensor -
(DPF) temperature sensor - Temperature sensor -
P042700 catalyst upstream circuit tests,
catalyst upstream circuit catalyst upstream
circuit: short circuit Exhaust System
low (right hand bank)
to ground
catalyst upstream
failure
circuit: short circuit For temperature sensor -
(DPF) temperature sensor -
P042800 to power catalyst upstream circuit tests,
catalyst upstream circuit
Exhaust System
high (right hand bank) Temperature sensor -
catalyst upstream
failure
catalyst downstream
Diesel particulate filter circuit: high For temperature sensor -
resistance
(DPF) temperature sensor - catalyst downstream circuit
P042C00
catalyst downstream circuit Temperature sensor - tests,
low (right hand bank) catalyst downstream Exhaust System
to ground
catalyst downstream
failure
P042D00 to power
catalyst downstream circuit tests,
high (right hand bank) Temperature sensor - Exhaust System
catalyst downstream
failure
catalyst upstream
circuit: high
resistance
(DPF) temperature sensor - circuit: short circuit For temperature sensor -
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P043600 catalyst upstream circuit to ground catalyst upstream circuit tests,

range/performance (left Exhaust System
hand bank) Temperature sensor -
catalyst upstream
to power
catalyst upstream
failure
catalyst upstream
circuit: high
resistance
For temperature sensor -
(DPF) temperature sensor - Temperature sensor -
P043700 catalyst upstream circuit tests,
catalyst upstream circuit catalyst upstream
circuit: short circuit Exhaust System
low (left hand bank)
to ground
catalyst upstream
failure
circuit: short circuit For temperature sensor -
(DPF) temperature sensor -
P043800 to power catalyst upstream circuit tests,
catalyst upstream circuit
Exhaust System
high (left hand bank) Temperature sensor -
catalyst upstream
failure
catalyst downstream
circuit: high
resistance
(DPF) temperature sensor - circuit: short circuit
catalyst downstream circuit
P043B00 catalyst downstream circuit to ground
tests,
range/performance (left
Temperature sensor - Exhaust System
hand bank)
catalyst downstream
to power
catalyst downstream
failure
catalyst downstream
circuit: high
resistance
Diesel particulate filter For temperature sensor -
(DPF) temperature sensor - Temperature sensor - catalyst downstream circuit
P043C00
catalyst downstream circuit catalyst downstream tests,
low (left hand bank) circuit: short circuit Exhaust System
to ground
catalyst downstream
failure
P043D00 to power
catalyst downstream circuit tests,
high (left hand bank) Temperature sensor - Exhaust System
catalyst downstream
failure
Fuel level sensor signal
circuit: high
resistance For fuel level sensor and circuit
tests,
Fuel level sensor, signal Fuel level sensor signal Fuel Tank and Lines - 2.7L V6 -
P046000
range high circuit: short circuit TdV6 Refer to the warranty
to power policy and procedures manual
ECM failure
circuit: high
resistance For fuel level sensor and circuit
tests,
Fuel level sensor, signal Fuel level sensor signal Fuel Tank and Lines - 2.7L V6 -
P046100
range low circuit: short circuit TdV6 Refer to the warranty
to ground policy and procedures manual
ECM failure
Cooling fan rotor
jammed/blocked Clear any obstruction, replace
P048300 Cooling fan rationality
the fan as necessary.
Cooling fan motor
damage/fault
Cooling fan seizure
Cooling fan current over Cooling fan rotor Clear any obstruction, replace
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P048400
load jammed/blocked the fan as necessary.
Cooling fan motor

damage/fault
resistance
EGR valve circuit(s): For left hand bank EGR valve

short circuit to circuit tests,
P048700 (EGR) valve H-bridges (left
hand bank)
power suspect.
EGR valve failure
ECM failure
Cooling fan signal circuit:
Cooling fan overspeed For cooling fan circuit tests, GO
(clutch locked) to Pinpoint Test G549822p21.
Cooling fan motor fault
high resistance
For cooling fan circuit tests, GO
P049400 Cooling fan speed low Cooling fan signal circuit:
short circuit to to Pinpoint Test G549822p21.
ground

short circuit to For cooling fan circuit tests, GO
P049500 Cooling fan speed high
power to Pinpoint Test G549822p21.

The brake pressure Check the brake switch

reading does not function, GO to Pinpoint Test
agree with the brake
Brake switch A/B G549822p18.
P050400 light switch value
correlation Refer to the warranty policy
Brake switch failure and procedures manual if an
ECM is suspect.
ECM failure
Programme keys using the
P051300 Incorrect immobilizer key Jaguar approved diagnostic
system.

resistance
Air conditioning (A/C) A/C refrigerant pressure

sensor circuit: short For A/C refrigerant pressure
refrigerant pressure sensor
P053100 circuit to ground sensor tests, GO to Pinpoint
A circuit
Test G549822p19.
range/performance A/C refrigerant pressure
circuit to power

sensor failure
Air conditioning (A/C) sensor circuit: short For A/C refrigerant pressure
P053200 refrigerant pressure sensor circuit to ground sensor tests, GO to Pinpoint
A circuit low input Test G549822p19.
sensor failure
Air conditioning (A/C) sensor circuit: high For A/C refrigerant pressure
P053300 refrigerant pressure sensor resistance sensor tests, GO to Pinpoint
A circuit high input Test G549822p19.
circuit to power

sensor failure
Battery voltage low
Battery ground cable:

high resistance For battery information,
Battery
Battery connections
loose/corroded
Battery current drain

System boosted from For battery information,
high voltage
Battery For charging system
P056300 System voltage high information,
Battery voltage high
Charging System - 2.7L V6 -
Generator over charge TdV6
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condition
Speed control cancel
switch signal circuit:
short circuit to
power
For speed control,
Speed control cancel switch
stuck closed Speed control cancel
switch G45704->G99999
stuck/jammed
Speed control cancel

switch failure
Speed control resume
short circuit to
power
For speed control,
switch stuck closed Speed control resume
switch G45704->G99999
stuck/jammed

switch failure
Speed control minus
For speed control,
Speed control minus switch short circuit to
stuck closed power
G45704->G99999
Speed control minus
switch
stuck/jammed
Speed control minus

switch failure
Speed control headway
plus switch signal
to power
For speed control,
Speed control headway plus
P056A00 Speed Control - VIN Range:
switch stuck closed Speed control headway
plus switch G45704->G99999
stuck/jammed

plus switch failure
minus switch signal
to power
For speed control,
P056B00 Speed Control - VIN Range:
minus switch stuck closed Speed control headway
minus switch G45704->G99999
stuck/jammed

minus switch failure
Speed control plus
short circuit to
power
For speed control,
Speed control plus switch
stuck closed Speed control plus
switch G45704->G99999
stuck/jammed
Speed control plus

switch failure
The brake pressure Check the brake switch
reading does not function, GO to Pinpoint Test
Brake switch A circuit G549822p18.
P057100 light switch value
plausibility Refer to the warranty policy
Brake switch failure and procedures manual if an
ECM is suspect.
ECM failure
P057800 function input A circuit Speed Control - VIN Range:
function input A
stuck circuit: high G45704->G99999
resistance

function input A
to ground

function input A
to power
Speed control switch

stuck
function input A
circuit: high
resistance
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function input A
P057900 function input A circuit Speed Control - VIN Range:
to ground
function input A
to power
Speed control switch

stuck
Cycle the ignition and allow
power latch. Clear the DTC and
Internal ECM monitoring retest. If the DTC resets, refer
P060600 ECM processor fault
to the warranty policy and
ECM failure procedure manual if an ECM is
suspect.

Internal control module Internal control module
retest. If the DTC resets, refer
P060A00 monitoring processor monitoring
processor to the warranty policy and
performance
performance procedure manual if an ECM is
suspect.
Internal control module A/D Internal control module Cycle the ignition and allow
P060B00 power latch. Clear the DTC and
processing performance A/D processing
performance retest. If the DTC resets, refer
procedure manual if an ECM is
suspect.

Pedal value not plausible to the warranty policy and
performance
suspect.
Configure the module using

Control module vehicle
P061000 the Jaguar approved diagnostic
options error VID block fault
system.

Fuel injection pump control
Internal control module retest. If the DTC resets, refer
P061100 module requesting engine
monitoring to the warranty policy and
stop performance procedure manual if an ECM is
suspect.

For starter relay and circuit
short circuit to
P061700 Starter relay circuit high tests, GO to Pinpoint Test
power
G549822p22.
calculation failure to the warranty policy and
suspect.

Internal control module retest. If the DTC resets, refer
P061C00 Processor monitoring
engine RPM performance speed not plausable to the warranty policy and
suspect.

Internal control module power latch. Clear the DTC and
P061E00 Cruise intervention not
brake signal performance plausible retest. If the DTC resets, refer
suspect.
For generator monitor circuit

Generator monitor circuit tests,
P062200
plausibility PWM signal failure Charging System - 2.7L V6 -
TdV6
Generator monitor
circuit: high For generator monitor circuit
Generator monitor circuit resistance tests,
P062500
low Charging System - 2.7L V6 -
Generator monitor TdV6
to ground
For generator monitor circuit
Generator monitor circuit Generator monitor tests,
P062600
high circuit: short circuit Charging System - 2.7L V6 -
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to power TdV6
Fuel pump module relay For fuel pump module relay

control circuit: short
Fuel pump module relay and circuit tests,
control circuit high Fuel Tank and Lines - 2.7L V6 -
Fuel pump module relay TdV6
failure
Fuel pump module relay
resistance For fuel pump module relay
P062800 Fuel pump module relay
control circuit low control circuit: short Fuel Tank and Lines - 2.7L V6 -
circuit to ground TdV6
Fuel pump module relay

failure
Fuel pump module relay For fuel pump module relay
P062900 resistance
control circuit/open Fuel Tank and Lines - 2.7L V6 -
Fuel pump module relay TdV6
failure
Internal control module - power latch. Clear the DTC and
Internal control module -
P062B00 fuel injector control
fuel injector control retest. If the DTC resets, refer
performance performance to the warranty policy and
suspect.
Injector circuit(s): high For injector circuit tests,

resistance, short
Fuel injector driver circuit Fuel Charging and Controls
circuit to ground,
P062D00 performance (right hand Refer to the warranty policy
short circuit to
bank) power and procedure manual if an
ECM is suspect.
Injector failure
ECM failure

resistance, short
Fuel injector driver circuit Fuel Charging and Controls
circuit to ground,
P062E00 performance (left hand Refer to the warranty policy
short circuit to
bank) power and procedure manual if an
ECM is suspect.
Injector failure
ECM failure
ECM internal temperature ECM internal retest. If the DTC resets, refer
P063400
too high temperature too to the warranty policy and
high procedure manual if an ECM is
suspect.
For ECM power supply tests,

ECM power supply GO to Pinpoint Test
circuit: high G549822p23.
resistance
ECM power supply G549822p20.
circuit: short circuit For ECM relay tests, GO to
to ground Pinpoint Test G549822p26.
ECM internal 5 volt sensor
P064200 Refer to the circuit diagrams
supply circuit A low ECM ground circuit: high for the 5 volt sensor supply.
resistance Cycle the ignition and allow
5 Volt supply
ECM relay malfunction to the warranty policy and
ECM failure suspect.
GO to Pinpoint Test
circuit: short circuit and GO to Pinpoint Test
to power G549822p20.
ECM ground circuit:
ECM internal 5 volt sensor short circuit to
P064300 power Refer to the circuit diagrams
supply circuit A high
for the 5 volt sensor supply.
5 Volt supply Cycle the ignition and allow
ECM relay malfunction retest. If the DTC resets, refer
ECM failure procedure manual if an ECM is
suspect.

ECM power supply
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GO to Pinpoint Test
circuit: high
G549822p23.
resistance
circuit: short circuit For ECM relay tests, GO to
to ground Pinpoint Test G549822p26.
ECM internal 5 volt sensor
P065200 Refer to the circuit diagrams
supply circuit B low ECM ground circuit: high for the 5 volt sensor supply.
resistance Cycle the ignition and allow
5 Volt supply
ECM relay malfunction to the warranty policy and
ECM failure suspect.

ECM power supply GO to Pinpoint Test
circuit: short circuit G549822p23.
to power
ECM ground circuit: G549822p20.
ECM internal 5 volt sensor short circuit to For ECM relay tests, GO to
P065300 power Pinpoint Test G549822p26.
supply circuit B high
Refer to the circuit diagrams
5 Volt supply for the 5 volt sensor supply.
ECM relay malfunction
ECM failure
suspect.

P066700
sensor range/performance temperature sensor to the warranty policy and
range/performance procedure manual if an ECM is
suspect.

P066800
sensor circuit low temperature sensor to the warranty policy and
circuit low procedure manual if an ECM is
suspect.

P066900
sensor circuit high temperature sensor to the warranty policy and
circuit high procedure manual if an ECM is
suspect.
Glow plug control

module, control
circuit: high
resistance
For glow plug control module
Glow plug control module -
P067000 Glow plug control circuit tests,
control circuit open module, control Glow Plug System
to ground
Glow plug control

module failure
Cooling fan control
Cooling fan control circuit to ground For cooling fan circuit tests, GO
P069100
low to Pinpoint Test G549822p21.
Cooling fan control
circuit: high
resistance
Cooling fan control circuit Cooling fan control For cooling fan circuit tests, GO
P069200
high circuit: short circuit to Pinpoint Test G549822p21.
to power
Park/Neutral switch
input circuit: high
resistance
Park/Neutral switch
input circuit: short
Park/Neutral switch input For Park/Neutral switch tests,
P085000 circuit to ground
circuit plausibility External Controls
Park/Neutral switch
input circuit: short
circuit to power
Park/Neutral switch
failure
Clear the DTC. Cycle the
ignition, allow power latch and
P0A0900 DC/DC converter circuit low DC/DC converter circuit
low to the warranty policy and
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suspect.
Clear the DTC. Cycle the

ignition, allow power latch and
DC/DC converter circuit retest. If the DTC resets, refer
P0A1000 DC/DC converter circuit
high high to the warranty policy and
suspect.
Active engine mount

resistance
Active engine mount For active engine mount circuit
P0A1400 control circuit open (right Active engine mount tests,
hand) control circuit: short Engine
circuit to ground
Active engine mount

actuator failure
Active engine mount
resistance
P0A1500 control circuit low (right Active engine mount tests,
circuit to ground
Active engine mount

actuator failure
Active engine mount
Active engine mount control circuit: short For active engine mount circuit
P0A1600 control circuit high (right circuit to power tests,
hand) Engine
Active engine mount
actuator failure
Active engine mount
resistance
P0AB600 control circuit open (left Active engine mount tests,
circuit to ground
Active engine mount

actuator failure
Active engine mount
resistance
P0AB700 control circuit low (left Active engine mount tests,
circuit to ground
Active engine mount

actuator failure
Active engine mount
Active engine mount control circuit: short For active engine mount circuit
P0AB800 control circuit high (left circuit to power tests,
hand) Engine
Active engine mount
actuator failure
Fuel reserve signal range
Low level fuel condition

Check the fuel level. If there is
Critical fuel level switch
signal circuit: high sufficient fuel check the critical
resistance fuel level switch and fuel level
Low fuel level - forced sensor circuits,
P115A00
limited power Critical fuel level switch Fuel Tank and Lines - 2.7L V6 -
signal circuit: short TdV6 Refer to the warranty
circuit to ground policy and procedures manual
failure

circuit: high
resistance

to ground

to power
ECM failure
Anti air suction
intervention
Low level fuel condition

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signal circuit: high

resistance

signal circuit: short
Check the fuel level. If there is
circuit to ground
sufficient fuel check the critical
Critical fuel level switch fuel level switch and fuel level
Low fuel level - forced failure sensor circuits,
P115B00
engine shutdown Fuel Tank and Lines - 2.7L V6 -
Fuel level sensor signal TdV6 Refer to the warranty
circuit: high policy and procedures manual
resistance
to ground

to power
ECM failure
Fuel rail pressure (FRP) resistance For FRP sensor tests,
P120E00 sensor - excessive fuel Fuel Charging and Controls
pressure variation FRP sensor circuit: short Refer to the warranty policy
circuit to ground and procedure manual if an
FRP sensor circuit: short ECM is suspect.
circuit to power
FRP sensor failure
ECM failure
resistance

circuit to ground For FRP sensor tests,
Fuel Charging and Controls For
FRP sensor circuit: short fuel pump module circuit and
circuit to power fuel line tests,
P120F00 regulator - fuel pressure
low at start FRP sensor failure TdV6 Refer to the warranty
policy and procedure manual if
an ECM is suspect.
Fuel pump module
failure
ECM failure
Configure the system using the
Immobilizer to PCM signal Incorrect ID received
P125900 Jaguar approved diagnostic
error from instrument
pack system.

high resistance,
short circuit to
Variable geometry ground, short circuit For right hand bank VGT
to power actuator circuit tests,
turbocharger (VGT)
P132A00 Turbocharger Refer to the
actuator H bridge fault Turbocharger vanes warranty policy and procedure
(right hand bank) stuck/sticking manual if an ECM is suspect.
ECM failure
high resistance, For right hand bank VGT
Variable geometry short circuit to
actuator circuit tests,
turbocharger (VGT) ground, short circuit
P132B00 to power Turbocharger Refer to the
actuator performance (right
warranty policy and procedure
hand bank)
Turbocharger vanes manual if an ECM is suspect.
stuck/sticking
ECM failure
high resistance,
short circuit to
Variable geometry ground, short circuit For left hand bank VGT
turbocharger (VGT)
P132D00 Turbocharger Refer to the
actuator H bridge fault (left Turbocharger vanes warranty policy and procedure
hand bank) stuck/sticking manual if an ECM is suspect.
ECM failure
high resistance,
short circuit to
Variable geometry ground, short circuit For left hand bank VGT
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turbocharger (VGT)
P132E00 Turbocharger Refer to the
actuator performance (left Turbocharger vanes warranty policy and procedure
hand bank) stuck/sticking manual if an ECM is suspect.
ECM failure
high resistance, For left hand bank VGT
Variable geometry short circuit to
actuator circuit tests,
turbocharger (VGT) ground, short circuit
P132F00 to power Turbocharger Refer to the
actuator voltage plausibility
warranty policy and procedure
(left hand bank)
VGT actuator failure manual if an ECM is suspect.
ECM failure
EGR valve stuck/sticking

resistance For EGR valve, intake air shut
off throttle and circuit tests,
(EGR) - intake air shut off
EGR valve circuit(s): Engine Emission Control Refer
P133400 throttle
short circuit to to the warranty policy and
minimum/maximum stop ground procedure manual if an ECM is
performance
suspect.
short circuit to
power
Intake air shut off
throttle
stuck/sticking
Intake air shut off

high resistance
Intake air shut off

short circuit to
ground
Intake air shut off

short circuit to
power
Intake air shut off

throttle failure
ECM failure
CKP sensor circuit: high
resistance

circuit to ground

circuit to power
For CKP and CMP sensor tests,
CMP sensor circuit: high GO to Pinpoint Test
Crankshaft/Camshaft
P133600 position (CKP/CMP) sensor
range/performance CMP sensor circuit: short and procedure manual if an
circuit to ground
ECM is suspect.
circuit to power
CKP sensor failure
CMP sensor failure
ECM failure
Variable geometry
VGT actuator circuit(s): For right hand bank VGT
turbocharger (VGT)
P138E00 high resistance, actuator circuit tests,
actuator adaption (right short circuit to Turbocharger
hand bank) ground, short circuit
to power

resistance
Exhaust gas recirculation For left hand bank EGR valve
P140A00 (EGR) valve circuit low (left EGR valve circuit(s): and circuit tests,
hand bank) short circuit to Engine Emission Control
ground
EGR valve failure

Exhaust gas recirculation For left hand bank EGR valve
short circuit to
P140B00 (EGR) valve circuit high (left and circuit tests,
power
hand bank) Engine Emission Control
EGR valve failure
Intake air shut off
high resistance
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Intake air shut off

throttle circuit(s): For intake air shut off throttle
P140C00 (EGR) - intake air shut off
Intake air shut off to the warranty policy and
throttle H bridges
throttle circuit(s): procedure manual if an ECM is
short circuit to suspect.
power
Intake air shut off

throttle failure
ECM failure
For IAT sensor circuit tests, GO
IAT sensor fault to Pinpoint Test G549822p9.
For MAP sensor circuit tests,
MAP sensor fault
GO to Pinpoint Test
MAF sensor fault G549822p12.
(EGR) control circuit
P140D00 EGR valve stuck closed, GO to Pinpoint Test
range/performance (left blocked G549822p10.
hand bank)
G549822p11.
resistance
For left hand bank EGR valve
EGR valve circuit(s): and circuit tests,
short circuit to Engine Emission Control
ground

short circuit to
power
EGR valve failure

resistance

P140E00 (EGR) valve circuit adaption
(left hand bank)
power suspect.
EGR valve failure
ECM failure
resistance

Exhaust gas recirculation short circuit to and circuit tests,
ground
(EGR) valve circuit Engine Emission Control Refer
P141A00
intermittent/erratic (right EGR valve circuit(s): to the warranty policy and
hand bank) short circuit to procedure manual if an ECM is
power suspect.
EGR valve failure
ECM failure
Intake air shut off
high resistance
Intake air shut off For intake air shut off throttle
Exhaust gas recirculation throttle circuit(s): and circuit tests,
(EGR) - intake air shut off short circuit to Engine Emission Control Refer
P141B00
throttle circuit ground to the warranty policy and
intermittent/erratic procedure manual if an ECM is
Intake air shut off suspect.
short circuit to
power
Intake air shut off

throttle failure
ECM failure
resistance

Exhaust gas recirculation short circuit to and circuit tests,
ground
(EGR) valve circuit Engine Emission Control Refer
P141C00
intermittent/erratic (left EGR valve circuit(s): to the warranty policy and
hand bank) short circuit to procedure manual if an ECM is
power suspect.
EGR valve failure
ECM failure
resistance
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P141D00 (EGR) valve circuit adaption
(right hand bank)
power suspect.
EGR valve failure
ECM failure

resistance, short
Injector circuit Fuel Charging and Controls
circuit to ground,
P150A00 range/performance cylinder Refer to the warranty policy
short circuit to
1 power and procedure manual if an
ECM is suspect.
Injector failure
ECM failure
P150B00 range/performance cylinder Injector circuit(s): high Refer to the warranty policy
2 resistance, short and procedure manual if an
short circuit to
power
Injector failure
ECM failure

resistance, short
circuit to ground,
P150C00 range/performance cylinder Refer to the warranty policy
short circuit to
ECM is suspect.
Injector failure
ECM failure
P151B00 Filtering Check the accessory
(defective/seized drive belt and components,
component) Accessory Drive - 2.7L Diesel
Intake air leak between

MAF sensor and Check the air intake system,
throttle
P151C00 Filtering Inspect the engine
higher than expected Intake air leak between
throttle and engine breather system,
Engine crankcase
breather leak

resistance, short
circuit to ground,
P155400 range/performance cylinder short circuit to
ECM is suspect.
Injector failure
ECM failure
P155500 range/performance cylinder Injector circuit(s): high Refer to the warranty policy
5 resistance, short and procedure manual if an
short circuit to
power
Injector failure
ECM failure

resistance, short
circuit to ground,
P155600 range/performance cylinder Refer to the warranty policy
short circuit to
ECM is suspect.
Injector failure
ECM failure
The brake pressure
reading does not
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light switch value Check the brake switch

function, GO to Pinpoint Test
Brake switch circuit(s):
Brake switch A circuit G549822p18.
P157200 high resistance,
plausibility short circuit to Refer to the warranty policy
ground, short circuit and procedures manual if an
Brake switch failure
ECM failure
Speed control module
ECM/speed control module For speed control,
off CAN
P169600 circuit/network - vehicle Speed Control - VIN Range:
speed set point CAN invalid Speed control module G45704->G99999
misaligned
circuit: high
resistance
For fuel level sensor and circuit
Fuel level sensor signal tests,
P193300 Fuel level sensor CAN signal to ground
TdV6 Refer to the warranty
Fuel level sensor signal policy and procedures manual
circuit: short circuit if an ECM is suspect.
to power

to other resistive
sensors
ECM failure
Vehicle speed sensor Vehicle speed: invalid
P193400 Check for TCM DTCs.
malfunction signal received over
CAN
function, GO to Pinpoint Test
Error on brake switch G549822p18.
P193500 Brake switch/sensor signal
sensor coming on Refer to the warranty policy
CAN and procedures manual if an
ECM is suspect.
Fuel fired heater control

circuit: high
resistance
P193700 No information available.
circuit open (where fitted) Fuel fired heater control
to ground
Fuel fired heater failure

circuit: high
resistance

P193800 circuit range/performance to ground No information available.
(where fitted)
to power

Invalid service test tool
Invailid command during
P193A00 communication - request Not a fault
engine operation.
invalid
Port de-activation Port de-activation solenoid

solenoid circuit: high
Port de-activation solenoid circuit tests,
P200800 resistance
circuit open Intake Air Distribution and
Port de-activation Filtering
solenoid circuit:
short circuit to
ground
Port de-activation
solenoid failure
Port de-activation
solenoid circuit: high
resistance
Port de-activation solenoid Port de-activation circuit tests,
P200900
circuit low solenoid circuit: Intake Air Distribution and
short circuit to Filtering
ground
Port de-activation
solenoid failure
Port de-activation
solenoid circuit: Port de-activation solenoid
Port de-activation solenoid short circuit to circuit tests,
P201000
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circuit high power Intake Air Distribution and

Filtering
Port de-activation
solenoid failure
circuit: high
resistance
Fuel fired heater disabled
(where fitted) Fuel fired heater control
to ground

circuit: high
resistance

Fuel fired heater circuit: short circuit
performance (where fitted) to ground

to power

For APP sensor circuit 1 tests,
Accelerator pedal position Accelerator pedal
(APP) sensor circuit 1 low position (APP) sensor
circuit 1: high G549822p4.
resistance
Accelerator pedal
circuit 1: short circuit
to ground
Accelerator pedal
failure
Accelerator pedal
circuit 1: short circuit For APP sensor circuit 1 tests,
P212300 to power GO to Pinpoint Test
(APP) sensor circuit 1 high
G549822p4.
Accelerator pedal
failure
Accelerator pedal
circuit 2: high
resistance
For APP sensor circuit 2 tests,
Accelerator pedal position Accelerator pedal
(APP) sensor circuit 2 low position (APP) sensor
circuit 2: short circuit G549822p5.
to ground
Accelerator pedal
failure
Accelerator pedal
circuit 2: short circuit For APP sensor circuit 2 tests,
P212800 to power GO to Pinpoint Test
(APP) sensor circuit 2 high
G549822p5.
Accelerator pedal
failure
Accelerator pedal
to power
For APP sensor circuit tests, GO
P213800 (APP) sensor 1 and 2
Accelerator pedal to Pinpoint Test G549822p17.
voltage correlation position (APP) sensor
to ground
Accelerator pedal
failure

resistance

short circuit to
ground

short circuit to
power
Intake air shut off

throttle For EGR valve, intake air shut
Exhaust gas recirculation stuck/sticking off throttle and circuit tests,
(EGR) - intake air shut off Engine Emission Control Refer
P214100
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throttle control deviation Intake air shut off to the warranty policy and
below minimum threshold throttle circuit(s): procedure manual if an ECM is
high resistance
suspect.
Intake air shut off
short circuit to
ground
Intake air shut off

short circuit to
power
Intake air shut off

throttle failure
ECM failure

resistance For EGR valve, intake air shut
Exhaust gas recirculation off throttle and circuit tests,
(EGR) - intake air shut off EGR valve circuit(s): Engine Emission Control Refer
P214200
throttle control deviation short circuit to to the warranty policy and
above maximum threshold ground procedure manual if an ECM is
suspect.
short circuit to
power
Intake air shut off
throttle
stuck/sticking
Intake air shut off

high resistance
Intake air shut off

short circuit to
ground
Intake air shut off

short circuit to
power
Intake air shut off

throttle failure
ECM failure
resistance, short
circuit to ground,
short circuit to For IAT sensor circuit tests, GO
power to Pinpoint Test G549822p9.
For ACT sensor circuit tests, GO
Intake air temperature (IAT) ACT sensor circuit: high
and air charge temperature resistance, short
P219900 circuit to ground,
(ACT) sensor correlation
short circuit to Intake Air Distribution and
after cold start
power Filtering Refer to the warranty
IAT sensor failure if an ECM is suspect.
ACT sensor failure
ECM failure
Barometric pressure (BARO)
P222800 BARO sensor failure and procedures manual if an
sensor circuit low input (internal ECM fault) ECM is suspect.

