1997-2003 Jaguar XJ Series (incl. Vanden Plas) Service & Repair Manual
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Workshop Manual
1998 MY On
XJ Series
TABLE OF CONTENTS
1: General Information
100: Service Information
100‐00: General Information
Description and Operation
General Service Information
Terminology Glossary
100‐01: Identification Codes
Description and Operation
Identification Codes
100‐02: Jacking and Lifting
Description and Operation
Jacking
Safety Precautions
Vehicle Recovery
General Procedures
Using the Vehicle Jack
Using the Workshop Jack
2: Chassis
204: Suspension
204‐00: Suspension System ‐ General Information
Specification
General Procedures
Front Camber and Caster Adjustment (57.65.02)
Front Camber, Caster and Toe Adjustment (57.65.03)
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
Wheel Bearing Circlip Inspection
Wheel Bearing Inspection
204‐01: Front Suspension
Specification
Description and Operation
Front Suspension
Removal and Installation
Ball Joint (60.15.02)
Rear Lower Arm (60.35.54)
Rear Lower Arm Bushing (60.35.56)
Front Shock Absorber (60.30.04)
Spring
Spring Seat (60.20.03)
Front Stabilizer Bar (60.10.01)
Front Stabilizer Bar Bushing (60.10.04)
Front Stabilizer Bar Link (60.10.02)
Upper Arm Bushing
Front Wheel Bearing (60.25.40)
Wheel Hub
Wheel Knuckle (60.25.23)
Wheel Knuckle and Wheel Hub Assembly (60.25.38.90)
Wheel Knuckle and Wheel Hub Assembly Conversion (60.25.43)
204‐02: Rear Suspension
Specification
Description and Operation
Rear Suspension
Removal and Installation
Axle Bump Stop (64.30.15)
Rear Suspension and Axle Assembly (64.25.01)
Rear Shock Absorber (64.30.02)
Shock Absorber Lower Bushing (64.30.39)
Spring (64.20.01)
Rear Stabilizer Bar (64.35.08) ‐ 4.0L SC V8 ‐ AJ26
Rear Stabilizer Bar Bushing (64.35.18) ‐ 4.0L SC V8 ‐ AJ26
Stabilizer Bar Mounting Frame (64.25.12)
Stabilizer Bar Mounting Frame Bushing (64.25.13)
Rear Wheel Bearing (64.15.14)
Wheel Hub Seal (64.15.15)
Wheel Knuckle Bushing (64.15.24)
204‐04: Wheels and Tires
Specification
Description and Operation
Wheels and Tires
Diagnosis and Testing
Wheels and Tires
Removal and Installation
Wheel and Tire (74.20.05)
204‐05: Vehicle Dynamic Suspension
Description and Operation
Vehicle Dynamic Suspension
Diagnosis and Testing
Vehicle Dynamic Suspension
205: Driveline
205‐00: Driveline System ‐ General Information
Description and Operation
Driveline System
205‐01: Driveshaft
Specification
Description and Operation
Driveshaft
Removal and Installation
Driveshaft (47.15.01)
205‐02: Rear Drive Axle/Differential
Specification
Description and Operation
Rear Drive Axle and Differential
General Procedures
Differential Output Shaft End Float Check (51.10.24)
In‐Vehicle Repair
Axle Shaft (47.10.01)
Differential Output Shaft Bearing (51.10.22)
Drive Pinion Flange and Drive Pinion Seal (51.20.01)
Removal and Installation
Axle Assembly (51.25.13)
206: Brake System
206‐00: Brake System ‐ General Information
Specification
Description and Operation
Brake System
Diagnosis and Testing
Brake System
General Procedures
Brake System Bleeding (70.25.03) ‐ Vehicles With: Standard Brakes
Brake System Bleeding (70.25.03) ‐ Vehicles With: High Performance Brakes