Barometric pressure (BARO)
P222900 BARO sensor failure and procedures manual if an
sensor circuit high input (internal ECM fault) ECM is suspect.
P223000 Barometric pressure (BARO) BARO sensor failure Refer to the warranty policy
(internal ECM fault) and procedures manual if an
sensor circuit intermittent ECM is suspect.
IAT sensor circuit(s): high

resistance, short
circuit to ground,
short circuit to
power
MAP sensor circuit(s):

high resistance,
short circuit to For IAT sensor circuit tests, GO
ground, short circuit
to power
For MAP sensor circuit tests,
MAF sensor circuit(s): GO to Pinpoint Test
Turbocharger boost system
high resistance, G549822p12.
performance, manifold
P226300 short circuit to For EGR circuit tests, For turbo
absolute pressure (MAP) ground, short circuit charger and circuit tests,
sensor control deviation to power Turbocharger Refer to the
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warranty policy and

EGR circuit(s): high
resistance, short procedures manual if an ECM is
circuit to ground, suspect.
short circuit to
power
Turbocharger vanes
stuck/sticking
ECM failure
pressure: too high
FPCV circuit fault For fuel pressure and fuel

pump module circuit tests,
Injector control pressure FPCV failure Fuel Tank and Lines - 2.7L V6 -
too high - fuel pressure TdV6 For FPCV and circuit
P228800 Fuel pump module
control valve (FPCV) circuit: short circuit tests,
minimum limit reached to power Fuel Charging and Controls For
fuel injection pump,
Fuel pump module Fuel Injection Pump
failure
Fuel injection pump

failure
P229000 Injector control pressure For fuel lines, fuel pressure and
too low - fuel pressure fuel pump module circuit tests,
control valve (FPCV) pressure: too low Fuel Tank and Lines - 2.7L V6 -
maximum limit reached TdV6 For FPCV and circuit
Fuel line leak tests,
Fuel Charging and Controls For
Fuel filter/system
fuel injection pump,
restriction
Fuel Injection Pump
FPCV circuit fault
FPCV failure
Fuel pump module

to ground
Fuel pump module

failure
Fuel injection pump

failure
pressure: erratic
FPCV circuit fault

For fuel lines, fuel pressure and
FPCV failure
fuel pump module circuit tests,
Injector control pressure Fuel pump module Fuel Tank and Lines - 2.7L V6 -
erratic - fuel pressure circuit(s): high TdV6 For FPCV and circuit
P229200
control valve (FPCV) resistance, short tests,
dynamic circuit to ground, Fuel Charging and Controls For
short circuit to fuel injection pump,
power
Fuel Injection Pump
Fuel pump module
failure
Fuel injection pump

failure
Brake pedal
position/accelerator pedal
P229900 function, GO to Pinpoint Test
position incompatible Brake switch failure
G549822p18.
plausibility
DPF temperature sensor

Diesel particulate filter For DPF temperature sensor
circuit: high
P242B00 (DPF) temperature sensor circuit tests,
resistance
circuit range/performance Exhaust System
to ground

to power

failure
circuit: high
resistance
Diesel particulate filter For DPF temperature sensor
P242C00 (DPF) temperature sensor DPF temperature sensor circuit tests,
circuit low circuit: short circuit Exhaust System
to ground

failure
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Diesel particulate filter circuit: short circuit For DPF temperature sensor
P242D00 (DPF) temperature sensor to power circuit tests,
circuit high Exhaust System
failure
circuit: high
resistance

Diesel particulate filter circuit: short circuit For DPF temperature sensor
P242E00 (DPF) temperature sensor to ground circuit tests,
circuit intermittent/erratic Exhaust System
to power

failure
Differential pressure
tubes/hoses For DPF,
P244A00 (DPF) exhaust back pressure split/leaking Exhaust System
too low
DPF split/leaking
tubes/hoses For DPF,
P244B00 (DPF) exhaust back pressure
blockage/restriction Exhaust System
too high
DPF blockage/restriction
Exhaust
blockage/restriction
DPF blockage/restriction
Diesel particulate filter resistance
For DPF differential pressure
(DPF) differential pressure
P245300 sensor circuit tests,
sensor value too high Differential pressure
sensor circuit: short Exhaust System
before engine start
circuit to ground
circuit to power
sensor failure
resistance
Diesel particulate filter For DPF differential pressure
P245400 (DPF) differential pressure Differential pressure sensor circuit tests,
sensor circuit low sensor circuit: short Exhaust System
circuit to ground
sensor failure
Diesel particulate filter sensor circuit: short For DPF differential pressure
P245500 (DPF) differential pressure circuit to power sensor circuit tests,
sensor circuit high Exhaust System
sensor failure
tubes/hoses
split/leaking
Diesel particulate filter Differential pressure

sensor circuit: high For DPF differential pressure
(DPF) differential pressure
P245600 resistance sensor circuit tests,
sensor circuit
Exhaust System
intermittent/erratic Differential pressure
circuit to ground
circuit to power
sensor failure
Driving conditions not Carry out DPF service remedy,
P245900 (DPF) regeneration
appropriate for DPF Exhaust System
frequency regeneration
ECM relay circuit: high

resistance
For ECM relay and circuit tests,
P250500 ECM relay circuit open GO to Pinpoint Test
ECM relay circuit: short
ECM relay failure

ECM relay circuit: high
resistance
For ECM relay and circuit tests,
P250700 ECM relay circuit low GO to Pinpoint Test
ECM relay circuit: short
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ECM relay failure

ECM relay circuit: short For ECM relay and circuit tests,
P250800 ECM relay circuit high circuit to power GO to Pinpoint Test
G549822p26.
ECM relay failure
resistance
Engine oil temperature EOT sensor circuit: short For EOT sensor circuit tests, GO
P250C00
(EOT) sensor circuit low circuit to ground to Pinpoint Test G549822p3.
EOT sensor failure
ECM failure
circuit to power
Engine oil temperature For EOT sensor circuit tests, GO
P250D00
(EOT) sensor circuit high EOT sensor failure to Pinpoint Test G549822p3.
ECM failure
resistance
Engine oil temperature
For EOT sensor circuit tests, GO
P250E00 (EOT) sensor circuit
EOT sensor circuit: short to Pinpoint Test G549822p3.
intermittent/erratic circuit to ground

circuit to power
EOT sensor failure
ECM failure
Inertia switch circuit:
high resistance

short circuit to For inertia switch circuit tests,
Engine shutdown circuit
P251D00 ground GO to Pinpoint Test
open
G549822p25.
short circuit to
power
Inertia switch failure

high resistance
For inertia switch circuit tests,
P251E00 Engine shutdown circuit low Inertia switch circuit: GO to Pinpoint Test
short circuit to G549822p25.
ground

For inertia switch circuit tests,
Engine shutdown circuit short circuit to
P251F00 GO to Pinpoint Test
high power
G549822p25.
resistance

Engine oil temperature circuit to ground
For EOT sensor circuit tests, GO
P252E00 (EOT) sensor circuit
intermittent/erratic EOT sensor circuit: short to Pinpoint Test G549822p3.
circuit to power
EOT sensor failure
ECM failure
High speed CAN For network tests,
U000100
communication bus CAN Mute
For network tests,

U007300 Control module CAN Link circuit
communication bus off - malfunction
CAN bus off

U010100 CAN Link ECM/TCM CAN
TCM - CAN timeout timeout


CAN Link ECM/Speed For network tests,
U010400 speed control module - CAN
control module CAN
timeout timeout
CAN Link ECM/restraints

U011700 control module
inertia switch (RCM) network
malfunction
CAN Link ECM/ABS For network tests,
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module network
(ABS) control module malfunction

For network tests,
U012200 stability assist module - CAN ECM/ASU compressor
timeout CAN timeout

For network tests,

heating ventilation and air For network tests,
U016400 CAN Link ECM/HEVAC
conditioning (HVAC) control network malfunction
module
Lost communication with Configure the system using the

U016600 auxiliary heater control Fuel fired heater Jaguar approved diagnostic
module (where fitted) fitted/not configured system.

For network tests,
U016700 vehicle immobilizer control
CAN timeout
module
Software incompatibility
For network tests,
U032600 with vehicle immobilizer Challenge does not
control module match
Invalid data received from ECM/Speed control For network tests,
U040500
speed control module module invalid data
received
Invalid data received from For network tests,
U041600 ECM/ABS module invalid
stability assist module torque drag request
Pinpoint tests
NOTE:
NOTE:
NOTE:
terminals.

SENSOR
G549822t1 : CHECK THE ECT PID VALUE
1.
Circuit Pin
Engine coolant temperature sensor - signal 01
Engine coolant temperature sensor - return 02

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2.
Circuit Pin
Engine coolant temperature sensor - signal C2
Engine coolant temperature sensor - return E2
Resistance (ohms) Temperature (degrees C) Temperature (degrees F) Volts
925021 -40 -40 4.8942
496051 -30 -22 4.8062
276959 -20 -04 4.6633
160313 -10 14 4.4454

123485 -5 23 4.3031
95851 0 32 4.1368
74914 5 41 3.9464
58987 10 50 3.7340
37340 20 68 3.2560
24253 30 86 2.7403
16113 40 104 2.2309
10926 50 122 1.7665
7548 60 140 1.3700
5335 70 158 1.0529
3837 80 176 0.8048
2804 90 194 0.6148
2080 100 212 0.4710
1564 110 230 0.3636
1191 120 248 0.2810
918 130 266 0.2194
3. Make sure that the engine is cold. 4. Key on, engine off. 5. Access the OBDII-engine coolant
temperature PID using the Jaguar approved diagnostic system or a scan tool.
Is the ECT reading as expected for the current environmental and engine conditions?
-> Yes
-> No
G549822t2 : CHECK THE ECT PID VALUE DURING WARM UP
1. Key on, engine running. 2. Access the OBDII-engine coolant temperature PID using the Jaguar
approved diagnostic system or a scan tool. 3. Increase the engine speed to 2,000 rpm and monitor
the ECT reading until the engine is at full operating temperature.
Did the ECT reading rise smoothly to a value of between 80 and 95 degrees C (176 and 203
degreees F)?
-> Yes
-> No
G549822t6 : CHECK FOR AN INTERMITTENT FAULT CONDITION

1.
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Were there any sudden or unexpected changes in the PID readings?
-> Yes
Key off. GO to Pinpoint Test G549822t3.
-> No
G549822t3 : CHECK THE ECT PID VALUE

1. Key on, engine off. 2. Access the OBDII-engine coolant temperature PID using the Jaguar approved
diagnostic system or a scan tool. 3. Check the ECT harness wiring and connectors for loose
connections and water ingress. Monitoring the temperature readings for sudden changes while
handling the harness and connectors may help in isolation of these types of fault.
Did you identify any loose connections or water ingress in the ECT harness wiring or
connectors?
-> Yes
REPAIR the fault as necessary. For additional information, refer to the wiring diagrams. Clear any
-> No
G549822t7 : CHECK THE ECT SENSOR RETURN CIRCUIT FOR HIGH
RESISTANCE
1. Key off. 2. Disconnect the ECT sensor connector, C34. 3. Key on, engine off. 4. Measure the
resistance between:
-> Yes
-> No
G549822t4 : CHECK THE ECT SENSOR RETURN CIRCUIT FOR SHORT CIRCUIT
TO POWER
Is the resistance geater than 100 Kohms?
-> Yes
-> No
G549822t5 : CHECK THE ECT SENSOR TO ECM RETURN CIRCUIT FOR HIGH
RESISTANCE
Pin 02 Pin E2
-> Yes
-> No
G549822t8 : CHECK THE ECT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

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GROUND
-> Yes
-> No
G549822t9 : CHECK THE ECT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

POWER

-> Yes
-> No
G549822t10 : CHECK THE ECT SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin C2
-> Yes
-> No

Pin 01 Pin 02
Is the resistance between 1 - 500 Kohms?
-> Yes
component(s): - ECT connector - ECT sensor - ECM connector - ECM
-> No
Engine Coolant Temperature (ECT) Sensor (18.30.10) Clear any DTCs, test the system for normal
operation.
G549822t12 : CHECK THE ECT SIGNAL AND RETURN CIRCUITS FOR SHORT
between:
Pin 01 Pin 02
-> Yes
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-> No

-> Yes
Suspect: - ECM
-> No
between:
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

TEMPERATURE SENSOR
G549822t16 : CHECK THE FUEL TEMPERATURE PID VALUE
1.
Circuit Pin
Fuel temperature sensor - signal 01
Fuel temperature sensor - return 02

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2.
Circuit Pin
Fuel temperature sensor - signal B2
Fuel temperature sensor - return G3
Temperature (degrees C) Temperature (degrees F) Volts
-40 -40 4.9701
-30 -22 4.9436
-20 -04 4.8983
0 32 4.7104
20 68 4.3092
40 104 3.6210
60 140 2.7528
80 176 1.8951
100 212 1.2389
120 248 0.7947
130 266 0.6362
150 302 0.4115
3. Make sure that the engine is cold. 4. Key on, engine off. 5. Access the ECM-fuel temperature PID
using the Jaguar approved diagnostic system or a scan tool.
There are two PIDs accessible for the fuel temperature sensor, the actual reading PID, and another
for limp-home. The limp-home PID is a default value, so is fixed. Make sure the actual reading PID is
used.
Is the PID reading as expected for the current environmental and engine conditions?
-> Yes
-> No
G549822t17 : CHECK THE FUEL TEMPERATURE PID VALUE DURING WARM

UP
1. Key on, engine running. 2. Access the ECM-fuel temperature and OBDII-engine coolant
temperature PIDs using the Jaguar approved diagnostic system or a scan tool.
used. 3. Increase the engine speed to 2,000 rpm and monitor the fuel temperature reading, until the
engine is at full operating temperature.
Did the fuel temperature reading rise smoothly and by more than 10 degrees C (50 degrees F)?
-> Yes
-> No
G549822t18 : CHECK THE FUEL TEMPERATURE PID VALUE

1.
used.
Were there any sudden or unexpected changes in the fuel temperature readings?
-> Yes
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-> No

1. Key on, engine off. 2. Access the ECM-fuel temperature PID using the Jaguar approved diagnostic
system or a scan tool. 3. Check the fuel temperature harness wiring and connectors for loose
Did you identify any loose connections or water ingress in the fuel temperature harness wiring
or connectors?
-> Yes
-> No
G549822t20 : CHECK THE FUEL TEMPERATURE SENSOR RETURN CIRCUIT

FOR HIGH RESISTANCE
1. Key off. 2. Disconnect the fuel temperature sensor connector, C35. 3. Key on, engine off. 4.
-> Yes
-> No
G549822t21 : CHECK THE FUEL TEMPERATURE SENSOR RETURN CIRCUIT

-> Yes
-> No
G549822t22 : CHECK THE FUEL TEMPERATURE SENSOR TO ECM RETURN

Pin 02 Pin G3
-> Yes
Suspect: - ECM connector - ECM
-> No
G549822t23 : CHECK THE VOLTAGE DIFFERENTIAL BETWEEN THE SIGNAL

AND RETURN CIRCUITS
Pin 01 Pin 02
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Is the voltage between 4.8 - 5.2 volts?
-> Yes
-> No
G549822t24 : CHECK THE FUEL TEMPERATURE SIGNAL CIRCUIT FOR

-> Yes
-> No
G549822t25 : CHECK THE FUEL TEMPERATURE SIGNAL CIRCUIT FOR

-> Yes
-> No
G549822t26 : CHECK THE FUEL TEMPERATURE SIGNAL CIRCUIT FOR HIGH

RESISTANCE
Pin 01 Pin B2
-> Yes
-> No

Pin 01 Pin 02
-> Yes
component(s): - Fuel temperature connector - Fuel temperature sensor - ECM connector - ECM
-> No
INSTALL a new fuel temperature sensor.
G549822t28 : CHECK THE FUEL TEMPERATURE SIGNAL AND RETURN

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CIRCUITS FOR SHORT CIRCUIT TO EACH OTHER

between:
Pin 01 Pin 02
-> Yes
-> No


-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

G549822t32 : CHECK THE EOT PID VALUE
1. Engine oil temperature (EOT) sensor connector, C28
Circuit Pin
Engine oil temperature sensor - signal 01
Engine oil temperature sensor - return 02

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Circuit Pin
Engine oil temperature sensor - signal A1
Engine oil temperature sensor - return K1
3. Make sure that the engine is cold. 4. Key on, engine off. 5. Access the ECM-Engine oil temperature
PID using the Jaguar approved diagnostic system or a scan tool.
Is the EOT reading as expected for the current enviromental and engine conditions?
-> Yes
-> No
G549822t33 : CHECK THE EOT PID VALUE DURING WARM UP

1. Key on, engine running. 2. Access the ECM-Engine oil temperature and OBDII-Engine coolant
temperature PIDs using the Jaguar approved diagnostic system or a scan tool. 3. Increase the engine
speed to 2,000 rpm and monitor the EOT reading, until the engine is at full operating temperature.
Did the EOT reading rise smoothly and by more than 20 degrees C (68 degrees F)?
-> Yes
-> No

1.
Were there any sudden or unexpected changes in the EOT readings?
-> Yes
-> No
G549822t35 : CHECK THE EOT PID VALUE

1. Key on, engine off. 2. Access the ECM-Engine oil temperature PID using the Jaguar approved
diagnostic system or a scan tool. 3. Check the EOT harness wiring and connectors for loose
Did you identify any loose connections or water ingress in the EOT harness wiring or
connectors?
-> Yes
-> No
G549822t36 : CHECK THE EOT SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the EOT sensor connector, C28. 3. Key on, engine off. 4. Measure the
resistance between:
-> Yes
-> No
G549822t37 : CHECK THE EOT SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
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-> Yes
-> No
G549822t38 : CHECK THE EOT SENSOR TO ECM RETURN CIRCUIT FOR HIGH
RESISTANCE
Pin 02 Pin K1
-> Yes
-> No
G549822t39 : CHECK THE EOT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No
G549822t40 : CHECK THE EOT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

POWER
-> Yes
-> No
G549822t41 : CHECK THE EOT SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin A1
-> Yes
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-> No

Pin 01 Pin 02
-> Yes
component(s): - EOT connector - EOT sensor - ECM connector - ECM
-> No
INSTALL a new EOT sensor. Clear any DTCs, test the system for normal operation.
G549822t43 : CHECK THE EOT SIGNAL AND RETURN CIRCUITS FOR SHORT
between:
Pin 01 Pin 02
-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

between:

-> Yes
Suspect: - ECM
-> No

between:

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-> Yes
Suspect: - ECM
-> No

(APP) SENSOR 1
G549822t47 : CHECK THE APP1 VALUE, WITH THE ACCELERATOR PEDAL
RELEASED
1.
Circuit Pin
Accelerator pedal position sensor 1 - signal 04
Accelerator pedal position sensor 1 - power 05
Accelerator pedal position sensor 1 - return 03
2.
Circuit Pin
Accelerator pedal position sensor 1 - signal D1
Accelerator pedal position sensor 1 - power E1
Accelerator pedal position sensor 1 - return C1
3. Key on, engine off. 4. Make sure the accelerator pedal is released. 5. Access the ECM-Pedal
position sensor 1 (voltage) PID using the Jaguar approved diagnostic system or a scan tool.
Is the voltage between 0 - 1 volts?
-> Yes
-> No
G549822t85 : CHECK THE APP1 VALUE, WITH THE ACCELERATOR FULLY

DEPRESSED
1. Make sure the accelerator pedal is fully depressed. 2. Access the ECM-Pedal position sensor 1
(voltage) PID using the Jaguar approved diagnostic system or a scan tool.
-> Yes
-> No
G549822t86 : CHECK THE APP1 SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the APP sensor connector, CR14. 3. Key on, engine off. 4. Measure the
resistance between:

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-> Yes
-> No
G549822t87 : CHECK FOR POWER TO THE APP1 SENSOR

-> Yes
-> No
G549822t88 : CHECK THE APP1 SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G549822t90 : CHECK THE APP1 SIGNAL AND POWER CIRCUITS FOR SHORT
Pin 04 Pin 05
-> Yes
-> No
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G549822t91 : CHECK THE APP1 SIGNAL CIRCUIT FOR HIGH RESISTANCE

1. Key off. 2. Disconnect the ECM connector, EC66. 3. Measure the resistance between:
Pin 04 Pin D1
-> Yes
component(s): - APP connector - APP sensor - ECM connector - ECM
-> No
G549822t92 : CHECK THE APP1 SIGNAL AND RETURN CIRCUITS FOR SHORT
1. Key off. 2. Disconnect the ECM connector, EC66. 3. Key on, engine off. 4. Measure the resistance
between:
Pin 04 Pin 03
-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

between:

-> Yes
Suspect: - ECM
-> No

OR THE MODULE
between:
Pin 04 Pin 05
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Pin 04 Pin 03
-> Yes
Suspect: -ECM
-> No

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G549822t98 : CHECK THE 5 VOLT SUPPLY CIRCUIT FOR HIGH RESISTANCE

Pin 05 Pin E1
-> Yes
Suspect : - ECM connector - ECM
-> No
G549822t99 : CHECK THE APP1 SUPPLY AND RETURN CIRCUITS FOR SHORT
between:
Pin 05 Pin 03
-> Yes
-> No
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G549822t100 : CHECK THE APP1 SENSOR TO ECM RETURN CIRCUIT FOR

HIGH RESISTANCE
Pin 03 Pin C1
-> Yes
-> No
G549822t101 : CHECK THE APP1 SUPPLY AND RETURN CIRCUITS FOR

between:
Pin 05 Pin 03
-> Yes
-> No
G549822t102 : CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN

THE HARNESS OR THE MODULE
-> Yes
Suspect: - ECM
-> No

between:

-> Yes
Suspect: - ECM
-> No
G549822t104 : CHECK THE APP1 SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER

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-> Yes
-> No

between:
-> Yes
Suspect: - ECM
-> No

(APP) SENSOR 2
RELEASED
1.
Circuit Pin
2.
Circuit Pin
Accelerator pedal position sensor 2 - signal C2
Accelerator pedal position sensor 2 - power D2

Accelerator pedal position sensor 2 - return B2
-> Yes
-> No

DEPRESSED
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-> Yes
-> No

RESISTANCE
resistance between:
-> Yes
-> No
G549822t108 : CHECK THE SUPPLY TO THE APP2 SENSOR

-> Yes
-> No

GROUND
-> Yes
-> No
POWER
-> Yes
-> No
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Pin 01 Pin 02
-> Yes
-> No


Pin 01 Pin C2
-> Yes
-> No
G549822t113 : CHECK THE APP2 SIGNAL AND RETURN CIRCUITS FOR

between:
Pin 01 Pin 06
-> Yes
-> No


-> Yes
Suspect: - ECM
-> No

between:

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-> Yes
Suspect: - ECM
-> No
G549822t116 : CHECK WHETHER SHORT CIRCUIT IS IN THE HARNESS OR

THE MODULE
Pin 01 Pin 02
-> Yes
Suspect: -ECM
-> No
G549822t117 : CHECK THE 5 VOLT SUPPLY CIRCUIT FOR SHORT CIRCUIT

TO GROUND
-> Yes
-> No

TO POWER
-> Yes
-> No

Pin 02 Pin D2
-> Yes
-> No

CIRCUIT TO POWER
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-> Yes
-> No

between:
Pin 02 Pin 06
-> Yes
-> No

HIGH RESISTANCE
Pin 06 Pin B2
-> Yes
-> No

Pin 02 Pin 06
-> Yes
-> No

-> Yes
Suspect: - ECM
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-> No

between:
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

CHARGE TEMPERATURE (ACT)
SENSOR
G549822t49 : CHECK THE ACT SENSOR RETURN CIRCUIT FOR HIGH
RESISTANCE
1.
Circuit Pin
Air charge temperature sensor - signal 01
Air charge temperature sensor - return 02

2.
Circuit Pin
Air charge temperature sensor - signal B1
Air charge temperature sensor - return G3

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Resistance (ohms) Temperature (degrees C) Temperature (degrees F) Volts
209603 -40 -40 4.9179
120372 -30 -22 4.8587
71668 -20 -04 4.7672
44087 -10 14 4.6323
27936 0 32 4.4433
18187 10 50 4.1931
12136 20 68 3.8808
8284 30 86 3.5149
5774 40 104 3.1130
4103 50 122 2.6983
2967 60 140 2.2940
2182 70 158 1.9201
1628 80 176 1.5874

1233 90 194 1.3026
949 100 212 1.0639
735 110 230 0.8678
578 120 248 0.7087
459 130 266 0.5797
3. Key off. 4. Disconnect the ACT sensor connector, C69. 5. Key on, engine off. 6. Measure the
resistance between:
-> Yes
-> No
G549822t50 : CHECK THE ACT SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G549822t51 : CHECK THE ACT SENSOR TO ECM RETURN CIRCUIT FOR HIGH
RESISTANCE
Pin 02 Pin G3
-> Yes
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-> No
G549822t52 : CHECK FOR POWER TO THE ACT SENSOR

-> Yes
-> No
G549822t53 : CHECK THE ACT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
G549822t55 : CHECK THE ACT SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin B1

-> Yes
-> No

Pin 01 Pin 02
Is the resistance between 578 ohms - 71 Kohms?

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-> Yes
component(s): - ACT connector. - ACT sensor. - ECM connector. - ECM
-> No
INSTALL a new ACT sensor.
G549822t57 : CHECK THE ACT SIGNAL AND RETURN CIRCUITS FOR SHORT
Pin 01 Pin 02
-> Yes
-> No
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

between:

-> Yes
Suspect: - ECM
-> No
PINPOINT TEST G549822p7 : KNOCK

SENSOR (KS) (RIGHT HAND BANK)
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G549822t61 : CHECK THE KS CIRCUIT(S) FOR SHORT CIRCUIT TO GROUND

1.
Circuit Pin
Knock sensor - positive 01
Knock sensor - negative 02
2.
Circuit Pin
Knock sensor - positive E4
Knock sensor - negative D4
3. Key off. 4. Disconnect the right hand bank KS connector, C87. 5. Disconnect the ECM connector,
-> Yes
-> No
G549822t62 : CHECK THE KS CIRCUIT(S) FOR SHORT CIRCUIT TO POWER

-> Yes
-> No
G549822t63 : CHECK THE KS SIGNAL AND RETURN CIRCUITS FOR SHORT

Pin 01 Pin 02
-> Yes
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-> No
G549822t64 : CHECK THE KS CIRCUIT(S) FOR HIGH RESISTANCE

Pin 01 Pin E4
Pin 02 Pin D4
-> Yes
component(s): - KS connector - KS sensor - ECM connector - ECM
-> No
PINPOINT TEST G549822p8 : KNOCK
SENSOR (KS) (LEFT HAND BANK)
G549822t65 : CHECK THE KS CIRCUIT(S) FOR SHORT CIRCUIT TO GROUND
1.
Circuit Pin
Knock sensor - positive 01
Knock sensor - negative 02
2.
Circuit Pin
Knock sensor - positive D3
Knock sensor - negative C4
3. Key off. 4. Disconnect the left hand bank KS connector, C88. 5. Disconnect the ECM connector,

-> Yes
-> No
G549822t66 : CHECK THE KS CIRCUIT(S) FOR SHORT CIRCUIT TO POWER


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-> Yes
-> No
G549822t67 : CHECK THE KS SIGNAL AND RETURN CIRCUITS FOR SHORT

Pin 01 Pin 02

-> Yes
-> No
G549822t68 : CHECK THE KS CIRCUIT(S) FOR HIGH RESISTANCE

Pin 01 Pin D3
Pin 02 Pin C4
-> Yes
component(s): - KS connector - KS sensor - ECM connector - ECM
-> No

G549822t69 : CHECK THE IAT PID VALUE
1.
Circuit Pin
Intake air temperature sensor - signal 02
Intake air temperature sensor - return 03
2.
Circuit Pin
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Intake air temperature - return L4
Intake air temperature - signal F1
Mass air flow sensor - return L4
Resistance (ohms) Temperature (degreees C) Temperature (degrees F) Volts
44373 -40 -40 4.7844
25572 -30 -22 4.6373
15141 -20 -04 4.4166
9202 -10 14 4.1073
5774 0 32 3.7137
3714 10 50 3.2499
2448 20 68 2.7518
1671 30 86 2.2759
1150 40 104 1.8254
816.5 50 122 1.4497
583.1 60 140 1.1287
426.1 70 158 0.8792
315.8 80 176 0.6818
238.1 90 194 0.5319
182.8 100 212 0.4187
141.2 110 230 0.3297
110.3 120 248 0.2613
87.45 130 266 0.2095
3. Make sure that the engine is cold. 4. Key on, engine off. 5. Access the ECM-Intake air temperature
Is the IAT reading as expected for the current environmental and engine conditions?
-> Yes
-> No
G549822t70 : CHECK THE IAT PID VALUE AT INCREASED RPM

1. Key on, engine running. 2. Access the ECM-Intake air temperature PID using the Jaguar approved
diagnostic system or a scan tool. 3. Slowly increase the engine speed to 4,000 rpm while monitoring
the IAT reading.
Did the IAT reading rise smoothly?
-> Yes
-> No

1.
Were there any sudden or unexpected changes in the IAT readings?
-> Yes
-> No

1. Key on, engine off. 2. Access the ECM-Intake air temperature PID using the Jaguar approved
www.JagDocs.com
diagnostic system or a scan tool. 3. Check the IAT harness wiring and connectors for loose
connections and water ingress. Monitoring the temperature readings for sudden changes, while
handling the harness and connectors, may help in isolation of these types of fault.
Did you identify any loose connections or water ingress in the IAT harness wiring or
connectors?
-> Yes
-> No
G549822t73 : CHECK THE IAT SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the MAF1 sensor connector, EC67. 3. Key on, engine off. 4. Measure the
resistance between:

-> Yes
-> No
G549822t74 : CHECK THE IAT SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G549822t75 : CHECK THE IAT SENSOR TO ECM RETURN CIRCUIT FOR HIGH
RESISTANCE
Pin 03 Pin L4
-> Yes
-> No
G549822t76 : CHECK FOR POWER TO THE IAT SENSOR
Is the voltage between 4.8 volts - 5.2 volts?
-> Yes
-> No
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G549822t77 : CHECK THE IAT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No
G549822t78 : CHECK THE IAT SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

POWER

-> Yes
-> No
G549822t79 : CHECK THE IAT SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 02 Pin F1
-> Yes
-> No

EC67, component side EC67, component side
Pin 02 Pin 03
Is the resistance between 150 ohms - 15 Kohms?
-> Yes
component(s): - MAF1 connector - MAF1 sensor - ECM connector - ECM
-> No
INSTALL a new MAF1 sensor.
G549822t81 : CHECK THE IAT SIGNAL AND RETURN CIRCUITS FOR SHORT
between:
Pin 02 Pin 03

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-> Yes
-> No

-> Yes
Suspect: - ECM
-> No
between:
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

AIR FLOW (MAF) SENSOR (RIGHT
HAND BANK)
G549822t127 : CHECK THE MAF PID VALUE
1.
Circuit Pin
Mass air flow sensor - signal 01
Mass air flow sensor - return 03
ECM relay controlled 12 volt supply 04

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2.
Circuit Pin
Mass air flow sensor - signal F4
3. Key on, engine running. 4. Access the ECM-Right hand bank mass air flow sensor signal frequency
Is the Hot$MAF between 4 g/sec - 18 g/sec?
-> Yes
-> No

1. Access the ECM-Right hand bank mass air flow sensor signal frequency PID using the Jaguar
Is the Hot$MAF less than 4 g/sec?
-> Yes
-> No
G549822t129 : CHECK FOR AIR LEAKAGE BETWEEN THE TURBOCHARGER

AND THE RIGHT HAND BANK MAF SENSOR
1. Key off. 2. Check for air leakage between the turbocharger and the right hand bank MAF sensor.
Are there any air leaks?
-> Yes
REPAIR the fault as necessary. Clear any DTCs, test the system for normal operation.
-> No
G549822t130 : CHECK FOR OIL INGESTION

1. Key off. 2. Check for oil ingestion via the engine manifold.
Is there any oil ingestion?
-> Yes
REPAIR/INSTALL a new right hand bank MAF sensor.
Mass Air Flow (MAF) Sensor (18.30.15) Check/rectify any external oil leaks.
-> No

1. Disconnect the right hand bank MAF sensor connector, EC67. 2. Measure the resistance between:
Pin 04 Pin 03
-> Yes
-> No
INSTALL a new right hand bank MAF sensor.
G549822t132 : CHECK THE SUPPLY TO THE MAF SENSOR

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-> Yes
-> No
REPAIR the ECM to right hand bank MAF sensor supply circuit as necessary. For additional
G549822t133 : CHECK THE MAF SENSOR CIRCUIT(S) FOR SHORT CIRCUIT

TO GROUND
between:

-> Yes
-> No

TO POWER
-> Yes
-> No
G549822t135 : CHECK THE MAF SIGNAL AND RETURN CIRCUITS FOR SHORT
Pin 01 Pin 03

-> Yes
-> No
G549822t136 : CHECK THE MAF SENSOR CIRCUIT(S) FOR HIGH RESISTANCE

Pin 03 Pin L4
Pin 01 Pin F4
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-> Yes
component(s): - MAF connector - MAF sensor - ECM connector - ECM
-> No

AIR FLOW (MAF) SENSOR (LEFT
HAND BANK)
1.
Circuit Pin
Mass air flow sensor - signal 02
Mass air flow sensor - return 03
ECM relay controlled 12 volt supply 04
2.
Circuit Pin
Mass air flow sensor - signal G4
3. Key on, engine running. 4. Access the ECM-Left hand bank mass air flow sensor signal frequency
Is the Hot$MAF between 4 g/sec - 18 g/sec?
-> Yes
-> No

1. Access the ECM-Left hand bank mass air flow sensor signal frequency PID using the Jaguar
Is the Hot$MAF less than 4 g/sec?

-> Yes
-> No
G549822t139 : CHECK FOR AIR LEAKAGE BETWEEN THE TURBOCHARGER

AND THE LEFT HAND BANK MAF SENSOR
1. Key off. 2. Check for air leakage between the turbocharger and the left hand bank MAF sensor.
Are there any air leaks?
-> Yes
REPAIR the fault as necessary. Clear any DTCs, test the system for normal operation.
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-> No
G549822t140 : CHECK FOR OIL INGESTION

1. Key off. 2. Check for oil ingestion via the engine manifold.
Is there any oil ingestion?
-> Yes
REPAIR/INSTALL a new left hand bank MAF sensor.
Mass Air Flow (MAF) Sensor (18.30.15) Check/rectify any external oil leaks.
-> No

1. Disconnect the left hand bank MAF sensor connector, EC68. 2. Measure the resistance between:
Pin 04 Pin 03

-> Yes
-> No
INSTALL a new left hand bank MAF sensor.
G549822t142 : CHECK THE SUPPLY TO THE MAF SENSOR

-> Yes
-> No
REPAIR the ECM to left hand bank MAF sensor supply circuit as necessary. For additional information,

TO GROUND
between:
-> Yes
-> No

TO POWER

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-> Yes
-> No
G549822t145 : CHECK THE MAF SIGNAL AND RETURN CIRCUITS FOR SHORT
Pin 01 Pin 03
-> Yes
-> No
G549822t146 : CHECK THE MAF SENSOR CIRCUIT(S) FOR HIGH RESISTANCE
Pin 03 Pin L4
Pin 01 Pin G4
-> Yes
component(s): - MAF connector - MAF sensor - ECM connector - ECM
-> No

(MAP) SENSOR
G549822t244 : CHECK THE MAP SENSOR CONNECTOR FOR PHYSICAL
DAMAGE OR CORROSION
1.
Circuit Pin
Manifold absolute pressure sensor - signal 02
Manifold absolute pressure sensor - power 01

Manifold absolute pressure sensor - return 03
2.
Circuit Pin
Manifold absolute pressure sensor - signal C1
Manifold absolute pressure sensor - power D1

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Manifold absolute pressure sensor - return E2
3. Inspect the sensor for damage, correct fitment, connection, etc.
Is the sensor correctly installed and in good condition?
-> Yes
-> No
CHECK and rectify as necessary.
G549822t243 : CHECK THE MAP PID VALUE

1. Key on, engine running. 2. Access the OBDII-Intake manifold absolute pressure PID using the Jaguar
approved diagnostic system or a scan tool. 3. Slowly increase the engine speed to 1,500 rpm while
monitoring the MAP reading.
Did the pressure increase smoothly as the engine speed was increased?
-> Yes
-> No
G549822t147 : CHECK THE MAP SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the MAP sensor connector, C31. 3. Measure the resistance between:
-> Yes
-> No
G549822t148 : CHECK THE SUPPLY TO THE MAP SENSOR

-> Yes
-> No
G549822t149 : CHECK THE MAP SIGNAL CIRCUIT FOR SHORT CIRCUIT TO

GROUND
-> Yes
-> No

POWER
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-> Yes
-> No

RETURN AND SUPPLY CIRCUITS
Pin 02 Pin 01
Pin 02 Pin 03
-> Yes
-> No
G549822t152 : CHECK THE MAP SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 02 Pin C1
-> Yes
component(s): - MAP connector - MAP sensor - ECM connector - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

between:

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-> Yes
Suspect: - ECM
-> No

OR THE MODULE
Pin 02 Pin 01
Pin 02 Pin 03
-> Yes
Suspect: - ECM
-> No
TO GROUND
-> Yes
-> No

TO POWER
-> Yes
-> No


Pin 01 Pin D1
-> Yes
Suspect : - ECM connector. - ECM
-> No
G549822t159 : CHECK THE MAP SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER

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-> Yes
-> No
G549822t160 : CHECK THE MAP SUPPLY AND RETURN CIRCUITS FOR

Pin 01 Pin 03

-> Yes
-> No
G549822t161 : CHECK THE MAP SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
between:
Pin 03 Pin E2
-> Yes
Suspect : - MAP connector - MAP sensor - ECM connector - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
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-> No

between:
-> Yes
Suspect: - ECM
-> No

OR THE MODULE
Pin 01 Pin 03
-> Yes
Suspect: - ECM
-> No

AIR TEMPERATURE (IAT) AND
CHARGE AIR TEMPERATURE (ACT)
SENSORS
1.
Circuit Pin
Air charge temperature sensor - signal 01
Air charge temperature sensor - return 02

2.
Circuit Pin
Intake air temperature - return L4
Intake air temperature - signal F1

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Circuit Pin
Air charge temperature sensor - signal B1
Air charge temperature sensor - return G3
3. Make sure that the engine is cold. 4. Key on, engine off. 5. Access the ECM-Boost air temperature
Is the IAT reading as expected for the current environmental and engine conditions?
-> Yes
-> No

1. Key on, engine running. 2. Access the ECM-Boost air temperature PID using the Jaguar approved
diagnostic system or a scan tool. 3. Slowly increase the engine speed to 4,000 rpm while monitoring
the IAT reading.
Did the IAT reading rise smoothly?

-> Yes
-> No

1.
Were there any sudden or unexpected changes in the IAT readings?
-> Yes
-> No

1. Key on, engine off. 2. Access the ECM-Boost air temperature PID using the Jaguar approved
diagnostic system or a scan tool. 3. Check the IAT harness wiring and connectors for loose
connections and water ingress. Monitoring the temperature readings for sudden changes, while
handling the harness and connectors, may help in isolation of these types of fault.
Did you identify any loose connections or water ingress in the IAT harness wiring or
connectors?
-> Yes
-> No
G549822t170 : CHECK THE ACT SENSOR RETURN CIRCUIT FOR HIGH

RESISTANCE
1. Key off. 2. Disconnect the ACT sensor connector, C69. 3. Key on, engine off. 4. Measure the
resistance between:

-> Yes
-> No
G549822t171 : CHECK THE ACT SENSOR RETURN CIRCUIT FOR SHORT

CIRCUIT TO POWER
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-> Yes
-> No
G549822t172 : CHECK THE ACT SENSOR TO ECM RETURN CIRCUIT FOR

HIGH RESISTANCE
Pin 02 Pin G3

-> Yes
-> No
G549822t173 : CHECK FOR POWER TO THE ACT SENSOR

-> Yes
-> No

GROUND
-> Yes
-> No
POWER
-> Yes
-> No
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G549822t176 : CHECK THE ACT SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 Pin B1
-> Yes
-> No

Pin 01 Pin 02
-> Yes
component(s): - ACT connector. - ACT sensor. - ECM connector. - ECM
-> No
INSTALL a new ACT sensor.
G549822t178 : CHECK THE ACT SIGNAL AND RETURN CIRCUITS FOR SHORT
between:
Pin 01 Pin 02
-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

between:
-> Yes
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Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No
SENSOR
G549822t182 : CHECK THE CKP CIRCUITS FOR SHORT CIRCUIT TO GROUND
1.
Circuit Pin
Crankshaft position sensor - signal 02
Crankshaft position sensor - positive 01
Crankshaft position sensor - negative 03
2.
Circuit Pin
Crankshaft position sensor - signal F1
Crankshaft position sensor - positive G1
Crankshaft position sensor - negative G2

between:
Pin G2 Negative terminal
Pin F1 Negative terminal
-> Yes
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-> No
REPAIR the short circuit to ground in the CKP harness or component. For additional information,
G549822t183 : CHECK THE CKP CIRCUITS FOR SHORT CIRCUIT TO POWER

Pin G2 Positive terminal
Pin F1 Positive terminal
-> Yes
-> No
G549822t184 : CHECK THE CKP CIRCUIT RESISTANCE
Pin G2 Pin F1
-> Yes
-> No
REPAIR the out of limits resistance in the CKP harness or component. This may be due to a short or
open circuit, depending on the result of the last measurement. For additional information, refer to
the wiring diagrams. Clear any DTCs, test the system for normal operation.

Pin G1 Pin F1
Pin G1 Pin G2
-> Yes
component(s): - Open circuit in sensor power line - CKP connector - CKP sensor - Crankshaft sensor
target wheel - ECM connector - ECM
-> No
CAMSHAFT POSITION (CMP) SENSOR
G549822t186 : CHECK THE CMP CIRCUITS FOR SHORT CIRCUIT TO GROUND
1.
Circuit Pin
Camshaft position sensor - signal 01

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Camshaft position sensor - return 02
Camshaft position sensor - power 03
2.
Circuit Pin
Camshaft position sensor - signal G4
Camshaft position sensor - return H3
Camshaft position sensor - power H4
between:
Pin H3 Negative terminal
-> Yes
-> No
REPAIR the short circuit to ground in the CMP harness or component. For additional information,
G549822t187 : CHECK THE CMP CIRCUITS FOR SHORT CIRCUIT TO POWER

Pin H3 Positive terminal
-> Yes
-> No
REPAIR the short circuit to power in the CMP harness or component. For additional information,
G549822t188 : CHECK THE CMP CIRCUIT RESISTANCE

Pin G4 Pin H3
Is the resistance between 100 Kohms - 120 Kohms?
-> Yes
-> No
REPAIR the out of limits resistance in the CMP harness or component. This may be due to a short or

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Pin H4 Pin G4
Pin H4 Pin H3
-> Yes
component(s): - Open circuit in sensor power line - CMP connector - CMP sensor - Camshaft sensor
target wheel - ECM connector - ECM
-> No

CRANKSHAFT (CKP) AND CAMSHAFT
(CMP) POSITION SENSORS
G549822t190 : CHECK THE CKP CIRCUITS FOR SHORT CIRUIT TO GROUND
1.
Circuit Pin
Crankshaft position sensor - signal 02
Crankshaft position sensor - positive 01
Crankshaft position sensor - negative 03
2.
Circuit Pin
Camshaft position sensor - signal 01
Camshaft position sensor - return 02
Camshaft position sensor - power 03

3.
Circuit Pin
Crankshaft position sensor - signal F1
Crankshaft position sensor - positive G1
Crankshaft position sensor - negative G2

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Camshaft position sensor - signal G4
Camshaft position sensor - return H3
Camshaft position sensor - power H4
between:
Pin F1 Negative terminal
-> Yes
-> No

Pin F1 Positive terminal
-> Yes
-> No

Pin G2 Pin F1
Is the resistance between 100 Kohms - 120 Kohms?
-> Yes
-> No
Pin G1 Pin F1
Pin G1 Pin G2
-> Yes
-> No
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G549822t194 : CHECK THE CMP CIRCUITS FOR SHORT CIRCUIT TO GROUND

-> Yes
-> No
REPAIR the short circuit to ground in the CMP harness or component. For additional information,
-> Yes
-> No
REPAIR the short circuit to power in the CMP harness or component. For additional information,

Pin G4 Pin H3
-> Yes
-> No

Pin H4 Pin G4
Pin H4 Pin H3
-> Yes
component(s): - Open circuit in sensor power line - CMP connector - CKP connector - CMP sensor -
CKP sensor - Crankshaft sensor target wheel - Camshaft sensor target wheel - ECM connector - ECM
-> No
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(APP) SENSORS 1 AND 2
RELEASED
1.
Circuit Pin

2.
Circuit Pin
Accelerator pedal position sensor 2 - signal C2
Accelerator pedal position sensor 2 - power D2
Accelerator pedal position sensor 2 - return B2
Accelerator pedal position sensor 1 - signal D1
Accelerator pedal position sensor 1 - power E1
Accelerator pedal position sensor 1 - return C1
-> Yes
-> No
RELEASED
1. Make sure the accelerator pedal is released. 2. Access the ECM-Pedal position sensor 2 (voltage)
-> Yes
-> No

DEPRESSED
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-> Yes
-> No

DEPRESSED
-> Yes
-> No
RESISTANCE
resistance between:
-> Yes
-> No
G549822t203 : CHECK FOR POWER TO THE APP1 SENSOR

-> Yes
-> No

GROUND

-> Yes
-> No

POWER
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-> Yes
-> No
Pin 04 Pin 05

-> Yes
-> No

Pin 04 Pin D1
-> Yes
-> No

between:
Pin 04 Pin 03
-> Yes
-> No

-> Yes
Suspect: - ECM
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-> No

between:
-> Yes
Suspect: - ECM
-> No

THE MODULE
between:
Pin 04 Pin 05
Pin 04 Pin 03
-> Yes
Suspect: -ECM
-> No

TO GROUND
-> Yes
-> No

TO POWER

-> Yes
-> No

Pin 05 Pin E1
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-> Yes
-> No

between:
Pin 05 Pin 03
-> Yes
-> No

HIGH RESISTANCE
Pin 03 Pin C1
-> Yes
-> No

between:
Pin 05 Pin 03
-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

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between:
-> Yes
Suspect: - ECM
-> No

CIRCUIT TO POWER

-> Yes
-> No

between:
-> Yes
Suspect: - ECM
-> No

RESISTANCE
resistance between:
-> Yes
-> No
G549822t223 : CHECK THE SUPPLY TO THE APP2 SENSOR

-> Yes
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-> No

GROUND
-> Yes
-> No

POWER
-> Yes
-> No
Pin 01 Pin 02
-> Yes
-> No

Pin 01 Pin C2

-> Yes
-> No

between:
Pin 01 Pin 06
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-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

THE MODULE
Pin 01 Pin 02
-> Yes
Suspect: -ECM
-> No

TO GROUND
-> Yes
-> No

TO POWER
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-> Yes
-> No

Pin 02 Pin D2

-> Yes
-> No

CIRCUIT TO POWER
-> Yes
-> No

between:
Pin 02 Pin 06
-> Yes
-> No

HIGH RESISTANCE
Pin 06 Pin B2
-> Yes
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-> No

Pin 02 Pin 06
-> Yes
-> No

-> Yes
Suspect: - ECM
-> No

between:
-> Yes
Suspect: - ECM
-> No

between:

-> Yes
Suspect: - ECM
-> No

PEDAL SWITCH
G549822t242 : CHECK THE OPERATION OF THE BRAKE PEDAL SWITCH
WITH THE BRAKE PEDAL RELEASED
1. Brake pedal switch connector, CR78
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Circuit Pin
Brake pedal switch - power 01
Brake pedal switch - signal 02
2. Engine control module (ECM) connector, EC66
Circuit Pin
Brake pedal switch - signal G2
3. Key off. 4. Disconnect the brake pedal switch connector, CR78. 5. Make sure the brake pedal is
released. 6. Measure the resistance between:
CR78, component side CR78, component side
Pin 01 Pin 02
-> Yes
-> No
INSTALL a new brake pedal switch. Clear any DTCs, test the system for normal operation.
G549822t245 : CHECK THE OPERATION OF THE BRAKE PEDAL SWITCH

WITH THE BRAKE PEDAL DEPRESSED
1. Make sure the brake pedal is depressed. 2. Measure the resistance between:
CR78, component side CR78, component side
Pin 01 Pin 02
-> Yes
-> No
INSTALL a new brake pedal switch. CLEAR the DTC, test the system for normal operation.
G549822t246 : CHECK FOR POWER TO THE BRAKE PEDAL SWITCH

-> Yes
-> No
REPAIR the power supply circuit as necessary. For additional information, refer to the wiring
diagrams. Clear any DTCs, test the system for normal operation.

CIRCUIT TO GROUND
-> Yes
-> No

CIRCUIT TO POWER
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-> Yes
-> No

RESISTANCE
1. Disconnect the ECM connector, EC66. 2. Measure the resistance between:
Pin 02 Pin G2
-> Yes
component(s): - Brake pedal switch connector - Brake pedal switch - ECM connector - ECM
-> No

SENSOR
G549822t253 : CHECK THE A/C PRESSURE SENSOR RETURN CIRCUIT FOR
HIGH RESISTANCE
1. Air conditioning (A/C) pressure sensor connector, EC101
Circuit Pin
Air conditioning pressure sensor - return 01
Air conditioning pressure sensor - signal 02
Air conditioning pressure sensor - power 03
Circuit Pin
Air conditioning pressure sensor - return B3
Air conditioning pressure sensor - signal F2
Air conditioning pressure sensor - power D3
3. Key off. 4. Disconnect the A/C pressure sensor connector, EC101. 5. Key on, engine off. 6. Measure

-> Yes
-> No
G549822t254 : CHECK THE A/C PRESSURE SENSOR RETURN CIRCUIT FOR

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-> Yes
-> No
G549822t255 : CHECK THE A/C PRESSURE SENSOR TO ECM RETURN

Pin 01 Pin B3

-> Yes
component(s): - A/C pressure sensor connector - A/C pressure sensor - ECM connector - ECM
-> No
G549822t256 : CHECK FOR POWER TO THE A/C PRESSURE SENSOR

-> Yes
-> No
G549822t252 : CHECK THE A/C PRESSURE SENSOR SIGNAL CIRCUIT FOR

-> Yes
-> No

-> Yes
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-> No

HIGH RESISTANCE
Pin 02 Pin F2
-> Yes
component(s): - A/C pressure sensor connector - A/C pressure sensor - ECM connector - ECM
-> No
RADIATOR COOLING FAN
G549822t263 : CHECK THE RADIATOR COOLING FAN MODULE GROUND
1. Radiator cooling fan connector, EC72
Circuit Pin
Radiator cooling fan - power 01
Radiator cooling fan - ground 02
2. Radiator cooling fan connector, GC01
Circuit Pin
Radiator cooling fan - control 01
Radiator cooling fan - ignition 02
Circuit Pin
Radiator cooling fan - control K2
4. Key off. 5. Disconnect the fan module electrical connector, EC72. 6. Measure the resistance
between:
-> Yes
-> No
G549822t264 : CHECK FOR POWER TO THE RADIATOR COOLING FAN

MODULE
-> Yes
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-> No
G549822t265 : CHECK THE IGNITION SUPPLY TO THE RADIATOR COOLING

FAN MODULE
1. Key off. 2. Disconnect the fan module electrical connector, GC01. 3. Key on, engine off. 4. Measure
GC01, harness side Battery
-> Yes
-> No
REPAIR the EMS relay to radiator cooling fan supply circuit as necessary. For additional information,
G549822t266 : CHECK THE RADIATOR COOLING FAN MODULE CONTROL
-> Yes
-> No

-> Yes
-> No

between:
GC01, harness side EC66, harness side
Pin 01 Pin K2
-> Yes
component(s): - Radiator cooling fan module connector(s) - Radiator cooling fan module - ECM
connector - ECM
-> No
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STARTER RELAY AND CIRCUITS
G549822t261 : CHECK THE STARTER RELAY AND CIRCUITS
1.
Starting System
-> Yes
-> No
PINPOINT TEST G549822p23 : ECM

POWER SUPPLY CIRCUIT
G549822t269 : CHECK FOR POWER TO THE ECM
1.
Circuit Pin
ECM - power K4
2. Key off. 3. Disconnect the ECM electrical connector, EC66. 4. Measure the voltage between:
Pin K4 Negative terminal
-> Yes
Recheck the DTCs. If no DTCs are set an intermittent fault may be present in the wiring harness.
Visually check for chaffed wires or other physical damage to the harness. If no fault is found in the
circuit, suspect the following component(s): - ECM connector - ECM
-> No
PINPOINT TEST G549822p20 : ECM

IGNITION SUPPLY CIRCUIT(S)
G549822t257 : CHECK THE IGNITION TO ECM SUPPLY CIRCUITS
1.
Circuit Pin
ECM - ignition supply A L2
ECM - ignition supply B L3
ECM - ignition supply C L1

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2. Key off. 3. Disconnect the ECM electrical connector, EC66. 4. Measure the voltage between:
Are the voltages greater than 10 volts?
-> Yes
Recheck the DTCs. If no DTCs are set an intermittent fault may be present in the wiring harness.
Visually check for chaffed wires or other physical damage to the harness. If no fault is found in the
circuit, suspect the following component(s): - ECM connector - ECM
-> No
REPAIR the ignition power supply circuit(s) as necessary. For additional information, refer to the
wiring diagrams. Clear any DTCs, test the system for normal operation.