Front Brake Disc Runout Check ‐ Vehicles With: Standard Brakes
Front Brake Disc Runout Check ‐ Vehicles With: High Performance Brakes
Rear Brake Disc Runout Check (70.12.36) ‐ Vehicles With: Standard Brakes
Rear Brake Disc Runout Check (70.12.36) ‐ Vehicles With: High Performance
Brakes
206‐03: Front Disc Brake
Specification
Description and Operation
Front Disc Brake
Removal and Installation
Brake Caliper (70.55.02) ‐ Vehicles With: Standard Brakes
Brake Caliper (70.55.02) ‐ Vehicles With: High Performance Brakes
Brake Disc (70.10.10) ‐ Vehicles With: Standard Brakes
Brake Disc (70.10.10) ‐ Vehicles With: High Performance Brakes
Brake Pads (70.40.02) ‐ Vehicles With: Standard Brakes
Brake Pads (70.40.02) ‐ Vehicles With: High Performance Brakes
206‐04: Rear Disc Brake
Specification
Description and Operation
Rear Disc Brake
Removal and Installation
Brake Caliper (70.55.03) (70.55.25) ‐ Vehicles With: Standard Brakes
Brake Caliper (70.55.03) (70.55.25) ‐ Vehicles With: High Performance Brakes
Brake Disc (70.10.11) ‐ Vehicles With: Standard Brakes
Brake Disc (70.10.11) ‐ Vehicles With: High Performance Brakes
Brake Pads (70.40.03) ‐ Vehicles With: Standard Brakes
Brake Pads (70.40.03) ‐ Vehicles With: High Performance Brakes
206‐05: Parking Brake and Actuation
Specification
Description and Operation
Parking Brake
General Procedures
Parking Brake Cable Adjustment (70.35.10)
Parking Brake Shoe and Lining Adjustment (70.35.37)
Removal and Installation
Parking Brake Control (70.35.08)
Parking Brake Control Shroud (76.13.63)
Parking Brake Shoes (70.40.05)
Parking Brake Warning Indicator Switch (86.65.45)
206‐06: Hydraulic Brake Actuation
Specification
Description and Operation
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)
Brake Pedal and Bracket (70.35.03)
Brake Pedal and Bracket, Brake Booster and Brake Master Cylinder (70.35.39)
206‐07: Power Brake Actuation
Specification
Description and Operation
Brake Booster
Removal and Installation
Brake Booster (70.50.17)
Brake Booster and Brake Master Cylinder (70.50.18)
206‐09: Anti‐Lock Control
Specification
Description and Operation
Anti‐Lock Control
Diagnosis and Testing
Anti‐Lock Control
Removal and Installation
Anti‐Lock Brake System (ABS) Module (70.60.02)
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU)
Rear Wheel Speed Sensor (70.60.04)
Wheel Speed Sensor Ring (70.60.25)
211: Steering System
211‐00: Steering System ‐ General Information
Specification
Description and Operation
Steering System
Diagnosis and Testing
Steering System
General Procedures
Power Steering System Filling and Bleeding
Power Steering System Flushing (57.15.08)
Power Steering System Vacuum Filling and Bleeding
Steering Gear Centralizing
211‐02: Power Steering
Specification
Description and Operation
Power Steering
Diagnosis and Testing
Power Steering
Removal and Installation
Steering Gear (57.10.01)
Steering Gear Bushing (57.10.30)
211‐03: Steering Linkage
Specification
Description and Operation
Steering Linkage
211‐04: Steering Column
Specification
Description and Operation
Steering Column
Removal and Installation
Steering Column Lower Shaft (57.40.05)
211‐05: Steering Column Switches
Specification
Description and Operation
Steering Column Switches