CONTROL RELAY
G549822t258 : CHECK THE EMS RELAY CONTROL CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1.
Circuit Pin
EMS relay - control J3
2. Remove the EMS relay. 3. Measure the resistance between:
EMS relay base Battery
-> Yes
-> No
G549822t259 : CHECK THE EMS RELAY CONTROL CIRCUIT FOR SHORT

CIRCUIT TO POWER

-> Yes
-> No
G549822t277 : CHECK THE EMS RELAY CONTROL CIRCUIT FOR HIGH

RESISTANCE
EMS relay base EC66
Pin 02 Pin J3
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-> Yes
-> No
G549822t278 : CHECK FOR POWER TO THE EMS RELAY BASE

Are the voltages greater than 10 volts?
-> Yes
component(s): - EMS relay - ECM connector - ECM
-> No
REPAIR the circuit between the battery and the EMS relay base as necessary. For additional
PINPOINT TEST G549822p25 : INERTIA

SWITCH
G549822t270 : CHECK THE INERTIA SWITCH SUPPLY CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Make sure the inertia switch is not tripped. 2. Key off. 3. Disconnect the inertia switch connector,
CR02. 4. Measure the resistance between:
-> Yes
-> No
G549822t271 : CHECK THE INERTIA SWITCH SUPPLY CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G549822t272 : CHECK THE INERTIA SWITCH SUPPLY CIRCUIT FOR HIGH

RESISTANCE
1. Disconnect the ignition switch connector, IP34. 2. Measure the resistance between:
CR02, harness side IP34
Pin 02 Pin 07
-> Yes
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-> No

CIRCUIT TO GROUND
-> Yes
-> No
CIRCUIT TO POWER
-> Yes
-> No
G549822t280 : CHECK THE INERTIA SWITCH TO ECM CIRCUIT FOR HIGH

RESISTANCE
1. Disconnect electrical connector, PI41. 2. Measure the resistance between:
CR02, harness side PI41
Pin 03 Pin 15
-> Yes
component(s): -Inertia switch connector -Inertia switch - ECM connector - ECM
-> No

Removal

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Installation
1
procedure.


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Camshaft Position (CMP) Sensor (18.30.63)
Removal
1 . Remove the left-hand exhaust gas recirculation (EGR) valve.
2 . Disconnect the camshaft position (CMP) sensor electrical connector.
3 . Remove and discard the CMP sensor.
Remove the CMP sensor retaining bolt.
Installation
1 NOTE:
.
Only turn the engine in the normal direction of rotation.
Turn the engine until one of the three webs on the back of the camshaft pulley is visible
through the CMP sensor housing (timing belt upper cover shown removed for clarity).
2
. CAUTION: The CMP sensor tip must rest on one of the three webs on the back of the
camshaft pulley. Incorrect installation may result in the CMP sensor being damaged.
Install the CMP sensor until the tip of the sensor touches the back of the camshaft pulley
(timing belt upper cover shown removed for clarity).
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3 . Install the CMP sensor retaining bolt.
Tighten to 10 Nm.
4 . Connect the CMP sensor electrical connector.

5 . Install the left-hand EGR valve.
(18.30.12)
Removal
All vehicles


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Lock in position, and remove the ignition key.

8 . Using suitable tie straps, secure the steering gear.
All vehicles
10 . Remove the CKP sensor blanking cover.

11 . NOTE:
The CKP sensor retaining bolt should not be removed from the CKP sensor.
Fully loosen the CKP sensor retaining bolt.

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Installation
1
. CAUTION: Install the CKP sensor correctly into the housing. Failure to follow this
instruction may result in damage to the CKP sensor.

Crankshaft Position (CKP) Sensor Ring
Installer - Timing Trigger Wheel

303-1130
Removal
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2 . Remove the crankshaft position (CKP) sensor.
3 . Remove the CKP sensor ring.
Discard the CKP ring.

Installation
1 . Install the alignment special tool to the crankshaft.
Align the special tool alignment peg to the timing hole on the crankshaft.
2 NOTE:
.
Install a new CKP ring.
NOTE:
Make sure that the CKP sensor ring is aligned correctly with the special tool pip and that
both mating surfaces are fully seated.
Install the CKP sensor ring to the installation special tool.
3 . NOTE:
Assemble the installation special tool to the alignment special tool.
Using the special tool, install the CKP sensor ring.

Tighten the special tool nut.
4 . Remove the installation special tool.

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5 Remove the special tool retaining bolts and reposition into the threaded holes on the special
. tool and tighten to remove the alignment special tool from the crankshaft.
6
. CAUTION: Install the CKP sensor correctly into the housing. Failure to follow this
instruction may result in damage to the CKP sensor.
Install the crankshaft position (CKP) sensor.

Tighten to 5 Nm.

Removal

3 . Remove the washer reservoir filler neck.

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6 . Remove the engine compartment left-hand panel.
7 . Detach the engine control module (ECM) module wiring harness from the bulkhead.
8 . Disconnect the ECM electrical connectors.

9 . Remove the ECM bracket retaining nuts.
10 . Remove the instrument panel left-hand lower trim panel.

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Remove the ECM bracket bolt.
Installation
Tighten to 6 Nm.
(18.30.10)
Removal
1
personal injury.
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injury.

1) Lift the locking tang.
2) Rotate the ECT sensor counterclockwise to remove.
Installation
Fill the cooling system up to the MAX mark on the coolant expansion tank.
Exhaust Gas Temperature Sensor
Exhaust gas temperature sensor wrench

303-1184
Removal
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2 . Disconnect the exhaust gas temperature sensor electrical connector.
3 . Detach the exhaust gas temperature sensor wiring harness from the transmission.
4 . Remove the exhaust gas temperature sensor.

Installation
1
wrench (1).
2
Install the exhaust gas temperature sensor.
Tighten to 35 Nm.
3 . Attach the exhaust gas temperature sensor wiring harness to the transmission.
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4 . Connect the exhaust gas temperature sensor electrical connector.

Engine Oil Pressure (EOP) Sensor
Removal
3 . Disconnect the engine oil pressure (EOP) sensor electrical connector.
4 . Remove the EOP sensor.

Installation
Tighten to 15 Nm.
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1 The fuel rail pressure sensor is removed as part of the fuel diverter rail and can not be
. serviced separately.
For additional information, refer to Fuel Diverter Rail
Removal
ignite. Failure to follow these instructions may result in personal injury. This procedure involves
fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling
precautions. Failure to follow these instructions may result in personal injury. Do not carry out any
repairs to the fuel injection system with the engine running. The fuel pressure within the system
can be as high as 1600 bar. Failure to follow this instruction may result in personal injury. Do not
carry out any repairs to the fuel injection system without checking that the fuel pressure has
dropped to zero. Failure to follow this instruction may result in personal injury. Wait at least one
minute after the engine stops before commencing any repair to the fuel injection system. Failure
to follow this instruction may result in personal injury. CAUTIONS:
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welding operations can contaminate the fuel system and may result in later malfunction. Always
carry out the cleaning process before carrying out any repairs to the fuel injection system
components. Failure to follow this instruction may result in foreign matter ingress to the fuel
injection system. Diesel fuel injection equipment is manufactured to very precise tolerances and

4
. CAUTION: Do not use excessive force when detaching the fuel return line from the
retaining bracket. Failure to follow this instruction may result in damage to the fuel return
line.
To gain access to the locking tangs, detach the fuel return line from the retaining bracket and
position to it one side.
5
. CAUTION: Do not use excessive force when releasing the fuel temperature sensor
locking tangs. Failure to follow this instruction may result in damage to the fuel
temperature sensor.
Remove the fuel temperature sensor.
1) Release the locking tangs.
2) Remove the fuel temperature sensor from the fuel return line.
Install a clean blanking caps to the fuel return line.
Discard the O-ring seal.

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Installation
ignite. Failure to follow these instructions may result in personal injury. This procedure involves
fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling
precautions. Failure to follow these instructions may result in personal injury. Do not carry out any
repairs to the fuel injection system with the engine running. The fuel pressure within the system
can be as high as 1600 bar. Failure to follow this instruction may result in personal injury. Do not
carry out any repairs to the fuel injection system without checking that the fuel pressure has
dropped to zero. Failure to follow this instruction may result in personal injury. Wait at least one
minute after the engine stops before commencing any repair to the fuel injection system. Failure
to follow this instruction may result in personal injury. CAUTIONS:
welding operations can contaminate the fuel system and may result in later malfunction. Always
carry out the cleaning process before carrying out any repairs to the fuel injection system
components. Failure to follow this instruction may result in foreign matter ingress to the fuel
injection system. Diesel fuel injection equipment is manufactured to very precise tolerances and
NOTE:
Install a new O-ring seal and fuel temperature sensor.
1 . NOTE:
Remove and discard the blanking caps from the fuel return line.

Intake Air Temperature (IAT) Sensor
(18.30.52)
Removal

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4 . Remove the IAT sensor.

Installation
Removal
2 NOTE:
.
clockwise.
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minutes.
Detach the KS wiring harness.

4 . Detach the left-hand glow plug rail.
5 NOTE:
.
Make a note of the orientation of the KS and make sure it is positioned in the same
position when installed.
Remove the KS.
Installation
1 . NOTE:
Prior to installing the KS, clean the cylinder head and KS mating surfaces.
NOTE:
Make sure the KS is installed in the same position as removed.
Tighten to 20 Nm.
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2 . NOTE:
Tighten to 25 Nm.
Removal
2 NOTE:
.
clockwise.
minutes.
Detach the KS wiring harness.

4 NOTE:
.
Make a note of the routing of the KS wiring harness and make sure it is routed in the
same position when installed.
Reposition the KS wiring harness under the intake air shutoff throttle.
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5 . Detach the right-hand glow plug rail.
6 NOTE:
.
Make a note of the orientation of the KS and make sure it is positioned in the same
position when installed.
Remove the KS.

Installation
1 . NOTE:
Prior to installing the KS, clean the cylinder head and KS mating surfaces.
NOTE:
Make sure the KS is installed in the same position as removed.
Tighten to 20 Nm.
2 . NOTE:
Tighten to 25 Nm.
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Manifold Absolute Pressure (MAP) Sensor
(18.30.86)
Removal

Installation
Tighten to 3 Nm.
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Removal
NOTE:
This procedure is showing the lower mass air flow (MAF) sensor removal and installation. The
upper MAF sensor removal and installation is similar.

2 . Remove the mass air flow (MAF) sensor.
Installation
Tighten MAF sensor retaining screws to 2 Nm.

Removal
Install the drain plug.
Tighten to 25 Nm.
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Installation
1 . Install the oil temperature sensor.
Tighten to 24 Nm.

4 . Remove the filler cap.

6 . Install the filler cap.

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307 : Automatic Transmission/Transaxle
307-01 : Automatic Transmission/Transaxle
Specifications
Specifications
Fluid Maintenance
CAUTION: Use only Shell M1375.4 Automatic transmission fluid. Use of any
other fluids may result in a transmission malfunction or failure.
Description Intervals
Normal Maintenance Not necessary. Filled for life.
Severe Duty Maintenance Change the fluid at 48,000 km (30,000 mile) intervals.
Transmission Fluid Shell M1375.4
Sealant WSS-M4G323-A6
Metal Surface Cleaner WSW-M5B392-A
High Temperature Grease Molecote FB180
Refill Capacity Approximate dry capacity, includes cooler and

tubes. Check the level at normal operating temperature. DO
Approximate
Engine NOT OVERFILL. If it is necessary to add or change fluid, use
Liters
only fluid which has been certified by the supplier as meeting
the Jaguar Cars Ltd specification shown. U.S. Quarts
3.0L 10.0 10.57
3.5L or
10.0 10.57
4.2L
2.7L 10.0 10.57
Diesel
lb- lb-
Description Nm
ft in
Converter housing to engine retaining bolts 48 35 -
Transmission mount retaining bolts 50 37 -
Transmission fluid fill plug A - -
Transmission control module (TCM) and Main control valve body retaining
8 - 71
screws
Output shaft flange retaining nut 60 44 -
Torque converter retaining bolts 55 41 -
Transmission fluid cooler pipes retaining bolt 23 17 -
Transmission selector cable retaining bolts 11 8 -
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Transmission fluid cooler tube to oil pan retaining bolt 10 – 89

Transmission fluid drain plug 8 - 71
Transmission fluid pan, gasket and filter retaining screws 8 - 71
Exhaust manifold retaining nuts (3.0L only) 20 15 -
Dipstick tube retaining bolt (3.0L only) 10 – 89
A = refer to the procedure for correct torque sequence
General procedures
Transmission Fluid Drain and Refill

(44.24.02)
Adaptor
307-452
Drain
1. Raise and support the vehicle.
Lifting
2. Remove the air deflector (vehicles fitted with diesel engines only).
3. Place a suitable container under the transmission.
4. Using the special tool, remove the transmission fluid filler plug.

5.
CAUTION: If the automatic transmission fluid is very dirty or it contains metallic particles,
then along with a new transmission, install a new automatic transmission fluid cooler and lines.
NOTE:
Discard the sealing washer.
Remove the transmission fluid drain plug.

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6. NOTE:
Install the new sealing washer.
Install the transmission fluid drain plug.
Refill
1. NOTE:
Use transmission fluid meeting Jaguar specification.

Fill the transmission with 8 liters of transmission fluid through the transmission fluid filler plug hole.
2. Carry out a transmission fluid level check.

3. Install the air deflector (vehicles fitted with diesel engines only).

Lifting
Adaptor
307-452
1. The following steps must be observed before starting the transmission fluid level check.
• The vehicle must be on a horizontal ramp.
• The parking brake must be applied.

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• The engine must be running for 2 minutes with the transmission selector lever in the ' P'
position.
2. Connect the Jaguar approved diagnostic system.
3. Make sure the transmission selector lever is in the ' P' position.
4. NOTE:
Make sure the transmission fluid temperature is below 30°C (86°F) on the Jaguar approved
diagnostic system.
With the engine running and the foot brake applied, circulate the transmission fluid by:
• Moving the transmission selector lever to the ' R' position.
• Waiting for three seconds.
• Moving the transmission selector lever to the ' D' position.
• Waiting for three seconds.

• Moving the transmission selector lever to the ' P' position.
5. Raise and support the vehicle.

Lifting
6. Remove the air deflector (vehicles fitted with diesel engines only).
7. Place a suitable container under the transmission fluid filler plug.
8.
WARNING: Make sure that care is exercised near rotating parts. Failure to follow this
With the engine running, remove the transmission fluid filler plug using the special tool.
9. NOTE:
Use transmission fluid meeting Jaguar specification.
If the transmission fluid does not come out of the transmission fluid filler plug hole the transmission
fluid level is insufficient. If this is the case add the transmission fluid in 0.5 liter units into the
transmission fluid filler plug hole until fluid comes out.
10. NOTE:
Make sure the transmission fluid temperature does not exceed 50°C (122°F). If the transmission
fluid temperature does exceed 50°C (122°F) stop the transmission fluid level check and allow the
transmission fluid to cool until the temperature is below 30°C (86°F).
Allow the transmission fluid to drain from the transmission fluid filler plug hole until the flow almost
stops.
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11. Using the special tool, install the transmission fluid filler plug.
12.
CAUTION: Make sure the transmission fluid filler plug is tightened to the correct
specification. Failure to follow this instruction may result in damage to the vehicle.
Using the special tool and a torque wrench, tighten the transmission fluid filler plug.
• Tighten the transmission fluid filler plug to the torque given by the calculation.
• To make sure the transmission filler plug is torqued to the correct specification. Using the
special tool and a torque wrench the following calculation steps must be followed.
Step 1. Multiply 35 Nm by the effective length of the torque wrench (1).
Step 2. Add the effective length of the special tool (2) to the effective length of the torque
wrench (1).
Step 3. Divide the total of step 1 by the total of step 2.
Step 4. Set the torque wrench to the figure arrived at in step 3.
• Tighten the transmission fluid filler plug to the torque given by the calculation.
13. Remove the container.
14. Install the air deflector (vehicles fitted with diesel engines only).

Lifting
16. Disconnect the Jaguar approved diagnostic system.

Transmission Description
The ZF 6HP26 automatic transmission has been developed for vehicles with an engine torque of up to
600 Newton-metres (Nm). This transmission uses planetary gears with hydraulic-electronic control.
The transmission control module (TCM) and the main control valve body units form a composite
element that is installed as a single unit inside the automatic transmission.
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The 6HP26 has the following features:
six forward speeds.
a torque converter with an integral converter lock up clutch.
electronic shift and pressure controls.
a single planetary gear set.

a double planetary gear set.
two fixed multi-disc brakes.
three multi-plate clutches.
All hydraulic functions are directed by electronic solenoids to control:
engagement feel.
shift feel.
shift scheduling.
modulated torque converter clutch (TCC) applications.
engine braking utilizing the coast clutch.
Engine power reaches the transmission by a torque converter with integral converter lock up clutch.
The 6 forward gears and 1 reverse gear are obtained from a single planetary set followed by a double
planetary set also known as lepelletier-type gear sets, these gear sets make it possible to obtain 6
forward gears.
The 6HP26 Automatic Transmission is a six speed electronically controlled transmission comprising
the basic elements of a TCM and main control valve body unit, a torque converter, one solenoid
valve and six pressure regulators. Gear selection is achieved by the control of Automatic
Transmission Fluid (ATF) flow to operate various internal clutches. The TCM operates the electrical
components and provides for the control of gear selection shift pressure which increases refinement
and torque converter slip control.
In the event of a system fault the TCM also provides for Failure Mode Effect Management (FMEM) to
maintain maximum functional operation of the transmission with a minimum reduction in driver,
passenger or vehicle safety. In the event of a total loss of control or electrical power the basic
transmission functions Park, Reverse, Neutral and Drive are retained. Also 3rd or 5th gear is retained
by the hydraulic system, the gear retained is dependant upon the gear selected at time of the failure.
The transmission also contains turbine and output shaft speed sensors, an internal P, R, N, D selector
shaft position sensor, and a transmission fluid temperature sensor. The TCM also requires
information from the J-Gate to determine when the driver has initiated manual gear selection. The
TCM communicates with other electronic control modules by the controller area network (CAN).
The TCM also provides for legislated transmission diagnostics, which meet the requirements of CARB
OBDII legislation, monitoring all components, which may effect vehicle emissions. Additional
diagnostic functions are also supported to ensure fast repairs of all failures in the service
environment.
Upshifts
Transmission upshifting is controlled by the TCM. The TCM receives inputs from various engine or
vehicle sensors and driver demands to control shift scheduling, shift feel and torque converter clutch
(TCC) operation.
The TCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel.
Downshifts
Under certain conditions the transmission will downshift automatically to a lower gear range
(without moving the gearshift lever). There are three categories of automatic downshifts, coastdown,
torque demand and forced or kickdown shifts.
Coastdown
The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the
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demand for torque is greater than the engine can provide at that gear ratio. If applied, the
transmission will disengage the TCC to provide added acceleration.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the
floor. A forced downshift into a lower gear is possible below calibrated speeds. Specifications for
downshift speeds are subject to variations due to tire size and engine and transmission calibration
requirements.
Range Selection
Depending on the vehicle options selected the transmission range selector may have different range
positions.
The standard range selector has eight positions: P, R, N, D, 5, 4, 3 and 2.
J-Gate Range Selection
"P"
In the PARK position:
there is no power flow through the transmission.
the parking pawl locks the output shaft to the case.
the engine may be started.
the ignition key may be removed.
"R"
In the REVERSE position:
the vehicle may be operated in a rearward direction, at a reduced gear ratio.
backup lamps are illuminated.
"N"
In the NEUTRAL position:
there is no power flow through the transmission.
the output shaft is not held and is free to turn.
the engine may be started.
"D"
DRIVE is the normal position for most forward driving.
The D position provides:
automatic shift 1-6 and 6-1.
apply and release of the torque converter clutch.
maximum fuel economy during normal operation.
engine braking in 6th gear.
"5"
The 5 position provides:
"4"
"3"
engine braking in 3rd gear.
"2"
engine braking in 2nd gear.

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"S"
The sport mode switch:
allows the driver to select or de-select the automatic transmission sport mode.
allows the automatic transmission to operate normally when the sport mode is selected, but
under acceleration the gear shift points are extended to make full use of the engine's power
reserves.
allows the driver to drive the vehicle in the "D" position with the full automatic transmission shift
or manually shift gears in the "second, third, fourth and fifth" positions.
is illuminated when Sport mode is selected.
communicates with the TCM through the CAN network to show the sport mode switch status.
Torque converter
The torque converter is a three element unit containing a single plate lock up clutch. The lock up
clutch can be controlled and engaged in any gear 1 to 6. The clutch is applied by removing
transmission fluid pressure from one side of the plate. The torque converter transmits and multiplies
torque. The torque converter is a three-element device:
impeller assembly
turbine assembly
reactor assembly
The standard torque converter components operate as follows:

The impeller, which is driven by the engine, imparts a circular flow to the transmission fluid in the
converter.
This transmission fluid strikes the turbine wheel, which causes the flow to change its direction.
The transmission fluid flows out of the turbine wheel close to the hub and strikes the stator,
where its direction is changed again to a direction suitable for re-entering the impeller.
The change in direction at the stator generates a torque reaction that increases the torque
reaching the turbine.
The ratio between turbine and impeller torque is referred to as torque multiplication or
conversion.
The greater the difference in speeds of rotation at the impeller and turbine, the greater the
increase in torque; The maximum increase is obtained when the turbine wheel is stationary.
As turbine wheel speed increases, the amount of torque multiplication gradually drops.
When the turbine wheel is rotating at about 85 % of the impeller speed, torque conversion
reverts to 1, that is to say torque at the turbine wheel is no higher than the torque at the
impeller.
The stator, which is prevented from rotating backwards by a freewheel and the shaft in the
transmission housing, runs freely in the transmission fluid flow and overruns the freewheel.
From this point on, the converter acts only as a fluid coupling. During the torque conversion
process, the stator ceases to rotate and bears against the housing by the freewheel.
Torque converter
1 Torque converter retaining plate
2 Lock-up clutch lined plate
3 Torque converter cover
4 Turbine
5 Impeller
6 Stator
7 Stator freewheel
8 Space behind lock-up clutch
9 Lock-up clutch piston

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Torque Converter Lock-up Clutch

The torque converter lock-up clutch is a device that eliminates slip in the torque converter and
therefore helps to keep fuel consumption to a minimum.
The torque converter lock-up clutch is engaged and released by the control system. During the
actuating phase, a slight difference is selected between the impeller and turbine wheels.
Pressure at the torque converter lock-up clutch piston is determined by an electronic pressure
control valve.
The torque converter lock-up clutch can be controlled and engaged in any gear from 1 to 6. When
decoupling takes place the actuating clutch A in the transmission is dependent on load and output
speed.
When the torque converter lock-up clutch is released, transmission fluid pressures behind the lock-
up clutch piston turbine area are equalized. The direction of flow is through the turbine shaft and the
area behind the piston into the turbine area.
To engage the torque converter lock-up clutch the direction of transmission fluid flow is changed and
reversed by a valve in the hydraulic control unit. At the same time the space behind the torque
converter lock-up clutch piston is vented.
Oil pressure extends from the turbine area to the torque converter lock-up clutch piston and presses
it against the cover outer shell of the torque converter. This locks the turbine wheel by way of the
lined disc between the piston and the cover and enables the drive to pass with limited slip to the
planetary gear train in normal operating conditions.
Geartrain
Power is transmitted from the torque converter to the planetary gearsets through the input shaft.
Clutches are used to hold and drive certain combinations of gearsets. This results in six forward ratios
and one reverse ratio, which are transmitted to the output shaft and differential.
Gear Ratio
Gear ratios
1st 4.17:1
2nd 2.34:1
3rd 1.52:1
4th 1.14:1
5th 0.87:1
6th 0.69:1
Rev 3.40:1
Single Planetary Gearset

The single planetary gear overdrive carrier is driven by the input shaft.
The single planetary gear set consists of:
1 sunwheel
4 planetary gears meshing with the sunwheel
1 planetary gear carrier
1 ring gear
Single Planetary Gearset
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1 Baffle plate A
2 Ring gear
3 Planetary gear 1
4 Sunwheel
5 Planetary gear spider
6 Turbine shaft
7 Cylinder A
Double Planetary Gearset

The double planetary gearset is splined to the output shaft.
The double planetary gear set consists of:
2 sunwheels of different sizes
3 short planetary gears meshing with the sunwheels
3 long planetary gears meshing with the sunwheels

1 planetary gear carrier
1 ring gear
Double Planetary Gearset
1 Planetary gear spider brake D
2 Planetary gears (short)
3 Ring gear 2
4 Output
5 Double planetary gears (long)
6 Planetary gear spider clutch E
7 Sunwheel 3 clutch B
8 Sunwheel 2 clutch A
Apply Components
Shift Elements
The other shift elements in addition to the torque converter lock-up clutch are:
three rotating multi-plate clutches A, B and E.
two fixed multi-disc brakes C and D.
All gear shifts from 1st to 6th or from 6th to 1st are power-on overlapping shifts, that is to say during
the shift one of the clutches must continue to transmit the drive at lower main pressure until the
other clutch is able to accept the input torque.
The shift elements, clutches or brakes are engaged hydraulically. The transmission fluid pressure is
built up between the cylinder and the piston, this presses the clutch plates together.
When the transmission fluid pressure drops, the cup spring pressing against the piston moves it back
to its original position.
The purpose of these shift elements is to perform in-load shifts with no interruption to traction.
Multi-plate clutches A, B and E supply power from the engine to the planetary gear train; multi-disc
brakes C and D bear against the transmission housing in order to achieve a torque reaction effect.
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Shift Elements
1 Multi-plate clutch B
2 Clutch cylinder B, outer plate carrier
3 Multi-disc brake C
4 Brake cylinder C, outer plate carrier

5 Shaft key
6 Brake cylinder C, outer plate carrier
7 Transmission housing
Multi Plate Clutch

Clutch E is equalized in terms of dynamic pressure, that is to say its piston is exposed to the
transmission fluid flow on both sides, in order to prevent pressure build up in the clutch as the speed
increases. This equalization process is achieved by a baffle plate and pressure-free transmission fluid
supply by a lubricating passage, through which the space between piston and baffle plate is filled
with transmission fluid.
The advantages of this dynamic pressure equalization are:
reliable clutch engagement and release in all speed ranges.
improved shift refinement.
Multi Plate Clutch
1 Lubricating transmission fluid passage
2 Turbine shaft
3 Main pressure supply to clutch E

4 Ring gear
5 Cylinder E
6 Piston E
7 Cup spring
8 Clutch plate cluster
9 Baffle plate
10 Space for dynamic pressure equalization
11 Inner plate carrier E

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Shift overlap control

When overlap gearshift takes place, freewheels (one-way clutches) are not used but are replaced by
suitable actuation of the relevant clutches. This both enables weight and space to be saved.
The electronic-hydraulic shift action is obtained by means of various valves in the transmission
control module (TCM) and main control valve body, actuated by pressure regulators. They engage or
disengage the relevant clutches or brakes at the correct moments.
Output is always by the ring gear of the second, downstream planetary gear set.
Hydraulic System
Fluid Pump
The fluid pump is of a "half-moon" pattern and delivers approximately 16 square cm of transmission
fluid per revolution.
It is located between the torque converter and the transmission housing.
The torque converter is supported in the fluid pump by a needle roller bearing. The fluid pump is
driven directly from the engine by the torque converter shell and supplies transmission fluid to the
transmission and the hydraulic control unit.
The fluid pump draws in transmission fluid through a filter and delivers it at high pressure to the
main pressure valve in TCM and main control valve body unit. This valve adjusts the pressure and
returns excess transmission fluid to the fluid pan.
Fluid Pump
1 Fluid pump housing
2 Intermediate plate
3 Centring plate
4 Stator shaft
5 Intake port
6 To mesh filter
7 Seal
8 Bearing
9 Retaining clip
10 Shaft seal
11 Impeller
12 Ring gear
Fluid Pan, Gasket and Filter

The transmission fluid pan, gasket and filter is a one piece assembly, all transmission fluid is drawn
from the transmission fluid pan by the fluid pump and passes through the fluid filter.
Electrostatic Discharge (ESD)

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CAUTION: When working with the transmission control module (TCM) and main control
valve body, all suitable safety precautions must be taken to protect the component against
electrostatic discharge (ESD). Failure to follow these instructions may result in component damage.
Make sure all possible safety precautions are taken to protect the TCM and main control valve body
unit against ESD.
Personal Wrist-Band Earthing

Earthing (grounding) by means of a wrist band or strap is the most reliable method of diverting
electrostatic charges away from working personnel, and should therefore be used wherever possible,
particularly if the person concerned is working while seated. The wrist band earthing (grounding)
device consists of a bracelet closely attached to the wrist and a spiral earthing (grounding) cable
connecting it to the earthing (grounding) contact point. This system must include a quick-release
device so that the wrist can be released in the event of danger.
Shoes and Foot Earthing Straps

Electrically conductive shoes should be worn by persons who mainly work standing up or either
standing or sitting in ESD protection zones, particularly if wrist band earthing (grounding) is
impracticable. The standard calls for ESD shoes to record values between 0 and 35 Megga-ohms
(MOhm) resistance. However, for antistatic working shoes resistance values between 0.1 and 1000
MOhm are called for, and a through-conducting resistance for protective shoes of 0.1 to 100 MOhm.
A lower limit value of not less than 0.1 MOhm must be maintained on account of the contact voltage
risk. For this reason the minimum value has been set contrary to the standard at the higher figure of
0.75 MOhm.

The transmission control module (TCM) and main control valve body is a combination of hydraulic
and electronic control units. Both these modules are installed in the transmission, in the fluid pan.
This technical principle has the following advantages:
Minimum tolerances (TCM is mated to solenoids)
Better coordination of gear shifts
Increased refinement
Optimized shift quality
Good reliability, since the number of plug connections and interfaces is reduced.
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1 TCM
2 Output speed sensor
3 Transmission fluid temperature sensor
4 Position switch
5 Pressure regulator 6
6 Solenoid valve
12 Discharge port
13 Suction port
14 Turbine speed sensor
15 Main control valve body
Transmission Electronic System

The transmission control module (TCM) and its input/output network control the following
transmission operations:
shift timing.
line pressure (shift feel).
torque converter clutch.
In addition, the TCM receives input signals from certain transmission-related sensors and switches.
The TCM also uses these signals when determining transmission operating strategy.
Using all of these input signals, the TCM can determine when the time and conditions are right for a
shift, or when to apply or release the torque converter clutch. It will also determine the pressure
needed to optimize shift feel. To accomplish this the TCM uses six pressure control solenoids and one
shift solenoid to control transmission operation.
The following provides a brief description of each of the sensors and actuators used to control
transmission operation.
TCM
The TCM for the transmission is mounted on top of the main control valve body. The control module
for the transmission has been designed to operate correctly in the environment in which the TCM is
located.
The transmission control module is activated and deactivated by the ignition supply and is connected
to the transmission link harness by a 16-way connector.
The TCM controls the operation of the transmission. The TCM processes information received in both
analogue and digital form such as:
Transmission input speed
Output speed
Throttle pedal position
Gear selector position
Engine torque
Engine speed
Transmission fluid temperature
Brake pedal status

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Engine oil temperature
Coolant temperature
ABS wheel speed
This information is then used by the TCM to decide which shift pattern to select and for shift energy
management. Electro-hydraulic solenoid valves and pressure regulators control the transmission gear
changes.
Five pressure regulators and one solenoid valve are used to control direct transmission fluid flow to
select internal clutches and control the fluid pressure at the clutch. A separate pressure regulator is
used exclusively for torque converter clutch control.
The TCM monitors all TCM inputs and outputs to confirm correct system operation. If a fault occurs
the TCM is able to perform default action and inform the driver of the problem, this is by the
instrument cluster message centre.
Solenoids
The hydraulic module contains one solenoid valve. The solenoid valve is actuated by the TCM and has
two positions of open or closed, it is used to switch the position valve.
There are six electronic pressure control valves, these convert an electric current into a proportional
hydraulic pressure. They are energized by the TCM and actuate the valves belonging to the relevant
switching elements.
Controller Area Network (CAN) Interface

For the TCM to be able to perform shift point and shift quality management a number of external
signals are required. For shift point management alone the TCM requires output speed sensor,
throttle pedal position, brake pedal status and gear selector position. The controller area network
(CAN) bus is used to share information between control modules. The TCM obtains most of its
required data over the CAN bus from the electronic engine controls, J-Gate and ABS, Instruments
pack and diagnostic tools.

The brake pedal position (BPP) switch tells the TCM when the brakes are applied, and disengages
torque converter clutch. The BPP switch closes when the brakes are applied and opens when they
are released. The BPP is also used to disengage the brake shift interlock and stops gradient
calculations.

The engine coolant temperature (ECT) sensor detects engine coolant temperature and supplies the
information to the TCM. The ECT sensor is used to control the torque converter clutch (TCC)
operation.
Accelerator Pedal Position (APP) Sensor

The accelerator pedal position (APP) sensor is a potentiometer mounted on the accelerator pedal.
The APP sensor detects the position of the accelerator pedal and sends this information to the
electronic control module (ECM). The APP sensor is used for shift scheduling and TCC lock-up.
Input Shaft Speed (ISS) Sensor

The input shaft speed (ISS) sensor is a Hall effect type sensor.
The ISS sensor is mounted internally on the transmission and is located on the TCM and main control
valve body unit.
Output Shaft Speed (OSS) Sensor

The output shaft speed (OSS) sensor is a Hall effect type sensor.
The OSS sensor is mounted internally on the transmission and is located on the TCM and main
control valve body unit and is used for shift scheduling.
Transmission Fluid Temperature (TFT) Sensor

The TCM utilizes one transmission fluid temperature sensor located on the main control valve body.
The TCM uses the sensor input to activate various shift strategies. The sensor is in the form of a
temperature dependent resistor.
The temperature sensor performs plausibility checks on each sensor reading. Obviously, the
transmission oil temperature should not jump in value excessively between sensor readings. If the
inputs from the temperature sensor are outside the working range it possible that the sensor is short
or open circuit.
Position sensor
The TCM uses the position of this switch housed on the TCM and main control valve body, to
determine the selected gear range on the Automatic side of the selector lever.
The selector lever is connected to the transmission by a cable, which operates the transmission
selector shaft between positions Park, Reverse, Neutral and Drive. The TCM detects the driver's
choice of manual range selection (5,4,3,2) by means of a 3-bit code generated by the J-gate. This 3-
bit code is then transformed in to a CAN message by the J-Gate module and transmitted on to the
CAN bus where it is detected by the TCM.
3-Bit Code
Position 3-Bit Code
2nd Gear 0 1 0
3rd Gear 0 1 1
4th Gear 1 0 0
5th Gear 1 0 1
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P, R, N, D 1 1 1
The TCM uses this information to generate the CAN message "Gear Position Selected", which must
not be confused with the similar message "Gear Position Actual" indicating the current mechanical
gear ratio activated by the TCM.
Movement of the lever between Park, Reverse, Neutral and Drive manually controls the flow of
transmission fluid, the TCM having control of the forward gear selected in Drive. Additional
movement of the lever to 5,4,3 and 2 positions does not manually modify the fluid flow, the TCM
detects these positions, and controls the gear selected electronically.
Sport mode switch

Allows the driver to select or de-select the automatic transmission sport mode.
Allows the automatic transmission to operate normally when the sport mode is selected, but
reserves.
Allows the driver to drive the vehicle in the "D" position with the full automatic transmission shift
Is illuminated when Sport mode is selected.
Communicates with the TCM through the CAN network to show the sport mode switch status.
TCM Monitoring Functions
As explained above the TCM monitors all input and outputs to identify possible failures. If a fault is
detected the TCM takes the appropriate action to ensure the transmission enters a safe mode of
operation, without sacrificing transmission durability or driver safety.
Supply Monitoring
If the battery voltage is either too great or too low, the TCM will detect a fault condition. For the TCM
to be able to identify this fault, the engine must be running and the transmission fluid temperature
sensor must be functioning correctly.
Solenoid Supply Monitoring

While the solenoid operating transistors are being activated, checks are run for open circuits, shorts
circuits to ground and short circuits to supply. The monitoring function evaluates the voltage
characteristics during the switch on process checking for the above faults.
All solenoid outputs are fully protected. The processor and the appropriate fail-safe action taken can
quickly identify open and short circuit faults.
Sensor Supply Monitoring

The sensor supply voltage is a stabilized supply. This supply is monitored by the micro-processor by
an Analogue to Digital Converter (ADC). If the voltage is out of the valid tolerance a raise a diagnostic
trouble code (DTC) is set and the appropriate fail-safe action is performed.
Electronically Erasable Program Read Only Memory (EEPROM) Monitoring

To diagnose errors with the electronically erasable program read only memory (EEPROM) the TCM
calculates 4 checksums continuously: If the processor identifies discrepancies in any of the four
checksums the TCM will engage mechanical limp-home mode.
The TCM can diagnose errors within the EEPROM. Diagnosis is only performed during TCM
initialization. There is no fail-safe mechanism associated with this function as the EEPROM is mainly
used for the storage of fault codes and transmission calibration adaptions. If a fault occurs the TCM is
able to perform default action and inform the driver of the problem, this is by the instrument cluster
message centre.
Watchdog Monitoring
The watchdog monitoring function has two functions. Firstly it checks that it is possible to inhibit
output control by the activation of the solenoid supply transistor. Secondly the watchdog checks that
the safety circuit is functioning correctly.
During initialization the watchdog checks that it is possible to inhibit control of the pressure regulator
and solenoid valves by switching the solenoid supply transistor. There is a fault if activation of the
solenoids cannot be inhibited by the watchdog (NB. The supply to the solenoids can still be inhibited
by the high side switch responsible for control of each solenoid i.e. One safety path is lost).
Monitoring the Substrate Temperature Sensor
The TCM is situated within the transmission on the valve body. As the TCM controls a number of high
power solenoids and is surrounded by ATF, the TCM can obviously get very hot. If the temperature of
the hardware rises above a pre-determined level the TCM will be shut down. Prior to the TCM
shutting down the TCM will log a fault code, during shutdown the transmission will enter mechanical
limp-home mode. Monitoring of the substrate temperature is performed by a temperature
dependent resistor mounted on the processor.
Plausibility Checking
The TCM detects a fault if an excessive voltage jump is identified between any two consecutive
measurements. Also, with the engine started from cold the transmission fluid temperature will start
to rise. Therefore the substrate or fluid temperature will also start to rise because the TCM is
surrounded by transmission fluid. If the engine and output shaft speed is higher than a set threshold
for a predetermined length of time without the substrate temperature rising above a set threshold a
fault will be detected.
Pressure Regulator/Solenoid Monitoring

Each pressure regulator and solenoid is monitored for open circuits and short circuits. The TCM also
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checks that the current being delivered to each solenoid valve or pressure regulator is within valid
limits. When each solenoid is being driven with minimum current the TCM checks that the current is
not above a threshold value. If a solenoid is being driven with maximum current, it checks that the
current is not below a valid threshold. If either of these two errors occurs a plausibility error is logged
and the appropriate fail-safe action is performed.
Output Speed Monitor

It is possible for the TCM to diagnose electrical errors associated with the output speed sensor while
the vehicle is stationary as well as moving. Plausibility monitoring is performed on the sensor output
when the vehicle is moving.
Input Speed Monitor

It is possible for the TCM to diagnose electrical errors associated with the input shaft speed sensor
while the vehicle is stationary as well as moving. Plausibility monitoring is performed on the sensor
output when the vehicle is moving.
Transmission Fluid Temperature Sensor Monitoring

The TCM monitors for faults associated with the transmission fluid temperature sensor in the
following ways:
1 . Open and short circuit fault detection.
2 . The temperature cannot alter by more than a predefined differential between any two
consecutive measurements.
3 . The transmission fluid temperature must rise after the engine has been started provided that the
fluid temperature was low enough to begin with (The vehicle must be driven and the diagnostic test
condition met).
Position Sensor Monitoring

The TCM can identify errors with the position switch located within the transmission. If an
unrecognized position code is read by the TCM a plausibility fault will be logged. (A code is checked
between positions).
The position switch outputs a 4-bit code to the TCM, the bits being labelled L1-L4. For the
transmission, the following codes are used to identify the selector position.
Only for the automatic side of the J-GATE P,R,N,D
Selector position switch code

Position Code
L1 L2 L3 L4
Park 0 0 1 0
Reverse 0 0 0 1
Neutral 0 1 0 0
Drive 1 1 1 0
Gear Ratio Monitoring

The gear ratio diagnostic checks that each gear ratio is correctly engaged. Also, following a gear shift
the diagnostic checks that the transmission has engaged the target gear within the allowed time.
Torque Converter Monitoring

The TCM checks that the torque converter can be locked correctly. If torque converter lock-up does
not occur correctly the TCM performs the appropriate fail-safe action of opening the Torque
converter clutch.
Torque Converter Lock-up Control

The TCM controls how the torque converter clutch is engaged as a function of the accelerator pedal
position , output speed, transmission fluid temperature, gear selected and shift program. Lock-up is
possible in all forward gears, but usually it is restricted to fourth, fifth and sixth gears. To make use of
the comfort enhancing effect of the torque converter, the converter clutch can be disengaged prior
to a downshift or up-shift. The torque converter lock up clutch is always modulated to allow for
controlled slip, to further improve the shift quality.
Shift Energy Management
This function involves reducing or increasing the engine output torque during shifting. The aim when
up-shifting is to reduce the energy that is dissipated in the friction elements of the transmission. This
is done by reducing the engine torque during synchronization without interrupting the tractive drive.
This function may be used for:
Increasing the transmission service life by shortening the slipping time.
Improving the shift comfort by reducing the step change in torque caused by the gearshift.
Transferring a higher engine power, this is allowed by the mechanical in-gear strength of the
transmission.
Real-time control of engine torque is required to maintain maximum shift quality and transmission
durability. The TCM has the ability to control the engine output torque during the gearshift to
synchronize with the operation of the transmission clutches.
Pressure Modulation
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To provide a high level of shift comfort and durability, the hydraulic pressure in the shift related
friction elements of the transmission must be matched very accurately to the transmission input
torque. This hydraulic pressure is composed of a hydraulically pre-set basic pressure and a controlling
pressure that is set by one of the electro-hydraulic pressure regulators.
The transmission input torque can be directly calculated from the following operating parameters:
engine torque signals, engine speed or any signals transmitted from the ECM by CAN, and converter
slip. Separate pressure characteristics for each gear change make it possible to adapt precisely to the
particular shift operation. A further improvement in shift comfort is achieved by individual treatment
of special cases, such as manual shifts.
Shift Quality Adapts

The shift quality adapts are used to obtain a high quality and consistant shift feel. This is achieved
through monitoring shift quality and then adapting the shift pressures and shift energy management
to overcome hardware variability and "in service wear".
It will typically take a new transmission approximately 161 kilometers (100 miles) of use to fully
adapt.
Shift Point Selection

The gearshift points are selected by the TCM, as a function of the output speed, accelerator pedal
position, selector position and shift program selected. The driver has control over the shift points by
the selector lever, accelerator pedal movement and mode switch.
Transmission Shift selection
Shift Map Selection

The transmission control system utilizes a number of driver selectable operating modes and also a
number of adaptive/automatically selectable modes. Sport, Normal and Cruise Control mode are all
driver selectable. Hot mode, traction control mode and trailer towing mode are all adaptive modes
i.e. the transmission will automatically select this mode dependent upon the current driving
conditions.
Normal Mode
Normal mode can be selected by activation of the transmission mode switch located on the J-Gate.
Once activated this mode will remain engaged until the driver deselects the mode or engages the
cruise control system. If the driver engages cruise control when Normal mode is active upon
deactivation of the cruise system the transmission will automatically re-engage Normal mode. This
mode can be over-ridden by a number of adaptive modes.
The mode switch is of the momentary type.
Cruise Mode
When the driver engages the cruise control system the TCM receives a CAN message transmitted by
the Adaptive Cruise Control (ACC) or engine electronic controls which informs the TCM that cruise
control is currently active. Upon receipt of this message the TCM selects a new transmission shift
map. This map has been developed to reduce busy gearshift during cruise mode. It has also been
developed to increase fuel economy.
Hot Mode
This is one of the adaptive modes the transmission can enter when conditions are correct. When the
transmission fluid temperature, chip temp, engine oil temp or coolant temperature becomes hot
enough to reach threshold values, the TCM will cause the transmission to enter Hot mode. This mode
will automatically engage new shift and lock-up maps to reduce heat generated within the
transmission. The shift map will enable the transmission to change to higher gears at lower vehicle
speeds and the lock-up map will engage the lock-up clutch at lower vehicle speeds and in lower
gears. The effect of this is that less heat will be generated within the transmission due to the effects
of lock-up clutch slip and churning effects. There will be forced upshift strategy used in hot mode. To
exit hot mode the selector lever must be moved or the brake pedal applied or the accelerator pedal
applied 100%, during all of these methods of exiting from hot mode the fluid temperature must be
lower than the threshold values.
Traction Control Mode

Traction Control Mode is an adaptive mode, which is automatically engaged when a traction event
occurs. When driving on slippery surfaces (i.e.sand, ice) it is possible for the driven wheels to begin to
spin. The TCM believes the vehicle speed is increasing and therefore it may begin to upshift. These
upshifts reduce the torque at the wheel and so tend to reduce wheel slip. The downshift lines are
forced downwards to prevent unwanted shifts. To reduce the effects of this, if a traction event
occurs a signal is transmitted by the ABS module to the TCM over the CAN network, the TCM uses
this signal to change the currently selected shift map. The new shift map will have gearshift lines
further apart, thus inhibiting the transmission shifting to a lower gear.
Hill/Trailer Towing Mode

This is an adaptive mode. When the TCM detects reduced vehicle acceleration for a certain
percentage of throttle opening then this mode is automatically engaged by the TCM. When this
mode is engaged a new shift map and torque converter lock-up map is selected. This new shift map is
designed to reduce the number of gearshifts when towing a trailer or with the car climbing a steep
hill. The shift map will cause the transmission to hold on to gears for longer this increases
acceleration and reduces the number of gearshifts. This mode can also give an advantage when
driving at high altitudes, where the torque produced by an engine is greatly reduced by the effects of
reduced ambient pressure and airflow.
Driving Mode Priority

Each of the above modes has an associated priority i.e. Normal mode cannot over-ride cruise mode
etc.
Adaptive Shift Strategies

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The TCM of the six speed ZF automatic transmission incorporates adaptive strategies which improve
the accessibility of the vehicle`s performance in driving conditions while maintaining a relaxed driving
experience when cruising.
In "Sport" mode, accelerator pedal usage and cornering behaviour are monitored to assess driving
style and road conditions. When an enthusiastic driving style or a demanding road is detected, 6th
gear is inhibited and the lower gears are made slightly more accesssible in order to prevent
unwanted "hunting" between gears. Conversely, when cruising conditions are detected, 6th gear is
once again made available to maximise driving refinement and economy.
Under conditions of heavy braking, the transmission will perform one or more downshifts to improve
response to a subsequent accelerator pedal application. Similarly if the accelerator pedal is released
rapidly following hard acceleration, one or more upshifts are inhibited to increase engine braking and
also improve subsequent response.
To complement these features, when a corner is detected transmission upshifts are inhibited. This
inhibition is also maintained for a short distance after the corner allowing the driver to achieve a
smooth balance through the bend without unwanted shifting mid-corner.
Safety features
The safety functions are designed to safeguard against mis-operation by the driver as well as against
system malfunctions. The mis-operation system prevents reverse gear from being engaged at high
forward speeds (Above 5 kph) and prevents manual downshifting at excessive engine speeds.
Great attention has been paid to safeguarding against, and detecting, malfunctions in the electronic
control system. The design of the electrical and diagnostic system is such that system integrity is
protected at all times.
The hydraulic system has "fail-safe" characteristics regarding its electrical energisation, i.e. as a result
of the power supply being lost to the electro-hydraulic actuators the transmission engages a reliable
emergency gear ratio to facilitate a basic limp-home mode.
Recognition of critical shift operation by monitoring the last element in the signal path, i.e. the
solenoid valve, and checking by means of redundant measured variables, i.e. engine speed, input
speed and output speed.
Measures are in place which guarantee a high degree of availability of safeguard functions, i.e.
monitoring of safety circuits. For this purpose each time the vehicle is started there is a check on the
entire safety hardware, this is during TCM initialization and the associated program parts and signal
paths used during the TCM operation status. A malfunction in this part of the system, or triggering of
the safety circuit, will be communicated to the driver by the instrument cluster message centre.
Diagnostic Strategy
No Data Available
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Removal
Transmission - 3.0L NA V6 - AJ27

(44.20.01)

HTJ1200-2
Removal
1 . Place the selector lever in the N position.


4
CAUTION: Make sure the front of the driveshaft does not put an excessive load on
the center bearing. Failure to follow this instruction may result in damage to the vehicle.

flexible joint.
5
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. CAUTION: Make sure the front of the driveshaft does not put an excessive load on
Using a suitable securing strap, reposition and support the driveshaft to the vehicle body.
6 . Detach the engine ground cable.

7
. CAUTION: Make sure the starter motor is supported. Failure to follow this
Detach the starter motor.
8 . Remove the rubber access cover.
9 . Remove the torque converter retaining bolts.
Rotate the torque converter to gain access to the remaining bolts.
10 . Detach the transmission fluid cooler tubes from the oil pan.
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11 . Detach the transmission fluid cooler tubes.
2) Remove the retaining plate.
3) Detach the transmission fluid cooler tubes.
Allow the transmission fluid to drain into a suitable container.
12 . Remove the torque converter rubber inspection cover.

13
. CAUTION: Make sure the automatic transmission weight is evenly supported on
the special tool. Failure to follow this instruction may result in damage to the vehicle.
14 Install the rubber blocks supplied with special tool HTJ1200-2, between the front subframe
. and the oil pan.
15 . Lower the rear of the transmission.
Remove the automatic transmission support retaining bolts.

16
. WARNING: Secure the automatic transmission to the special tool using the tie
down straps. Failure to follow this instruction may result in personal injury.
Install the tie down strap.

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17 . Detach the selector lever cable.
18 . Reposition the selector lever cable.

19
. CAUTION: Make sure the transmission control module (TCM) and main control
valve body is protected against electrostatic discharge. Failure to follow this instruction
may result in component damage.
Disconnect the automatic transmission electrical connector.
20 . Remove the automatic transmission retaining bolts.

22
. WARNING: Do not let the torque converter drop out of the automatic
transmission. Failure to follow this instruction may result in personal injury.
NOTE:
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Special tool shown removed for clarity.
Remove the automatic transmission from the vehicle.
Lower the automatic transmission from the vehicle.

Transmission - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8/3.5L NA V8 - AJV8 (44.20.01)

HTJ1200-2
Removal
1 . Place the selector lever in the N position.


4
flexible joint.
5
Using a suitable securing strap, reposition and support the driveshaft to the vehicle body.
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6 . Detach the transmission fluid cooler tubes from the oil pan.
7 . Detach the transmission fluid cooler tubes.

3) Detach the transmission fluid cooler tubes.
8 . Remove the torque converter rubber inspection cover.
9
. CAUTION: Make sure the automatic transmission weight is evenly supported on the
special tool. Failure to follow this instruction may result in damage to the vehicle.
10 Install the rubber blocks supplied with special tool HTJ1200-2, between the front subframe
and the oil pan.
.
11 . Lower the rear of the transmission.
Remove the automatic transmission support retaining bolts.

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12

15
. CAUTION: Make sure the transmission control module (TCM) and main control
valve body is protected against electrostatic discharge. Failure to follow this instruction
may result in component damage.
Disconnect the automatic transmission electrical connector.

17 . Remove the torque converter retaining bolts.

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19
. WARNING: Do not let the torque converter drop out of the automatic
transmission. Failure to follow this instruction may result in personal injury.
NOTE:
Special tool shown removed for clarity.



303-1129
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303-021

HTJ1200-2
Removal
1 . Move the automatic transmission selector lever to the “N” position.

3 . Remove the filler cap.

7 Install the special tool.

.
Rotate the special tool adjustment bolt a suitable amount of turns to
support the engine.
9 . Remove the diesel particulate filter.

For additional information, refer to Diesel Particulate Filter (DPF)
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10 . Remove both catalytic converters.

11
loosened or removed from the driveshaft. Failure to follow this instruction may result in
Detach the driveshaft from the automatic transmission flange.
Mark the position of the driveshaft in relation to the automatic

transmission flange.
Mark the position of each nut and bolt in relation to the automatic
transmission flexible joint.
Detach the driveshaft from the automatic transmission flange.
12 . Loosen the retaining nut.
13 . Install suitable cord to the heat shield retaining nut stud.
Tighten the retaining nut.
14
Reposition and support the driveshaft.

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17 . Release the automatic transmission fluid cooler tube retaining bracket.

18
. CAUTION: Make sure the transmission fluid cooler tubes are not removed from the
automatic transmission by using a pry bar. Failure to follow this instruction may result in
NOTE:
Detach the transmission fluid cooler tubes from the automatic transmission.
Allow the automatic transmission fluid to drain into a suitable container.


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21
. CAUTION: Make sure the automatic transmission control module (TCM) and main
control valve body is protected against electrostatic discharge. Failure to follow this
instruction may result in component damage.
Disconnect the automatic transmission electrical connectors.
22 Detach the diesel particulate filter high-pressure and low-pressure pipes from the automatic
. transmission.
23
. CAUTION: Make sure the automatic transmission weight is evenly supported on
the special tool. Failure to follow this instruction may result in damage to the vehicle.
24 . Using the special tool, lower the rear of the automatic transmission.

25
CAUTION: Make sure the tie down strap does not trap the automatic transmissions
sensors or harness etc. Failure to follow this instruction may result in damage to the
vehicle.

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29
. WARNING: Do not allow the torque converter to become disengaged from the
automatic transmission. Failure to follow this instruction may result in personal injury.
NOTE:
Shown with the powertrain assembly jack removed for clarity.

Transmission - 3.0L NA V6 - AJ27
(44.20.01)

HTJ1200-2
Installation
1
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. CAUTION: If the automatic transmission fluid is very dirty or it contains metallic

particles, then along with a new transmission, install a new automatic transmission fluid
cooler and lines.
Flush the transmission oil cooler and fluid tubes.
2 NOTE:
.
Use high-temperature grease meeting Jaguar specification.
Apply a thin layer of high-temperature grease to the centering spigot bore on the torque
converter.
3
. WARNING: Do not let the torque converter drop out of the automatic transmission.
CAUTION: The torque converter hub must engage fully in the oil pump drive gear
throughout the whole installation procedure.
Install the automatic transmission to the vehicle.
Raise the automatic transmission to the vehicle.
Tighten to 48 Nm.
4 . Install the automatic transmission retaining bolts.
Tighten to 48 Nm.
Tighten to 48 Nm.
6
. CAUTION: Make sure the transmission control module (TCM) and main control valve
body is protected against electrostatic discharge. Failure to follow this instruction may
result in component damage.
Connect the automatic transmission electrical connector.

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7 . Attach the selector lever cable.
Tighten to 11 Nm.
9 . Remove the tie down strap.
10 . Install the automatic transmission support retaining bolts.
Raise the rear of the transmission.
Tighten to 50 Nm.
11 . Remove the rubber blocks supplied with special tool HTJ1200-2.

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13 . Install the torque converter rubber inspection cover.
14 . Attach the transmission fluid cooler tubes.
1) Attach the transmission fluid cooler tubes.
2) Install the retaining plate.
Tighten to 23 Nm.
15 . Attach the transmission fluid cooler tubes to the oil pan.
Tighten to 10 Nm.
16 . Install the torque converter retaining bolts.
Tighten to 55 Nm.
17 . Install the rubber access cover.
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18 . Attach the starter motor.
Tighten to 25 Nm.
19 . Attach the engine ground cable.

20
Detach the driveshaft.
21
CAUTION: Make sure all components are installed to the position they were
removed from. Failure to follow this instruction may result in damage to the vehicle.
Attach the driveshaft to the transmission flange.
Tighten to 108 Nm.


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24 . Carry out a transmission fluid level check.

25 NOTE:
.

Test
Transmission - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8/3.5L NA V8 - AJV8 (44.20.01)

HTJ1200-2
Installation
1
cooler and lines.
Flush the transmission oil cooler and fluid tubes.
2 NOTE:
.
converter.
3
. WARNING: Do not let the torque converter drop out of the automatic transmission.
CAUTION: The torque converter hub must engage fully in the oil pump drive gear
throughout the whole installation procedure.
Tighten to 48 Nm.
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Tighten to 48 Nm.
5 . Install the torque converter retaining bolts.
Tighten to 55 Nm.
7
body is protected against electrostatic discharge. Failure to follow this instruction may
Connect the automatic transmission electrical connector.
Tighten to 11 Nm.
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11 . Install the automatic transmission support retaining bolts.
Raise the rear of the transmission.
Tighten to 50 Nm.
12 . Remove the rubber blocks supplied with special tool HTJ1200-2.
14 . Install the torque converter rubber inspection cover.

15 . Attach the transmission fluid cooler tubes.
1) Attach the transmission fluid cooler tubes.
Tighten to 23 Nm.
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16 . Attach the transmission fluid cooler tubes to the oil pan.
Tighten to 10 Nm.
17
Detach the driveshaft.

18
Tighten to 108 Nm.


22 NOTE:
.

Test
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303-1129

303-021

HTJ1200-2
Installation
1
cooler and lines.
Flush the automatic transmission fluid oil cooler and fluid tubes.
2 NOTE:
.
converter.
3
. WARNING: Do not allow the torque converter to become disengaged from the
automatic transmission. Failure to follow this instruction may result in personal injury.
CAUTION: The torque converter hub must engage fully into the pump drive gear
throughout the whole installation procedure. Failure to follow this instruction may result in
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NOTE:
Shown with the powertrain assembly jack removed for clarity.
Loosely install the retaining bolts.
4 . Install the retaining bolts.
Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 48 Nm.
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9 . Install the automatic transmission mount retaining bolts.
Raise the rear of the automatic transmission.
Tighten to 50 Nm.

11 Attach the diesel particulate filter high-pressure and low-pressure pipes to the automatic
. transmission.
12
. CAUTION: Make sure the automatic transmission control module (TCM) and main
control valve body is protected against electrostatic discharge. Failure to follow this
instruction may result in component damage.
Connect the automatic transmission electrical connectors.

Tighten to 11 Nm.

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15 . Attach the automatic transmission fluid cooler tubes to the automatic transmission.
Tighten to 23 Nm.
16 . Attach the automatic transmission fluid cooler tube retaining bracket.

Tighten to 55 Nm.
19
Reposition the driveshaft.
Undo the cord.
Remove the cord from the heat shield retaining nut stud.
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21 . Tighten the retaining nut.
22
Attach the driveshaft to the automatic transmission flange.
Tighten to 88 Nm.
23 . Install both catalytic converters.

24 . Install the diesel particulate filter.


Loosen the special tool adjustment bolt.

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In vehicle repair
Extension Housing Seal (44.20.18)

Crankshaft Damper Remover

303-D121
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Output Shaft Flange Holding Tool

205-053
Pinion Seal Replacer

204-264

HTJ1200-2
Seal Remover Input and Output
308-375
Slide Hammer
100-012
Slide Hammer Adaptor

100-012-01
Socket Output Flange Remover/Installer

205-789
Removal
Vehicles with diesel engine
2 . Remove the diesel particulate filter.

All vehicles
3
loosened or removed from the driveshaft. Failure to follow this instruction may result in
flexible joint.
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4 . Loosen the heat shield retaining nut.
5 . Install suitable cord to the heat shield retaining nut stud.
Tighten the retaining nut.

6 . Reposition the driveshaft.
7 . Using the special tool, remove the transmission support.
Lower the transmission to a suitable height.
8 . Using the special tools, remove and discard the output shaft flange retaining nut.
9 . Using the special tool, remove the output shaft flange.
Remove the output shaft flange spacing shim.

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10
. CAUTION: Make sure the transmission housing seal face is not damaged when
removing the extension housing seal. Failure to follow this instruction may result in
Using the special tools, remove the extension housing seal.

11 NOTE:
.
Using a suitable metal surface cleaner meeting Jaguar specification, clean the seal face
on the housing before installing the new seal.
Clean and inspect the transmission housing seal face.
Installation
All vehicles
1 . Using the special tool, install the extension housing seal.
2 . Using the special tools install a new output shaft flange retaining nut.
Install the output shaft flange spacing shim.
Install the output shaft flange.
Tighten to 60 Nm.
3 . Install the transmission support.
Using the special tool, raise the transmission.
Tighten to 55 Nm.
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5
Reposition the driveshaft.

Undo the cord.
Remove the cord from the heat shield retaining nut stud.
7 . Tighten the retaining nut.
8
Tighten to 88 Nm.
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10 . Install the diesel particulate filter.

Transmission Fluid Pan, Gasket and Filter
(44.24.07)
Removal
All vehicles

All vehicles
3 . Drain the transmission.
For additional information, refer to Transmission Fluid Drain and Refill (44.24.02)

4 . Detach the catalytic converter temperature sensor wiring harness from the fluid pan.
All vehicles
5 . NOTE:
Discard the fluid pan, gasket and filter.
Remove the fluid pan, gasket and filter.

Installation
All vehicles
1 . Install the new fluid pan, gasket and filter.
Tighten to 8 Nm.
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2 . Attach the catalytic converter temperature sensor wiring harness onto the fluid pan.
All vehicles
3 . Fill the transmission.
For additional information, refer to Transmission Fluid Drain and Refill (44.24.02)

All vehicles

Transmission Control Module (TCM) and
Main Control Valve Body
Removal
1 . Remove the fluid pan, gasket and filter.
For additional information, refer to Transmission Fluid Pan, Gasket and Filter (44.24.07)
2
body are protected against electrostatic discharge. Failure to follow this instruction may
Reposition the locking device.

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3 . Disconnect the TCM and main control valve body electrical connector.
1) Reposition the electrical connector retaining ring.

4
. CAUTION: Make sure all suitable safety precautions are taken to protect the TCM
and main control valve body electrical connector pins against electrostatic discharge.
Remove the sealing tube.
5 . Remove and discard the seals.
6 . Remove the TCM and main control valve body.
7 . Remove the TCM and main control valve body sealing block.
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Installation
1 . Install the new seals.
3 . Install the TCM and main control valve body sealing block.
4
. CAUTION: Make sure the TCM and main control valve body are protected against
electrostatic discharge. Failure to follow this instruction may result in component damage.
Align the transmission selector shaft to the TCM and main control valve body.
5 . Install the TCM and main control valve body retaining bolts.
Tighten to 8 Nm.
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7
. CAUTION: Make sure all suitable safety precautions are taken to protect the TCM
and main control valve body electrical connector pins against electrostatic discharge.
Install the sealing tube.
8 . Reposition the TCM and main control valve body electrical connector retaining ring.
1) Connect the electrical connector.
2) Reposition the electrical connector retaining ring.

9 . Reposition the locking device.
10 . Install the fluid pan, gasket and filter.

For additional information, refer to Transmission Fluid Pan, Gasket and Filter (44.24.07)
Input Shaft Seal (44.32.07)

Front Seal Installer

308-246
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Seal Remover Input and Output

308-375
Slide Hammer
100-012
Slide Hammer Adaptor

100-012-01
Torque Converter Handles
307-139
1 Remove the transmission assembly.

. For additional information, refer to Transmission - 3.0L NA V6 - AJ27 (44.20.01)
For additional information, refer to Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (44.20.01)
For additional information, refer to Transmission - 2.7L V6 - TdV6 (44.20.01)
2
. WARNING: Do not let the torque converter drop out of the transmission. Failure to
Using the special tools, remove the torque converter.
• Drain any remaining fluid into a suitable container.
3
. CAUTION: Make sure the transmission housing seal face is not damaged when
removing the torque converter seal. Failure to follow this instruction may result in damage
to the vehicle.
Using the special tools, remove the input shaft seal.
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4 NOTE:
.
Using a suitable metal surface cleaner meeting Jaguar specification. clean the seal face
on the housing before fitting the new seal.
Clean and inspect the transmission housing seal face.

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5 . Using the special tool, install a new input shaft seal.
6
. WARNING: Do not let the torque converter drop out of the transmission. Failure to
NOTE:
The torque converter hub must engage fully in the oil pump drive gear.
Using the special tools, install the torque converter.
7 Install the transmission assembly.

. For additional information, refer to Transmission - 3.0L NA V6 - AJ27 (44.20.01)
For additional information, refer to Transmission - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L
NA V8 - AJV8 (44.20.01)
For additional information, refer to Transmission - 2.7L V6 - TdV6 (44.20.01)
307-02 : Transmission/Transaxle Cooling
Specifications
Specifications
Item Specification
Transmission fluid type ATF Shell M1375.4
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lb- lb-
Description Nm
ft in
Transmission fluid cooler tube to transmission fluid cooler retaining bolt -
10 - 89
Vehicles with diesel engines
Transmission fluid cooler tubes to transmission fluid cooler retaining bolt -
20 15 -
Vehicles without diesel engines
Transmission fluid cooler tubes to transmission 22 16 -
Transmission fluid cooler tubes to engine oil pan 22 16 -
All except vehicles with diesel engine
1 — Fluid cooler
2 — Transmission
3 — Fluid cooler tubes
Fluid Cooler
The fluid cooler is of an aluminium construction consisting of a tube and louvered fin core-type, the
tubes are arranged horizontally for the crossflow of the fluid.
It is divided into two sections to provide cooling for both the transmission and the engine, each
section is separate within the same unit.
When carrying out any transmission procedures the drained fluid should be checked thoroughly for
any metal filings or particles, in the event of this the transmission fault should be located followed by
a thorough flushing of the fluid cooler and fluid cooler tubes.

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1 — Fluid cooler inlet hose
2 — Fluid cooler outlet hose
3 — Transmission
4 Fluid cooler tubes
5 Fluid cooler tube retaining bracket
6 Fluid cooler tube retaining bracket
7 Fluid cooler retaining bracket
8 Fluid cooler
Fluid Cooler
The fluid cooler is mounted to the left-hand side of the front subframe via a retaining bracket. The
fluid cooler is cooled by the engine coolant system.
When carrying out any transmission procedures the drained fluid should be checked thoroughly for
any metal filings or particles, in the event of this the transmission fault should be located followed by
a thorough flushing of the fluid cooler and fluid cooler tubes.

Mechanical
Feed and return tubes
Connections to the automatic transmission and the automatic transmission fluid cooler
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Automatic transmission fluid level
2 . If the concern is not visually evident, verify the sympton and refer to the Sympton chart.
Symptom chart
Condition Possible sources Action
Flush out the automatic transmission

fluid cooler with new automatic
Over heating of the
Obstruction in the automatic transmission fluid.
automatic
transmission fluid cooler.
transmission. If the flushing is unsucessful install a
new automatic transmission fluid
cooler.
Flush out the automatic transmission
fluid cooler tubes with new
Over heating of the
Obstruction in the automatic automatic transmission fluid.
automatic
transmission fluid tubes.
transmission. If the flushing is unsucessful install
new automatic transmission fluid
cooler tubes.
Connections to the automatic Check the torque of the tubes.
Loss of automatic
transmission and the automatic
transmission fluid Check the tubes, connections and
transmission fluid cooler.
seals.
Check the torque of the tubes.
Loss of automatic
Leak at oil cooler. Check the tubes, connections and
transmission fluid seals.
INSTALL new oil cooler.

Transmission Fluid Cooler - 2.7L V6 - TdV6

(44.24.10)
Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
Removal
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2 . Reposition the left-hand splash shield.
3 . NOTE:
Detach the transmission fluid cooler tubes.

4 . NOTE:
Install a suitable pipe clamp to minimize coolant loss.
Using the special tool, detach the transmission fluid cooler coolant hose.
5 . NOTE:
Install a suitable pipe clamp to minimize coolant loss.
Using the special tool, detach the transmission fluid cooler coolant hose.
6 . Detach the transmission fluid cooler.

7 . Remove the transmission fluid cooler.
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Installation
1 . Install the transmission fluid cooler.
2 . Attach the transmission fluid cooler.
Tighten to 5 Nm.
3 . NOTE:
Remove the pipe clamp.
Using the special tool, attach the transmission fluid cooler coolant hose.
4 . NOTE:
Remove the pipe clamp.
Using the special tool, attach the transmission fluid cooler coolant hose.
5 . NOTE:
Attach the transmission fluid cooler tubes.
Tighten to 10 Nm.
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Transmission Fluid Cooler Tubes - 4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (44.24.19)
Removal
1 . Remove the air cleaner. <<303-12A>>

All vehicles
5 . Disconnect the transmission fluid cooler tubes.
Drain fluid into a suitable container.
Remove and discard transmission fluid cooler tube O-ring seals.


8 . Release the transmission fluid cooler tube retaining bracket.
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9 . Remove the transmission fluid cooler tube retaining bracket.
10 . Remove the power steering pump to steering gear pressure line retaining nut.
All vehicles
13 . Remove the transmission fluid cooler pipes.
3) Remove the transmission fluid cooler pipes.

Installation
All vehicles
1 . Install the transmission fluid cooler tubes.
1) Install the transmission fluid cooler tubes.
3) Install the retaining bolt .
Tighten to 23 Nm.
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2 . Install the transmission fluid cooler tube retaining bracket.

4 . Install the power steering pump to steering gear pressure line retaining nut.
Tighten to 10 Nm.
Tighten to 10 Nm
6 . Attach the transmission fluid cooler tube retaining bracket.

All vehicles
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10 . Connect the transmission fluid cooler tubes.
Tighten to 20 Nm.
11 . Install the air cleaner. <<303-12B>>

12 . Install the air cleaner. <<303-12A>>
All vehicles
13 . Carry out transmission fluid level check. <<307-01>>
Transmission Fluid Cooler Tubes - 2.7L V6 -
TdV6 (44.24.19)
Removal
2 . Remove the catalytic converter.


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4 . NOTE:
Detach the transmission fluid cooler tubes.


9 . Using a suitable piece of string, secure the steering gear.
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10 . Release the transmission fluid cooler tube retaining bracket.
11
. CAUTION: Make sure that the transmission fluid cooler tubes are not removed
from the automatic transmission by using a pry bar. Failure to follow this instruction may
NOTE:

Remove the transmission fluid cooler tubes.
Installation
1 . NOTE:
Install the transmission fluid cooler tubes.
Tighten to 23 Nm.
2 . Attach the transmission fluid cooler tube retaining bracket.

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Tighten to 100 Nm.
Tighten to 35 Nm.
7 Make sure that the alignment mark on the steering gear pinion seal protection cover is central
. to the steering gear pinion casting.
8 . NOTE:
Attach the transmission fluid cooler tubes.
Tighten to 10 Nm.
9 . Install the left-hand splash shield.
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10 . Install the catalytic convertor.


307-05 : Automatic Transmission/Tranxle External
Controls
Specifications
Specifications

Transmission selector lever retaining bolts 11 8 -
Selector lever cable bracket retaining bolts 11 8 -
Selector lever cable retaining nuts 20 15 -
General procedures
Selector Lever Cable Adjustment (44.15.07)

1. Remove the floor console. <<501-12>>
2. Move the transmission selector lever to the ' R' position.
3. Detach the wiring harness bracket.

• Reposition the wiring harness.
• Detach the wiring harness bracket.
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4. Loosen the selector lever cable retaining nuts.
5. Detach the selector lever cable.

6. NOTE:
Fully extend the selector cable, then retract the selector cable one detent.
Make sure the selector lever cable is in the ' R' position.
7. Make sure the transmission selector lever is in the ' R' position.
8. Connect the selector lever cable.
9. Adjust the selector lever cable retaining nuts to lock against the retaining bracket without
moving the set position of either the shift lever or the selector lever cable.
10. NOTE:
Make sure all transmission selector lever positions select the relevant automatic
transmission states.
Move the transmission selector lever to all positions.
11. NOTE:
When tightening the selector lever cable retaining nuts, make sure both retaining nuts are
tightened to the specified torque simultaneously.
Tighten the selector lever cable retaining nuts.

12. Attach the wiring harness bracket.
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13. Install the floor console. <<501-12>>

External Controls
1 — Transmission selector lever
2 — Selector cable and bracket
Transmission selector lever

The transmission selector lever:
has eight positions: Park, Reverse, Neutral, Drive, Fifth, Fourth, Third and Second.
operates the transmission selector shaft in the Park, Reverse, Neutral, Drive positions by means
of a cable.
communicates the transmission selector lever position to the transmission control module (TCM)
using electronic code through the Controlled Area Network (CAN) bus.
uses "Hall Effect" switches and a micro controller inside the transmission selector lever to
generate the electronic code.
when moved to the left-hand side of the transmission selector lever, allows manual electronic
selection of Fifth, Fourth, Third and Second gears.
The transmission selector illumination:
is provided by the TCM by using electronic code.
is possible by decoding the electronic code received by the transmission selector lever from the
TCM and illuminating the relevant transmission selector lever position.
provides a red transmission lever position illumination to indicate the selected gear.
provides a green background for the transmission selector lever module and is hard-wired to the
front electronics module (FEM).
The eight transmission selector positions are:
P: The transmission is mechanically locked (starting available).
R: Reverse gear.
N: No power to the rear wheels (starting available).

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D: All six forward gears available.
5: Upshift to fifth gear only.
4: Upshift to fourth gear only.
3: Upshift to third gear only.
2: Upshift to second gear only.
Sport mode switch

allows the driver to select or de-select the automatic transmission sport mode.
allows the automatic transmission to operate normally when the sport mode is selected, but
reserves.
allows the driver to drive the vehicle in the "D" position with the full automatic transmission shift
is illuminated when Sport mode is selected.
communicates with the TCM through the CAN network to show the sport mode switch status.
Transmission unit gear selector

The gear selector at the transmission unit:
is connected to the transmission selector lever module by a selector cable.
operates the manual selector valve, which is part of the electro-hydraulic control unit.
Transmission selector lever interlock solenoid
Transmission selector lever interlock solenoid:
prevents the transmission selector lever from being moved from the Park position, unless the
ignition switch is in the "ON" position and the brake pedal is applied.
is controlled by an input from the brake pedal switch through the CAN bus.
Transmission selector lever interlock solenoid operation

When the driver first enters the vehicle and turns the ignition switch to the "ON" position, the
transmission selector lever position indicator "P" will flash. If the driver then applies the brake pedal
while the transmission selector lever position indicator "P" is flashing, the driver will then be able to
move the transmission selector lever out of the "P" position.
Once the transmission selector lever has been moved out of the "P" position, the transmission
selector lever interlock solenoid will de-energise after 5 seconds. If the transmission selector lever is
moved back into the "P" position before the 5 seconds have elapsed, the transmission selector lever
interlock solenoid will de-energise as soon as the transmission selector lever detects it is in the "P"
position.
If the transmission selector lever is moved into a gear selection position for longer than 5 seconds
and then returned to the "P" position whilst the brake pedal is applied. The transmission selector
lever interlock solenoid will remain de-energised and the transmission selector lever position
indicator "P" will flash. The driver must release and re-apply the brake pedal to allow the
transmission selector lever to be moved from the "P" position.
If the driver runs the vehicle for a short period of time, with the brake pedal applied and then turns
the vehicle off without moving the transmission selector lever out of the "P" position. The driver will
not be able to remove the key from the ignition switch, until the brake pedal has been released.
External Controls
WARNING: Danger of accident. Apply the parking brake. Shift the gear selector lever to "P".

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Visibly damaged or worn parts. Fuse(s).
Loose or missing nuts or bolts. Loose or corroded electrical connector(s).
Diagnostic System.
Pinpoint Tests
PINPOINT TEST G189073p1 : J-GATE

SYSTEM CIRCUIT CHECKS
G189073t1 : CHECK FOR IGNITION FEED TO THE J-GATE
1. Disconnect the J-gate assembly electrical connector CA245. 2. Turn the ignition to the "ON"
position. 3. Measure the voltage at CA245 Pin 1 (GO).
Is the voltage greater than 10 Volts?
-> Yes
-> No
Repair the electrical circuit between the J-gate assembly electrical connector CA245 Pin 1 (GO) and
the rear power distribution box FUSE 3. Clear the DTC. TEST the system for normal operation. NOTE:
This circuit incorporates the ignition switch and the primary junction box. For additional information,
refer to the vehicle wiring diagrams.
G189073t6 : CHECK THE GROUND SUPPLY TO THE J-GATE

1. Measure the resistance between the J-gate assembly electrical connector CA245 Pin 2 (B) and
GROUND.
Is the resistance less than 5.0 Ohms?
-> Yes
-> No
Repair the circuit between the J-gate assembly electrical connector CA245 Pin 2 (B) and GROUND.
Clear the DTC. TEST the system for normal operation.
G189073t2 : CHECK FOR J-GATE ILLUMINATION FEED

1. Turn the ignition to the "ON" position. 2. Measure the voltage at CA245 Pin 3 (UY).
Is the voltage greater than 10 Volts?
-> Yes
-> No
Repair the electrical circuit between the J-gate assembly electrical connector CA245 Pin 3 (UY) and
the front electronics module electrical connector. For additional information, refer to the vehicle
wiring diagrams. Clear the DTC. TEST the system for normal operation.
G189073t3 : CHECK FOR KEY INTERLOCK FEED CIRCUIT FOR CONTINUITY

1. Disconnect the J-gate assembly electrical connector CA245. 2. Disconnect the ignition switch
electrical connector FC018. 3. 3) Measure the resistance between the J-gate assembly electrical
connector CA245 Pin 4 (Y) and the ignition switch electrical connector FC018 Pin 3 (Y).
Is the resistance less than 5.0 Ohms?
-> Yes
-> No
Repair the electrical circuit between the J-gate assembly electrical connector CA245 Pin 4 (Y) and the
ignition switch electrical connector FC018 Pin 3 (Y). Clear the DTC. TEST the system for normal
operation.
G189073t4 : CHECK FOR KEY INTERLOCK ACTION

1. Check for continuity between Pin 3 and Pin 4 of the ignition switch lock cylinder.
Is the circuit continuous?
-> Yes
Install a new J-gate. For additional information,
Clear the DTC. TEST the system for normal operation.
-> No
Install a new ignition switch lock cylinder. For additional information, <<211-04>> Clear the DTC. TEST
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Selector Lever Cable and Bracket

(44.15.08)
Removal
1 . Remove the floor console. <<501-12>>
2 . Move the transmission selector lever to the "R" position.
3 . Detach the wiring harness bracket.
1) Reposition the wiring harness.
2) Detach the wiring harness bracket.
Loosen the selector lever cable retaining nuts.

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9 . Remove the selector lever cable.
Installation
1 . Install the selector lever cable.
Tighten to 11 Nm.
2 NOTE:
.
Make sure the selector lever cable is fully seated to the transmission unit gear selector
pivot ball.
Attach the selector lever cable.
4 . NOTE:
Make sure the selector lever cable grommet is seated correctly.

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Attach the selector lever cable.
5 . NOTE:
Make sure the selector lever cable is in the "R" position.
6 . Make sure the transmission selector lever is in the "R" position.

Do not tighten the selector lever cable retaining nuts.
8 . Connect the selector lever cable.
9 Adjust the selector lever cable retaining nuts to lock against the retaining bracket without
. moving the set position of either the shift lever or the selector lever cable.
Do not tighten the selector lever cable retaining nuts.
10 NOTE:
.
Make sure all transmission selector lever positions are illuminated to indicate the
selected gear and the automatic transmission selects the relevant transmission state.
11 NOTE:
.
When tightening the selector lever cable retaining nuts, make sure both retaining nuts
are tightened to the specified torque simultaneously.
Tighten the selector lever cable retaining nuts.
Tighten to 20 Nm.
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12 . Attach the wiring harness bracket.
13 . Install the floor console. <<501-12>>

Selector Lever Assembly (44.15.04)
Removal
1 . Remove the instrument panel console. <<501-12>>
2 . Remove the ash tray retaining screws.
3 . Detach the ash tray.
4 . Place the transmission selector lever to the "R" position.
5 . NOTE:
Shown with the electric parking brake switch removed for clarity.

6 . Detach the wiring harness bracket.
1) Reposition the wiring harness.
2) Detach the wiring harness bracket.

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8 . Detach the transmission selector lever.

9 . Disconnect the ignition switch interlock cable.
1) Detach the ignition switch interlock cable.
2) Disconnect the ignition switch interlock cable.
Installation
1 . Attach the ignition switch interlock cable.
1) Connect the ignition switch interlock cable.
2) Attach the ignition switch interlock cable.

2 . Attach the transmission selector lever.
Tighten to 11 Nm.
3 . NOTE:
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Shown with the electric parking brake switch removed for clarity.
Connect the electrical connector.
4 . NOTE:
Make sure the selector lever cable is in the "R" position.
5 . Make sure the transmission selector lever is in the "R" position.

7 . Loosen the selector lever cable lock nuts.
8 Adjust the selector lever cable lock nuts to lock against the retaining bracket without moving
. the set position of either the shift lever or the selector lever cable.
Do not fully tighten the selector lever cable lock nuts.
9 NOTE:
.
Make sure all transmission selector lever positions select the relevant automatic
transmission states.
10 NOTE:
.
When tightening the selector lever cable lock nuts, make sure both lock nuts are
tightened to the specified torque simultaneously.
Tighten the selector lever cable lock nuts.
Tighten to 20 Nm.
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11 . Attach the wiring harness bracket.
12 . Attach the ash tray.

13 . Install the ash tray retaining screws.
14 . Install the instrument panel console. <<501-12>>

309 : Exhaust System
309-00 : Exhaust System
Specifications
Specifications
lb- lb-
Description Nm
ft in
Exhaust manifold to catalytic converter retaining nuts - Vehicles without
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40 30 -
diesel engines
Catalytic convertor retaining clamp - Vehicles without diesel engines 55 41 -
Front muffler retaining clamps - Vehicles without diesel engines 55 41 -
Muffler and tailpipe retaining clamp 55 41 -
Heated oxygen (HO2S) sensors - Vehicles without diesel engines 40 30 -
Catalyst monitor sensors - Vehicles without diesel engines 40 30 -
Catalyst temperature sensors - Vehicles with diesel engines 35 26 -
Diesel particulate filter temperature sensor - Vehicles with diesel engines 35 26 -
Turbocharger to catalytic convertor retaining studs - Vehicles with diesel
15 11 -
engines
Turbocharger to downpipe catalytic convertor retaining nuts - Vehicles with
25 18 -
diesel engines*
Catalytic convertor to diesel particulate filter retaining clamp retaining bolts -
11 8 -
Vehicles diesel engines
Diesel particulate filter to front muffler retaining clamp retaining bolts -
55 41 -
Vehicles diesel engines
Diesel particulate filter differential pressure sensor retaining nuts - Vehicles
5 4 -
diesel engines
*For vehicles prior to VIN 5B001494, refit old fixings and tighten to 22 Nm (16 lb.ft)
Exhaust System
1 Catalytic converters
2 Diesel particulate filter
3 Front muffler
4 Muffler and tailpipes

1 Diesel particulate filter differential pressure sensor
The exhaust system for various engines are of similar design but utilize different internal elements to
achieve a distinct exhaust note for each variant.
Catalytic Converters
The catalytic converters are of a monolithic structure and are coated in platinum. The platinum
coating is used to control the emissions of hydrocarbons (HC), carbon monoxide (CO) and oxides of
nitrogen (NOx) and to convert them into less harmful products for example carbon dioxide (CO)
nitrogen (N) and water (HO).
The catalytic converters are connected to the turbocharger by a three nut flange and is sealed by a
gasket. Exhaust jointing compound must not be applied to these joints due to the possibility of
catalytic converter contamination. Avoid allowing any foreign particles of debris into the catalytic
downpipe as this can result in damage to the catalytic converter.
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Diesel Particulate Filter

In order to meet strict Euro IV emission limits there is now a stipulation to reduce gaseous and
particulate emissions greatly. The primary component within the exhaust system of the diesel is the
diesel particulate filter. The diesel particulate filter uses new filter technology based on a combined
filter and oxidation catalytic converter to store, and when conditions allow, destroy the particulates.
The diesel particulate filter is of a silicon carbide filter construction. It has an additional wash coating
on its filter surface of platinum and other active components which are used in the manufacture of
oxidation catalytic converters. The exhaust gasses pass through the filter, leaving the particulates
behind that are too big to pass through the filters pores. With engine management intervention and
the catalytic coating this will promote particulate combustion and oxidation of carbon monoxide (CO)
and hydrocarbon (HC) emissions. By carrying out this process, this will regenerate the diesel
particulate filter to prevent increased back-pressure and the possibility of a completely blocked filter.
Diesel particulate filter differential pressure sensor

The diesel particulate filter differential pressure sensor monitors the differential pressure in the
pipeline, upstream and downstream of the diesel particulate filter. The filtering of the particulates
will lead to a greater resistance to the exhaust gas flow through the diesel particulate filter. This
leads to a greater pressure difference upstream and downstream of the diesel particulate filter. The
diesel particulate filter differential pressure sensor is a membrane sensor with strain resistances. The
strain resistances change depending on the pressure difference. This leads to a change in the signal
voltage. This signal is one of the parameters required for the strategy of the regeneration of the
diesel particulate filter.
Exhaust System – Armoured Vehicles
Muffler and Tailpipe

The exhaust system is modified so that the engine cannot be stalled by stopping the flow of exhaust
system emissions. Unique muffler and tailpipes are installed to the vehicle for this purpose.
Exhaust System
Overview
2006MY sees the introduction of diesel to X350 and is accompanied by a diesel particulate filter
(DPF) system to comply with strict stage four emissions requirements. The engine management
system (EMS) makes use of 7-digit diagnostic trouble codes (DTCs) rather than the familiar 5-digit.

Exhaust System

Leaks
Metal fatigue Battery charge and condition
Pipes, mufflers and catalytic converters Wiring harness
Diesel particulate filter (DPF) Electrical connector(s)
DPF differential pressure sensor tubes 5 volt sensor supply
Joints Sensor(s)
Mountings Engine control module (ECM)
Clearance around components
Symptom Chart
Noisy or
Install new components as necessary.
leaking
Exhaust system/components Exhaust System - 2.7L V6 - TdV6
exhaust
Air intake system fault

Diesel particulate fliter (DPF) Intake Air Distribution and Filtering Check for a
blocked/restricted blocked DPF or catalytic converter, install new
Restricted exhaust system Diesel Particulate Filter (DPF) or
Lack of power
Catalytic Converter - 2.7L V6 - TdV6 (17.50.05)
Low fuel pressure Check the fuel pressure,
Engine Emission Control For turbocharger tests,
(EGR) valve(s) fault
Turbocharger
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Turbocharger(s) fault
DTC index
NOTE:
NOTE:

Diesel particulate filter catalyst
(DPF) temperature downstream
circuit: high For temperature sensor - catalyst
sensor - catalyst
P024B00 resistance downstream circuit tests, GO to
downstream circuit
range/performance Temperature sensor -
(right hand bank) catalyst
downstream
circuit: short
circuit to ground
catalyst
downstream
circuit: short
circuit to power
catalyst
downstream
failure
catalyst upstream
circuit: high
resistance
Diesel particulate filter Temperature sensor -

(DPF) temperature catalyst upstream
circuit: short For temperature sensor - catalyst
sensor - catalyst
P042600 circuit to ground upstream circuit tests, GO to
upstream circuit
range/performance Temperature sensor -
(right hand bank) catalyst upstream
circuit: short
circuit to power
catalyst upstream
failure
catalyst upstream
circuit: high
Diesel particulate filter resistance
(DPF) temperature For temperature sensor - catalyst
P042700 sensor - catalyst upstream circuit tests, GO to
catalyst upstream
upstream circuit low circuit: short Pinpoint Test G552286p1.
(right hand bank) circuit to ground
catalyst upstream
failure
catalyst upstream
(DPF) temperature For temperature sensor - catalyst
circuit: short
P042800 sensor - catalyst upstream circuit tests, GO to
circuit to power
upstream circuit high Pinpoint Test G552286p1.
(right hand bank) Temperature sensor -
catalyst upstream
failure
catalyst
downstream
circuit: high
resistance
(DPF) temperature Temperature sensor - For temperature sensor - catalyst
P042C00 sensor - catalyst catalyst downstream circuit tests, GO to
downstream circuit low downstream Pinpoint Test G552286p2.
(right hand bank) circuit: short
circuit to ground
catalyst
downstream
failure
catalyst
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Diesel particulate filter downstream

(DPF) temperature circuit: short For temperature sensor - catalyst
P042D00 sensor - catalyst circuit to power downstream circuit tests, GO to
downstream circuit high Pinpoint Test G552286p2.
(right hand bank) Temperature sensor -
catalyst
downstream
failure
catalyst upstream
circuit: high
resistance

(DPF) temperature catalyst upstream
sensor - catalyst
P043600 circuit to ground upstream circuit tests, GO to
upstream circuit
range/performance (left Temperature sensor -
hand bank) catalyst upstream
circuit: short
circuit to power
catalyst upstream
failure
For temperature sensor - catalyst
catalyst upstream
P043700 (DPF) temperature circuit: high
upstream circuit tests, GO to
sensor - catalyst Pinpoint Test G552286p3.
resistance
upstream circuit low
(left hand bank) Temperature sensor -
catalyst upstream
circuit: short
circuit to ground
catalyst upstream
failure
P043800 sensor - catalyst circuit to power upstream circuit tests, GO to
upstream circuit high Pinpoint Test G552286p3.
catalyst upstream
failure
catalyst
downstream
circuit: high
resistance
Diesel particulate filter catalyst
(DPF) temperature downstream
sensor - catalyst
P043B00 circuit to ground downstream circuit tests, GO to
downstream circuit
range/performance (left Temperature sensor -
hand bank) catalyst
downstream
circuit: short
circuit to power
catalyst
downstream
failure
catalyst
downstream
Diesel particulate filter circuit: high
(DPF) temperature resistance For temperature sensor - catalyst
P043C00 sensor - catalyst downstream circuit tests, GO to
downstream circuit low Temperature sensor - Pinpoint Test G552286p4.
(left hand bank) catalyst
downstream
circuit: short
circuit to ground
catalyst
downstream
failure
catalyst
Diesel particulate filter downstream
P043D00 sensor - catalyst circuit to power downstream circuit tests, GO to
downstream circuit high Pinpoint Test G552286p4.
catalyst
downstream
failure
DPF temperature
resistance
DPF temperature
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Diesel particulate filter sensor circuit:

short circuit to For DPF temperature sensor circuit
(DPF) temperature
P242B00 ground tests, GO to Pinpoint Test
sensor circuit
G552286p5.
range/performance DPF temperature
sensor circuit:
short circuit to
power
DPF temperature
sensor failure
DPF temperature
resistance
Diesel particulate filter For DPF temperature sensor circuit
DPF temperature
P242C00 (DPF) temperature tests, GO to Pinpoint Test
sensor circuit:
sensor circuit low short circuit to G552286p5.
ground
DPF temperature
sensor failure
DPF temperature
sensor circuit:
Diesel particulate filter For DPF temperature sensor circuit
short circuit to
P242D00 (DPF) temperature tests, GO to Pinpoint Test
power
sensor circuit high G552286p5.
DPF temperature
sensor failure
DPF temperature
resistance
DPF temperature
short circuit to For DPF temperature sensor circuit
(DPF) temperature
P242E00 ground tests, GO to Pinpoint Test
sensor circuit
G552286p5.
intermittent/erratic DPF temperature
sensor circuit:
short circuit to
power
DPF temperature
sensor failure
Differential pressure Check the DPF and differential
sensor pressure sensor tubes/hoses for
tubes/hoses leaks/damage, install new
Diesel particulate filter split/leaking
P244A00 (DPF) exhaust back
DPF split/leaking Diesel Particulate Filter (DPF) For
pressure too low
DPF differential pressure sensor
DPF differential circuit tests, GO to Pinpoint Test
pressure sensor G552286p6.
failure
tubes/hoses Check the DPF and differential
blockage/restrictio pressure sensor tubes/hoses for
n blockages/damage, install new
P244B00 (DPF) exhaust back DPF
pressure too high blockage/restrictio Diesel Particulate Filter (DPF) For
n DPF differential pressure sensor
DPF differential G552286p6.
pressure sensor
failure
Exhaust
blockage/restrictio Check the DPF and differential
n pressure sensor tubes/hoses for
blockages/damage, install new
(DPF) differential DPF
P245300 pressure sensor value blockage/restrictio
n Diesel Particulate Filter (DPF) For
too high before engine
DPF differential pressure sensor
start
Differential pressure circuit tests, GO to Pinpoint Test
sensor circuit: high G552286p6.
resistance
sensor circuit:
short circuit to
ground
sensor circuit:
short circuit to
power
sensor failure
resistance
For DPF differential pressure sensor
(DPF) differential Differential pressure
P245400 circuit tests, GO to Pinpoint Test
pressure sensor circuit sensor circuit:
short circuit to G552286p6.
low
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ground
sensor failure
For DPF differential pressure sensor
(DPF) differential short circuit to
P245500 circuit tests, GO to Pinpoint Test
pressure sensor circuit power
G552286p6.
high
sensor failure
tubes/hoses
split/leaking
DPF split/leaking
Check the DPF and differential
Differential pressure pressure sensor tubes/hoses for
Diesel particulate filter sensor circuit: high leaks/damage, install new
resistance
(DPF) differential components as necessary.
P245600
pressure sensor circuit Differential pressure Diesel Particulate Filter (DPF) For
intermittent/erratic sensor circuit: DPF differential pressure sensor
short circuit to circuit tests, GO to Pinpoint Test
ground G552286p6.
sensor circuit:
short circuit to
power
sensor failure
Carry out DPF service remedy, drive
the vehicle, preferably on a main
road or motorway, until the engine
reaches its normal operating
temperature. The vehicle should
then be driven for approximately a
further 20 minutes, preferably at a
Driving conditions not speed of 48 km/h (30 mph) or more,
P245900 (DPF) regeneration
appropriate for but always observing speed limits
frequency DPF regeneration and road conditions. Successful
regeneration of the DPF is indicated
by the warning message and AMBER
priority indicator being extinguished
from the message centre. For
additional information refer to the
owner's handbook
Pinpoint tests
NOTE:
NOTE:
NOTE:
terminals.
HAND TEMPERATURE SENSOR -
CATALYST UPSTREAM
G552286t1 : CHECK THE RIGHT HAND TEMPERATURE SENSOR - CATALYST
UPSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Right hand temperature sensor - catalyst upstream connector, GB09
Circuit Pin
Right hand temperature sensor catalyst upstream - signal 01
Right hand temperature sensor catalyst upstream - ground 02

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Circuit Pin
Right hand temperature sensor catalyst upstream - signal B1
Circuit Pin
Right hand temperature sensor catalyst upstream - ground F4
3. Key off. 4. Disconnect the right hand temperature sensor - catalyst upstream connector, GB09. 5.
GB09, harness side Battery
-> Yes
-> No

UPSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No

UPSTREAM GROUND CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
UPSTREAM SIGNAL CIRCUIT FOR HIGH RESISTANCE
GB09, harness side C100, harness side
Pin 01 B1
-> Yes
-> No
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UPSTREAM GROUND CIRCUIT FOR HIGH RESISTANCE
Pin 02 F4
-> Yes
component(s): - Right hand temperature sensor - catalyst upstream connector. - Right hand
temperature sensor - catalyst upstream. - ECM connector(s). - ECM.
-> No
CATALYST DOWNSTREAM
DOWNSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Right hand temperature sensor - catalyst downstream connector, GB07
Circuit Pin
Right hand temperature sensor catalyst downstream - signal 01
Right hand temperature sensor catalyst downstream - ground 02
Circuit Pin
Right hand temperature sensor catalyst downstream - signal E3
Right hand temperature sensor catalyst downstream - ground F4
3. Key off. 4. Disconnect the right hand temperature sensor - catalyst downstream connector, GB07.
-> Yes
-> No
DOWNSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
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DOWNSTREAM GROUND CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No

DOWNSTREAM SIGNAL CIRCUIT FOR HIGH RESISTANCE

Pin 01 E3
-> Yes
-> No

DOWNSTREAM GROUND CIRCUIT FOR HIGH RESISTANCE
Pin 02 F4
-> Yes
component(s): - Right hand temperature sensor - catalyst downstream connector. - Right hand
temperature sensor - catalyst downstream. - ECM connector. - ECM.
-> No

CATALYST UPSTREAM
G552286t11 : CHECK THE LEFT HAND TEMPERATURE SENSOR - CATALYST
UPSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Left hand temperature sensor - catalyst upstream connector, GB08
Circuit Pin
Left hand temperature sensor catalyst upstream - signal 01
Left hand temperature sensor catalyst upstream - ground 02
Circuit Pin
Left hand temperature sensor catalyst upstream - signal A4
Left hand temperature sensor catalyst upstream - ground F3
3. Key off. 4. Disconnect the left hand temperature sensor - catalyst upstream connector, GB08. 5.
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-> Yes
-> No

UPSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO POWER

-> Yes
-> No

UPSTREAM GROUND CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No

UPSTREAM SIGNAL CIRCUIT FOR HIGH RESISTANCE
Pin 01 A4
-> Yes
-> No

UPSTREAM GROUND CIRCUIT FOR HIGH RESISTANCE
Pin 02 F3
-> Yes
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component(s): - Left hand temperature sensor - catalyst upstream connector. - Left hand
temperature sensor - catalyst upstream. - ECM connector. - ECM.
-> No

CATALYST DOWNSTREAM
DOWNSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Left hand temperature sensor - catalyst downstream connector, GB06
Circuit Pin
Left hand temperature sensor catalyst downstream - signal 01
Left hand temperature sensor catalyst downstream - ground 02
Circuit Pin
Left hand temperature sensor catalyst downstream - signal E4
Left hand temperature sensor catalyst downstream - ground F3
3. Key off. 4. Disconnect the left hand temperature sensor - catalyst downstream connector, GB06. 5.
-> Yes
-> No

DOWNSTREAM SIGNAL CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
DOWNSTREAM GROUND CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
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DOWNSTREAM SIGNAL CIRCUIT FOR HIGH RESISTANCE
Pin 01 E4
-> Yes
-> No

DOWNSTREAM GROUND CIRCUIT FOR HIGH RESISTANCE

Pin 02 F3
-> Yes
component(s): - Left hand temperature sensor - catalyst downstream connector. - Left hand
temperature sensor - catalyst downstream. - ECM connector. - ECM.
-> No
PINPOINT TEST G552286p5 : DIESEL

PARTICULATE FILTER (DPF)
TEMPERATURE SENSOR
G552286t21 : CHECK THE DPF TEMPERATURE SENSOR SIGNAL CIRCUIT FOR
1. Diesel particulate filter (DPF) temperature sensor connector, GB10
Circuit Pin
Diesel particulate filter (DPF) temperature sensor - signal 01
Diesel particulate filter (DPF) temperature sensor - ground 02
Circuit Pin
Diesel particulate filter (DPF) temperature sensor - signal D4
Diesel particulate filter (DPF) temperature sensor - ground F3
3. Key off. 4. Disconnect the DPF temperature sensor connector, GB10. 5. Measure the resistance
between:
-> Yes
-> No

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-> Yes
-> No
G552286t23 : CHECK THE DPF TEMPERATURE SENSOR GROUND CIRCUIT


-> Yes
-> No

HIGH RESISTANCE
Pin 01 D4
-> Yes
-> No
G552286t25 : CHECK THE DPF TEMPERATURE SENSOR GROUND CIRCUIT

FOR HIGH RESISTANCE
Pin 02 F3
-> Yes
component(s): - DPF temperature sensor connector. - DPF temperature sensor. - ECM connector. -
ECM.
-> No
PINPOINT TEST G552286p6 : DIESEL

PARTICULATE FILTER (DPF)
DIFFERENTIAL PRESSURE SENSOR
G552286t26 : CHECK THE POWER SUPPLY TO THE DPF DIFFERENTIAL
PRESSURE SENSOR
1. Diesel particulate filter (DPF) differential pressure sensor connector, EC65
Circuit Pin
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Diesel particulate filter (DPF) differential pressure sensor - signal 01
Diesel particulate filter (DPF) differential pressure sensor - ground 02
Diesel particulate filter (DPF) differential pressure sensor - supply 03
Circuit Pin
Diesel particulate filter (DPF) differential pressure sensor - signal D3
Diesel particulate filter (DPF) differential pressure sensor - ground D2
Diesel particulate filter (DPF) differential pressure sensor - supply C3
3. Key off. 4. Disconnect the DPF differential pressure sensor connector, EC65. 5. Key on, engine off.

-> Yes
-> No
G552286t27 : CHECK THE DPF DIFFERENTIAL PRESSURE SENSOR SIGNAL

-> Yes
-> No

-> Yes
-> No

Pin 01 D3
-> Yes
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-> No
G552286t30 : CHECK THE DPF DIFFERENTIAL PRESSURE SENSOR GROUND

Pin 02 D2
-> Yes
component(s): - DPF differential pressure sensor connector. - DPF differential pressure sensor. - ECM
connector. - ECM.
-> No
Catalytic Converter - 4.2L NA V8 -

AJ27/3.5L NA V8 - AJV8 (17.50.05)
Removal

3 . Support the exhaust system with suitable stands.
4 . NOTE:
Disconnect the heated oxygen sensor electrical connector (HO2S).
5 . NOTE:
Remove the (HO2S).

6 . NOTE:
Disconnect the catalyst monitor sensor electrical connector.

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7 . NOTE:
Detach the catalyst monitor sensor.

8 . NOTE:
9 . NOTE:
Loosen the catalytic converter retaining clamp.
10 . NOTE:
Detach the catalytic converter.

11 . NOTE:
Remove the catalytic converter.

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Installation
1.
CAUTION: Never use jointing compound forward of the catalytic converter.
NOTE:
To install reverse, the removal procedure.
Tighten to 40 Nm.
2 . NOTE:
Tighten to 55 Nm.
3 . NOTE:
Tighten to 40 Nm.
4 . NOTE:
Tighten to 40 Nm.
5 NOTE:
.

Test
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Catalytic Converter - 2.7L V6 - TdV6
(17.50.05)
Removal
2 . NOTE:
Loosen the catalytic converter to particulate filter retaining clamp.
3 . NOTE:
Disconnect the catalytic converter temperature sensor electrical connectors.

4 . NOTE:
Detach the catalytic converter temperature sensor wiring harness from the transmission.
5 . NOTE:

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Remove and discard the catalytic converter to turbocharger retaining nuts.
6
. CAUTION: Make sure the catalytic converter is fully supported during removal.
Failure to follow this instruction will result in damage to the catalytic converter decoupler
joint.
NOTE:
Remove the catalytic converter.

Installation
1
. CAUTION: Make sure the catalytic converter is fully supported during installation.
Failure to follow this instruction will result in damage to the catalytic converter decoupler
joint.
CAUTION: Never use jointing compound forward of the catalytic converter.
NOTE:
Loosely install the catalytic converter.

2 . NOTE:
Install new retaining nuts.
Tighten to 22 Nm.
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3 . NOTE:
Install the catalytic convertor to particulate filter retaining clamp.
Tighten to 11 Nm.
4 . NOTE:
Fully tighten the catalytic converter bracket retaining bolts.
Tighten to 25 Nm.
NOTE:
For vehicles prior to VIN H16767, refit old fixings and tighten to 22 Nm.
5 . NOTE:
Attach the catalytic converter temperature sensor wiring harness to the transmission.
6 . NOTE:
Connect the catalytic converter temperature sensor electrical connectors.

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Diesel Particulate Filter (DPF)
Removal
2 . Loosen the front muffler retaining clamps.
3 Remove the diesel particulate filter mount bracket.

.
Remove and discard the diesel particulate filter mount bracket retaining
nuts.
4 . Disconnect the diesel particulate filter temperature sensor electrical connector.

5 NOTE:
.
Note the orientation of the diesel particulate filter high-pressure and low-pressure hoses
and make sure they are installed in the same position. There is a paint mark to identify
their position.
Detach the diesel particulate filter high-pressure and low-pressure hoses.

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6 . NOTE:
Remove the diesel particulate filter to catalytic convertor retaining clamps.

7 . Using an assistant remove the diesel particulate filter.
Installation
1 . NOTE:
Tighten to 11 Nm.
3 . NOTE:
Install new diesel particulate filter mount bracket retaining nuts.
Tighten to 9 Nm.
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Diesel Particulate Filter (DPF) Differential
Pressure Sensor
Removal
1 . Disconnect the diesel particulate filter differential pressure sensor electrical connector.
2
Detach the diesel particulate filter differential pressure sensor high-pressure and low-pressure
hoses.
3 . Remove the diesel particulate filter differential pressure sensor.

Installation
1
Tighten to 5 Nm.
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Exhaust System - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA
V8 - AJV8
Removal
1 . Remove both muffler and tailpipes.
4 . NOTE:
Disconnect the heated oxygen sensor (HO2S) electrical connector.
5 . NOTE:
Disconnect the catalyst monitor sensor electrical connector.

6 . NOTE:
Detach the catalyst monitor sensor.

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7 . NOTE:
Detach the catalytic converter.

Installation
1 . NOTE:
Tighten to 40 Nm.
Exhaust System - 2.7L V6 - TdV6
Removal
2 . NOTE:
Loosen the catalytic converter to particulate filter retaining clamp.

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3 . NOTE:
Discard the diesel particulate filter mount bracket retaining nuts.
Remove the diesel particulate filter mount bracket.
4 . Disconnect the diesel particulate filter temperature sensor electrical connector.

5 NOTE:
.
Note the orientation of the diesel particulate filter high-pressure and low-pressure hoses
and make sure they are installed in the same position. There is a paint mark to identify
the high-pressure hose.
Detach the diesel particulate filter high-pressure and low-pressure hoses.
6 . NOTE:
Detach the under body tray.
1) Remove the under body tray retaining bolts.
2) Reposition the under body tray.

7 . Remove the support bracket.
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9 . NOTE:
Discard the exhaust system to catalytic converter gaskets.
Using an assistant remove the exhaust system.

Installation
1 . NOTE:
NOTE:
Install new exhaust system to catalytic converter gaskets.
Tighten to 11 Nm.
4 . NOTE:
Install new diesel particulate filter mount bracket retaining nuts.
Tighten to 9 Nm.
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Front Muffler - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 -
AJV8 (30.10.18)
Removal
2 . Support the exhaust system using suitable stands.
3 . NOTE:
Loosen both front muffler retaining clamps.
4 . Remove the front muffler.

Installation
1 . NOTE:
Tighten to 55 Nm.
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Front Muffler - 2.7L V6 - TdV6 (30.10.18)
Removal
2
. CAUTION: The hanger insulators are constructed of a special material. Make sure
the insulators are not damaged on removal of the front muffler. Failure to follow this
Detach the rear muffler and tailpipe assemblies.
Loosen the rear muffler and tailpipe retaining clamps.
3 . Remove the front muffler.
Loosen the front muffler to particulate filter retaining clamps.

Installation
1 NOTE:
.
Make sure the front muffler is installed fully to the alignment pips on the diesel
particulate filter outlet pipes.
Install the front muffler.
Tighten to 55 Nm.
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2
the insulators are not damaged on installation. Split or cracked insulators should be
CAUTION: Alignment marks are provided for the correct alignment of the muffler
and tailpipe assemblies to the front muffler. Make sure the muffler and tailpipe assemblies
align between the two tolerance markers. Failure to follow this instruction may result in
NOTE:
Make sure the muffler and tailpipe is central in the bumper aperture.
Attach the rear muffler and tailpipe assemblies.
Tighten to 55 Nm.
Muffler and Tailpipe (30.10.52)
Removal
2 . NOTE:
Loosen the muffler and tailpipe retaining clamp.

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3 . NOTE:
Detach the muffler and tailpipe hanger insulator.
4
. CAUTION: Do not over stretch the hanger insulator. Failure to follow this instruction
NOTE:
Detach the muffler and tailpipe hanger insulator.
5 . NOTE:
Remove the muffler and tailpipe.
Installation
1
the insulators are not damaged on installation. Split or cracked insulators should be
CAUTION: Alignment marks are provided for the correct alignment of the muffler
and tailpipe assemblies to the front muffler. Make sure the muffler and tailpipe assemblies
align between the two tolerance markers. Failure to follow this instruction may result in
NOTE:
Make sure the muffler and tailpipe is central in the bumper aperture.
NOTE:
Tighten to 55 Nm.
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310 : Fuel System
310-00 : Fuel System – General Information
Specifications
Specifications
Item Specification
Usable fuel tank capacity 85 liters
General procedures
Fuel System Pressure Check

NOTE:
This procedure is for the installation of the adaptor into the fuel line due to the removal of
the schraeder valve from the fuel line.
1.
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.
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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.
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: After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow these instructions may result in personal injury.

3. Remove the air cleaner outlet pipe.

4. Detach the power steering fluid reservoir and reposition.
5. Disconnect the electrical connector.
6. Detach the fuel line retaining clip.
7. Disconnect the fuel rail feed pipe.

8. NOTE:
Make sure the special tool is fully seated to the fuel pipe connections.
9. NOTE:

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10. NOTE:
11. Install the air cleaner outlet pipe.

12. NOTE:
Vehicles with 4.2L engine shown, other vehicles similar.
Install the fuel pressure gauge.

13. Connect the battery ground cable.
14. Carry out the fuel system pressure check.

Fuel System Pressure Release - 4.2L NA V8
- AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -
AJ27/3.5L NA V8 - AJV8 (19.50.02)
Fuel Pressure Gauge

310-012 (JD209)
1.
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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: 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.
seek medical attention.
irritation. Should irritation develop, seek medical attention.
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.

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• 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.

Fuel System Pressure Release - 2.7L V6 -
TdV6 (19.50.02)
personal injury.
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WARNING: If taken internally do not induce vomiting, seek immediate medical

solution and seek medical attention.
WARNING: Wash hands thoroughly after handling, as prolonged contact may

cause irritation. Should irritation develop, seek medical attention.
1. Disconnect the battery ground cable.

2. NOTE:

• Disconnect the fuel filter to fuel pump supply line from the fuel filter.
3. Connect the fuel filter to fuel pump supply line to the fuel filter.

Fuel Tank Draining - VIN Range: G00442-
>G45703
Remover/Installer, Fuel Pump Module/Fuel Transfer Pump Locking Ring

310-072A
1.
WARNING: Place the vehicle in a well ventilated, quarantined area and arrange "No
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WARNING: Do not carry or operate cellular phones when working on any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these
personal injury.
Release the pressure in the fuel system.

Fuel System Pressure Release - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 - AJ27/3.5L NA V8 -
AJV8 (19.50.02)
2. Open the fuel filler flap.
3. Disconnect the battery ground cable. <<414-01>>
4. Detach the fuel tank filler pipe cap.
5. Raise and support the vehicle. <<100-02>>

6. Remove the left-hand under body tray.
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7.
CAUTION: Using a suitable container, catch any escaping fuel.
Disconnect the fuel feed pipe.
8. Using a suitable pneumatic pump, remove the fuel from the fuel tank. Follow the manufacturers
operating instructions.
• Connect the pneumatic fuel draining equipment to the fuel feed pipe.
9. Connect the fuel feed pipe.

10. Fit the left-hand under body tray.
12. Remove the rear seat cushion. <<501-10>>
13. NOTE:
Remove the scuff plate trim panel.

14. NOTE:
Detach and reposition the floor covering.
15. NOTE:

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Detach and reposition the rear seat cushion insulation.
16. Remove the floor aperture cover.
17. Disconnect the fuel pump module quick release coupling.

18. Detach the fuel pump module electrical connector from the retaining bracket.
19. Disconnect the fuel pump module electrical connector.
20. Using the special tool, remove the fuel pump module locking ring.
21. Detach and reposition the upper part of the fuel pump module.
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23. NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
Detach the fuel transfer pump module electrical connector from the retaining bracket.
24. NOTE:
Disconnect the fuel transfer pump electrical connector.

25. NOTE:
Using the special tool, remove the fuel transfer pump locking ring.
26. NOTE:
Detach and reposition the upper part of the fuel transfer pump.
27.
CAUTION: Make sure no damage occurs to the fuel level float.

Remove the fuel transfer pump.
• Disconnect the fuel cross over lines.
28. Remove and discard the fuel transfer pump O-ring seal.
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29.
Remove the fuel pump module.
• Remove and discard the fuel pump module O-ring seal.
30. Using the fuel pump module hole in the fuel tank to gain access to the fuel, remove the fuel from
the fuel tank using the fuel tank draining equipment. Follow the manufacturers operating
instructions.
31. Using the fuel transfer pump hole in the fuel tank to gain access to the fuel, remove the fuel
from the fuel tank using the fuel tank draining equipment. Follow the manufacturers operating
instructions.
32.
CAUTION: On vehicles with supercharger make sure the arrow on the fuel pump module
and the 'SC' marker on the fuel tank are aligned.
CAUTION: On vehicles without supercharger make sure the arrow on the fuel pump module
and the 'NA' marker on the fuel tank are aligned.
CAUTION: On vehicles without supercharger make sure the arrow on the fuel transfer
module and the 'NA' marker on the fuel tank are aligned.
CAUTION: Make sure no damage occurs to the fuel level floats.
NOTE:
Install a new O-ring seal to the fuel pump module flange.
NOTE:
Take care not to stretch the O-ring seal.
Install the fuel pump module.
• For vehicles without supercharger feed the fuel cross-over lines through the fuel pump module
hole and across the front of the fuel tank saddle.
33. Using the special tool, install the fuel pump module locking ring.
34. Connect the fuel pump module electrical connector.
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35. Attach the fuel pump module electrical connector to the retaining bracket.
36. Connect the fuel pump module quick release coupling.
• Make sure the quick release coupling has latched onto the fuel pump module fuel pipe by
pulling the pipe after the connection has been made.
37. Install the floor aperture cover.
38.
CAUTION: Vehicles with supercharger - make sure the arrow on the left-hand fuel pump
module lines up with the 'SC' marker on the fuel tank.
CAUTION: Vehicles without supercharger - make sure the arrow on the fuel transfer pump
lines up with the 'NA' marker on the fuel tank.
NOTE:
Install a new O-ring seal to the fuel transfer pump flange.
NOTE:
Take care not to stretch the O-ring seal.
Install the fuel transfer pump.

39. NOTE:
Using the special tool, install the fuel transfer pump locking ring.
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40. NOTE:
Connect the fuel transfer pump electrical connector.

41. NOTE:
Attach the fuel transfer pump module electrical connector to the retaining bracket.
43. NOTE:
Attach the rear seat cushion insulation.
44. NOTE:
Attach the floor covering.

45. NOTE:
Install the scuff plate trim panels.

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46. Install the rear seat cushion. <<501-10>>
47. Attach the fuel tank filler pipe cap.
48. Connect the battery ground cable. <<414-01>>
49. Close the fuel tank filler pipe flap.

Fuel Tank Draining - VIN Range: G45704-
>G99999
Fuel tank drain adaptor

310-154
WARNING: Do not carry or operate cellular phones when working on any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these
personal injury.
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1. Release the pressure in the fuel system.

Fuel System Pressure Release - 2.7L V6 - TdV6 (19.50.02)
2. Remove the rear seat cushion.

3. Remove the scuff plate trim panel.

4. Detach and reposition the floor covering.
6.
CAUTION: The correct measurement must be used to remove the fuel tank drain port top.
NOTE:
The fuel tank drain port is marked with DRAIN.
NOTE:
Vehicles without Diesel engine shown, vehicles with Diesel engine similar.
Using a suitable tool, remove the top of the fuel tank drain port.
7. NOTE:
Install the special tool to the right-hand side of the fuel tank.
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8. Using a suitable fuel vacuum drainer, remove the fuel from the right-hand side of the fuel tank.
9. NOTE:

10.
CAUTION: Make sure the new fuel tank drain port sealing cap is correctly installed. Failure
NOTE:
Install a new fuel tank drain port sealing cap.
12. Attach the floor covering.
13. Install the scuff plate trim panel.

14. Remove the scuff plate trim panel.
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15. Detach and reposition the floor covering.

17.
CAUTION: The correct measurement must be used to remove the fuel tank drain port top.
NOTE:
The fuel tank drain port is marked with DRAIN.
NOTE:
Using a suitable tool, remove the top of the fuel tank drain port.
18. NOTE:
Install the special tool to the left-hand side of the fuel tank.
19. Using a suitable fuel vacuum drainer, remove the fuel from the left-hand side of the fuel tank.
20. NOTE:
21.
CAUTION: Make sure the new fuel tank drain port sealing cap is correctly installed. Failure
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NOTE:
Install a new fuel tank drain port sealing cap.

23. Attach the floor covering.
24. Install the scuff plate trim panel.
25. Install the rear seat cushion.

High-Pressure Fuel System Bleeding - 2.7L
V6 - TdV6
Pneumatic vacuum gun
WARNING: Place the vehicle in a well ventilated, quarantined, area and arrange
"No Smoking/Fuel Fumes" signs about the vehicle.
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WARNING: Do not carry out any repairs to the fuel injection system with the
engine running. The fuel pressure within the system can be as high as 1650 bar. Failure
personal injury.

WARNING: Wash hands thoroughly after handling fuel, as prolonged contact

may cause irritation. Should irritation develop, seek medical attention.

observed when working with these components. Always fit blanking plugs to any open
orifices or lines.
CAUTION: Always carry out the cleaning process before carrying out any
repairs to the fuel injection system components. Failure to follow these instructions may
result in foreign matter ingress to the fuel injection system.
CAUTION: The low-pressure fuel system bleeding procedure must be carried out
before this procedure is carried out, or the engine is attempted to be started, following
removal or replacement of any low-pressure fuel system component. Failure to follow
this instruction may result in damage to the fuel injection pump.
CAUTION: The engine must not be cranked using the starter motor for more
than 30 seconds. The starter motor must be allowed to cool for at least 5 minutes after
cranking for 30 seconds. Failure to follow these instructions will result in damage to the
starter motor.
NOTE:
If a new fuel filter is to be installed, make sure the fuel filter is installed AFTER the high-
pressure fuel system has been bled.
NOTE:
This procedure is necessary if the fuel injection pump, or the fuel line between the fuel
filter and the fuel injection pump is removed, drained of fuel or replaced.
1. Bleed the low-pressure fuel system.

Low-Pressure Fuel System Bleeding - 2.7L V6 - TdV6
2. Remove the oil filler cap.

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4. Install the engine oil filler cap to prevent foreign material entering the valve cover.
5. Remove the cowl vent screen.

6. Detach the high-pressure fuel supply line clamp.
7. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors, high-
8.
CAUTION: Make sure that the high-pressure fuel supply line remains in contact
with the fuel injection supply manifold and fuel injection diverter rail until both unions
CAUTION: Make sure that the tool used to loosen the high-pressure fuel supply
line unions is used at the top of the unions as this is where there is most material. Failure
to follow this instruction may result in damage to the unions.
Loosen the high-pressure fuel supply lines.
9. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors, high-
10. Remove and discard the high-pressure fuel supply line.
11. Install a new high-pressure fuel supply line, but do not fully tighten the unions at this
stage.
12. Position suitable lint free material under the left-hand high-pressure fuel line unions to
catch escaping fuel.
13. Turn the ignition switch to the RUN position for 20 seconds.
14. If fuel does not appear at the fuel line unions after 20 seconds, allow the starter motor to
cool for five minutes.
15. Repeat steps 11 and 12 until fuel appears at the fuel line unions.
16.
CAUTION: Make sure that the tool used to tighten the high-pressure fuel supply
line unions is used at the top of the unions as this is where there is most material. Failure
to follow this instruction may result in damage to the unions.
Tighten the the high-pressure fuel supply line unions.

• Tighten the high-pressure fuel supply line in the sequence shown:
• Tighten the high-pressure fuel supply line union 1 to fuel diverter rail to 15 Nm.
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• Tighten the high-pressure fuel supply line union 2 to fuel rail to 15 Nm.
• Tighten the high-pressure fuel supply line union 1 to fuel diverter rail to 30 Nm.
• Tighten the high-pressure fuel supply line union 2 to fuel rail to 30 Nm.
17. Attach the high-pressure fuel supply line clamp.

18.
WARNING: Do not carry out any repairs to the fuel system with the engine
19. Install the cowl vent screen.

20. Remove the engine oil filler cap.
22. Install the oil filler cap.

Low-Pressure Fuel System Bleeding - 2.7L
V6 - TdV6
personal injury.
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observed when working with these components. Always fit blanking plugs to any
exposed ports.
CAUTION: This procedure must be carried out before the engine is attempted to
be started, following removal or replacement of any low pressure fuel system
component. Failure to follow this instruction will result in damage to the fuel injection
pump.
CAUTION: The engine must not be cranked using the starter motor for more
than 30 seconds. The starter motor must be allowed to cool for at least 5 minutes after
cranking for 30 seconds. Failure to follow these instructions will result in damage to the
starter motor.
NOTE:
This procedure is necessary if any low-pressure fuel system components are removed or
replaced. These include the fuel filter, fuel lines, fuel tank or fuel cooler.
1. Disconnect the battery ground cable.

2. NOTE:
NOTE:
Fit a suitable blanking cap to the exposed port on the fuel filter.

• Disconnect the fuel filter to fuel pump supply line from the fuel filter.
3.
CAUTION: The tube used to bleed the low-pressure fuel system must be
absolutely clean. Failure to follow this instruction may result in foreign matter ingress to
the fuel injection system.
Connect a suitable clean, clear tube to the fuel pump supply outlet.
4. Place a suitable container under the tube to catch any escaping fuel.
5. Turn the ignition switch to the ON position for 10 seconds. The fuel pump in the fuel tank
will be audible.
6. Turn the ignition switch to the OFF position.
7. Repeat steps 5 and 6 until air-free fuel escapes from the tube.
8. Disconnect and discard the tube from the fuel pump supply outlet.
9. NOTE:
Remove the blanking cap.
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Connect the fuel filter to fuel pump supply line to the fuel filter.

11.
CAUTION: If any high-pressure fuel system components have been removed or

replaced, the high-pressure fuel system bleeding procedure must be carried out before
the engine is started. Failure to follow this instruction may result in damage to the
vehicle.
If necessary, bleed the high-pressure fuel system.
12. Start the engine and allow to idle.

Quick Release Coupling
Disconnect
1.

personal injury.


2. Disconnect the quick release fitting.

1. Release the retaining clip.
2. Disconnect the quick release fitting.
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Connect
1. To connect, reverse the disconnect procedure.
Disconnect
1.

personal injury.


2. Disconnect the push connect fitting.

• Press the collar.
• Disconnect the push connect fitting.
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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 Coupling Tool or Equivalent

310-D005 (23-040)
Disconnect
1.
personal injury.
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Relieve the fuel system pressure. For additional information, refer to the procedure in this section: .
2. Remove the safety clip from the spring lock coupling.
3. Install the special tool.

4. Close the special tool and push it into the female end of the spring lock coupling.
5. Disconnect the spring lock coupling.
6. Remove the special tool.
Connect
1. NOTE:
NOTE:
Install a new garter spring.
Clean and inspect the male and female ends of the spring lock coupling.
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2.
WARNING: Make sure the garter spring snaps over the male end of the spring lock coupling.
Connect the spring lock coupling.
3. Check the spring lock coupling to make sure it is correctly connected.
4. Install the safety clip to the spring lock coupling.

Description and operations
Fuel System - VIN Range: G00442-

>G45703
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1 — Inertia fuel shutoff (IFS) switch
2 — Fuel filter
3 — Right-hand side fuel pump module
4 — Fuel tank
5 — Fuel tank filler pipe
6 — Left-hand side fuel pump module

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1 — Inertia fuel shutoff (IFS) switch
2 — Fuel filter
3 — Fuel pump module
4 — Fuel tank
6 — Fuel transfer pump
The electronic returnless fuel system utilized has the following advantages:
reduced fuel tank vapor generation
requires less electrical power
does not require a fuel return line
The intelligence of this system is contained within the Engine control module (ECM).
The ECM determines the required fuel flow and communicates this information to the rear electronic
module (REM). The REM has the fuel pump driver functions fully integrated into the microprocessor.
The fuel pump relay is activated by the ECM power relay and provides a fused power supply to the
REM. The ECM and the REM calculate the frequency and determine the current required by the fuel
pump to maintain the correct fuel pressure at the fuel injectors.
The fuel tank is of a saddle design which incorporates a pump/sender unit in both sides of the tank
on vehicles with superchargers. On vehicles without superchargers, the right-hand side houses the
fuel pump module and the left-hand side houses the fuel transfer pump. The fuel pump cross over
lines are internal to the fuel tank to reduce potential leak paths.
Fuel is supplied at high pressure to the injectors via a fuel rail which incorporates a fuel pressure and
a fuel temperature sensor. The ECM increases the fuel pressure to minimize fuel vapor formation to
maintain fuel flow across the injectors. An inertia type fuel shutoff switch will cut power to the fuel
pump in the event of an accident.
Fuel System - VIN Range: G45704-
>G99999
Vehicles without Diesel engine
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1 — Inertia fuel shut-off (IFS) switch
2 — Fuel filter
4 — Fuel tank
6 — Fuel transfer pump
The electronic returnless fuel system utilized has the following advantages:
reduced fuel tank vapor generation
requires less electrical power
does not require a fuel return line.
The intelligence of this system is contained within the engine control module (ECM).
The ECM determines the required fuel flow and communicates this information to the rear electronic
module (REM). The REM has the fuel pump driver functions fully integrated into the microprocessor.
The fuel pump relay is activated by the ECM power relay and provides a fused power supply to the
REM. The ECM and the REM calculate the frequency and determine the current required by the fuel
pump to maintain the correct fuel pressure at the fuel injectors.
The fuel tank is of a saddle design which incorporates a fuel pump module on the right-hand side and
a fuel transfer module on the left-hand side. The fuel pump crossover lines are internal to the fuel
tank to reduce potential leak paths.
Fuel is supplied at high pressure to the injectors through a fuel rail which incorporates a fuel pressure
and a fuel temperature sensor. The ECM increases the fuel pressure to minimize fuel vapor formation
to maintain fuel flow across the injectors. An inertia type fuel shut-off switch will cut power to the
fuel pump in the event of an accident.
Vehicles with Diesel Engine
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3 — Fuel level sensor
4 — Fuel tank
5 — Fuel filter
6 — Inertia fuel shut-off (IFS) switch
7 — Fuel Cooler
Fuel System - Vehicles with Diesel Engine

The diesel fuel is drawn from the fuel tank by an internal electric lift pump which is supplied with
battery voltage from the fuel pump relay located in the rear power distribution box. The fuel pump
relay is controlled by the ECM. The fuel pump provides a low pressure diesel fuel supply to the
transfer pump incorporated in to the fuel injection pump. The fuel metering valve (FMV) governs the
amount of fuel supplied to the fuel injection pump. The fuel injection pump has a fuel return circuit
to the fuel filter, which is independent of the injector return pipes.
The fuel tank is of a saddle design which incorporates a fuel pump module and fuel level sensor in
the right-hand side and a fuel level sensor module in the left-hand side of the tank. The fuel pump
crossover lines are internal to the fuel tank to reduce potential leak paths. The signals from the fuel
level sensors are used both for the fuel gauge and the run dry prevention strategy within the ECM.
The driver will always be aware of the risk of running out of fuel as the fuel gauge will show empty
and the fuel warning lamp will be illuminated. In order to protect the fuel lift pump and fuel injection
pump and to prevent the need for fuel priming after the vehicle has run out of fuel, the ECM will
instigate the run dry prevention strategy prior to the fuel tank becoming completely empty. In order
to recognize the fuel tank becoming empty, a low level switch is incorporated in to the fuel tank swirl
pot. The signal from this switch, together with the signal from two fuel level sensors is relayed to the
ECM, through the controller area network (CAN) bus.
Before a run dry event occurs the ECM will take a series of actions to inform the driver of the low fuel
level in the fuel tank.
Fuel remaining in fuel Approximate distance Action

tank remaining*
Low Fuel warning lamp illuminated in

9·4 L 112 Km (70 Miles)
instrument cluster
Fuel gauge reads Empty; RANGE display reads

5·2 L 48 Km (30 Miles)
0 Km (0 Miles)
3·9 L 28 Km (18 Miles) ECM simulates engine misfire
3·7 L 25 Km (16 Miles) Engine is stopped but restarts with misfire

2·0 L 0 Km (0 Miles) Engine stops and will not restart
* Dependant on average fuel consumption
If, when the ignition key is turned to the ON position, the run dry event is still detected, this would
indicate that either no, or insufficient, fuel has been added to the fuel tank, or that the vehicle may
be parked on a slope. In this instance the fuel pump will run to fill the swirl pot and cover the low fuel
level switch. The ECM will not prevent the engine from cranking, but it will inhibit fuel injection. If,
after a delay, a run dry event is still detected, the fuel pump will be inhibited for the rest of the
ignition cycle. As soon as a run dry event is no longer detected normal starting can resume.
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310-01 : Fuel Tank and Lines
Specifications
Specifications

Engine compartment brace bar retaining bolt 25 18 -
Fuel tank support strap retaining bolts 35 26 -
Fuel pump module locking ring 60 44 -
Fuel transfer pump locking ring 60 44 -
Fuel transfer unit locking ring 60 44 -
Fuel filter support bracket retaining bolts - Vehicles without diesel engines 10 - 89
Fuel filter support bracket retaining bolt - Vehicles with diesel engines 5 - 44
Fuel filter connection to pipe 30 22 -
Fuel filler pipe retaining bolts 5 - 44
Fuel filler pipe retaining nut 4 - 35
Fuel filler hose worm drive 2 - 18
Fuel Tank and Lines - VIN Range: G00442-

>G45703
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1 Fuel pump module
2 Fuel transfer pump
3 Fuel tank
1 — Right-hand fuel pump module
2 — Left-hand fuel pump module
3 — Fuel tank
Fuel Tank
The fuel tank is of a plastic construction and is retained to the vehicle by means of two steel support
straps. The fuel tank support straps are mounted onto the underside of the vehicle chassis towards
the front of the fuel tank and bolt to the vehicle towards the rear of the fuel tank. Fuel tank
ventilation is achieved through a fuel tank roll-over valve into an evaporative emission canister which
absorbs fuel tank vapor. The fuel tank roll-over valve is integral to the fuel tank and will prevent fuel
loss from the fuel tank if the vehicle becomes inverted.
Fuel Filter
The fuel filter is of a conventional construction being that of a paper element sealed within a steel
canister. The fuel filter is located on the left-hand front longitudinal member, under the left-hand
splash shield.
Fuel Tank Filler Pipe

The fuel tank filler pipe is of steel construction and is retained to the vehicle by means of two lower
retaining bolts and one upper retaining nut. The fuel tank filler pipe is fitted with a twist-fit filler cap,
which seals the system.
Inertia Fuel Shutoff (IFS) Switch

The inertia fuel shutoff (IFS) switch is designed to cut power to the fuel pump in the event of an
accident. It is located behind the left-hand cowl side trim panel.
Fuel Pumps
The fuel pumps are electric turbine type pumps and are located inside the fuel tank, one on the left-
hand side and one on the right-hand side on supercharged vehicles. They both feature an integral
fuel tank sender unit and each is retained to the fuel tank by means of a locking ring.
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As the fuel tank is of a saddle design, a fuel pump module and a fuel transfer pump are incorporated.
The fuel pump module located in the right-hand side of the fuel tank transfers fuel to the left-hand
side of the fuel tank. The fuel transfer pump located in the left-hand side of the fuel tank transfers
fuel to the fuel pump module and then the engine.

Both pumps continually transfer fuel from one side of the tank to the other, whilst also providing a
fuel supply to the engine.
Fuel Tank and Lines - VIN Range: G45704-
>G99999
Vehicles without Diesel Engine
1 Fuel tank filler pipe
2 Fuel transfer module
3 Fuel tank
4 Fuel pump module

Vehicles with Diesel Engine
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1 Auxiliary heater fuel supply pump
2 Fuel tank ventilation filter
3 Left-hand fuel level sensor module
4 Fuel tank

Jaguar X 350 Workshop Manual

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Workshop Manual

VIN G00442 to VIN H99999

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

204-00 : Suspension System - General Information

Wheel Bearing Inspection

204-01 : Front Suspension

204-02 : Rear Suspension

204-04 : Wheels and Tires

204-05 : Vehicle Dynamic Suspension

Diagnosis and Testing

205-00 : Driveline System - General Information

205-02 : Rear Drive Axle/Differential

206 : Brake System

206-00 : Brake System - General Information

206-03 : Front Disc Brake

206-04 : Rear Disc Brake

206-05 : Parking Brake and Actuation

206-06 : Hydraulic Brake Actuation

206-07 : Power Brake Actuation

Steering Wheel Rotation Sensor (86.56.58)

211 : Steering System

211-00 : Steering System - General Information

211-03 : Steering Linkage

211-04 : Steering Column

211-05 : Steering Column Switches

Description and Operation

Diagnosis and Testing

303-00 : Engine System - General Information

303-01B : Engine - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 - AJV8

Cylinder Head (12.29.22)

303-01C : Engine - 2.7L V6 - TdV6

303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L NA V6 -

303-03C : Engine Cooling - 2.7L V6 - TdV6

303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L

303-04D : Fuel Charging and Controls - Turbocharger - 2.7L V6 - TdV6

303-05 : Accessory Drive

303-06 : Starting System

303-07A : Engine Ignition - 3.0L NA V6 - AJ27

Removal and Installation

303-07B : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.5L NA V8 -

303-07C : Glow Plug System

303-08A : Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8/3.0L

303-12A : Intake Air Distribution and Filtering - 3.0L NA V6 - AJ27

303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8/4.2L SC V8 -

303-12C : Intake Air Distribution and Filtering - 2.7L V6 - TdV6

303-13 : Evaporative Emissions

303-14A : Electronic Engine Controls - 3.0L NA V6 - AJ27

Electronic Engine Controls

Fuel Rail Pressure (FRP) Sensor (18.30.98)

307 : Automatic Transmission/Transaxle

307-01 : Automatic Transmission/Transaxle

307-02 : Transmission/Transaxle Cooling

307-05 : Automatic Transmission/Transaxle External Controls