Removal and Installation
Steering Column Multifunction Switch (86.65.92)
3: Powertrain
303: Engine
303‐00: Engine System ‐ General Information
303‐01: Engine
Diagnosis and Testing
Engine
DTC P1392 VVT solenoid A circuit low input
DTC P1397 VVT solenoid B circuit low input
DTC P1393 VVT solenoid A circuit high input
DTC P1398 VVT solenoid B circuit high input
DTC P1396 VVT solenoid B malfunction
Pinpoint test A: P1392 (P1397) VVT solenoid circuit low input
Pinpoint test B: P1393 (P1398) VVT solenoid circuit high input
Pinpoint test C: P1396 VVT solenoid malfunction
In‐Vehicle Repair
Connecting Rod Bearings (12.17.16)
Crankshaft Front Seal Vehicles Without: Supercharger (12.21.14)
Crankshaft Front Seal Vehicles With: Supercharger (12.21.14)
Crankshaft Inner Sprocket 4.0L, Vehicles Without: Supercharger (12.65.76)
Crankshaft Inner Sprocket 3.2L (12.65.76)
Crankshaft Outer Sprocket (12.65.75)
Crankshaft Pulley Vehicles Without: Supercharger (12.21.09)
Crankshaft Pulley Vehicles With: Supercharger (12.21.09)
Crankshaft Rear Seal Vehicles Without: Supercharger (12.21.20)
Crankshaft Rear Seal Vehicles With: Supercharger (12.21.20)
Cylinder Head LH (12.29.02)
Cylinder Head RH (12.29.03)
Engine Front Cover (12.65.01)
Engine Front Cover Gasket (12.65.04)
Exhaust Camshaft LH (12.13.17)
Exhaust Camshaft RH (12.13.15)
Exhaust Camshaft Sprocket LH 4.0L, Vehicles Without: Supercharger (12.65.74)
Exhaust Camshaft Sprocket LH 3.2L/4.0L, Vehicles With: Supercharger (12.65.74)
Exhaust Camshaft Sprocket RH 4.0L, Vehicles Without: Supercharger (12.65.73)
Exhaust Camshaft Sprocket RH 3.2L/4.0L, Vehicles With: Supercharger (12.65.73)
Exhaust Manifold LH (30.15.55)
Exhaust Manifold RH (30.15.56)
Exhaust Manifold LH and RH (30.15.57)
Exhaust Manifold Gasket LH (30.15.58)
Exhaust Manifold Gasket RH (30.15.59)
Exhaust Manifold Gasket LH and RH (30.15.60)
Flexplate Vehicles Without: Supercharger (12.53.13)
Flexplate Vehicles With: Supercharger (12.53.13)
Intake Camshaft LH (12.13.16)
Intake Camshaft RH (12.13.14)
Intake Manifold (30.15.01)
Intake Manifold Gaskets (30.15.08)
Intake Manifold LH (18.50.26)
Intake Manifold RH (18.50.25)
Intake Manifold Gasket LH (18.50.28)
Intake Manifold Gasket RH (18.50.27)
Oil Pan (12.60.44)
Oil Pan Gasket (12.60.38)
Oil Pressure Switch (88.25.07)
Oil Pump Vehicles Without: Supercharger (12.60.26)
Oil Pump Vehicles With: Supercharger (12.60.26)
Primary Timing Chain LH 4.0L, Vehicles Without: Supercharger (12.65.67)
Primary Timing Chain LH 3.2L/4.0L, Vehicles With: Supercharger (12.65.67)
Primary Timing Chain RH (12.65.66)
Primary Timing Chain Inner Guide LH (12.65.58)
Primary Timing Chain Inner Guide RH (12.65.60)
Primary Timing Chain Outer Guide LH (12.65.61)
Primary Timing Chain Outer Guide RH (12.65.57)
Primary Timing Chain Tensioner LH (12.65.55)
Primary Timing Chain Tensioner RH (12.65.54)
Secondary Timing Chain LH (12.65.69)
Secondary Timing Chain RH (12.65.68)
Secondary Timing Chain Tensioner LH 4.0L, Vehicles Without: Supercharger
(12.65.64)
Secondary Timing Chain Tensioner LH 3.2L/4.0L, Vehicles With: Supercharger
(12.65.64)
Secondary Timing Chain Tensioner RH 4.0L, Vehicles Without: Supercharger
(12.65.63)
Secondary Timing Chain Tensioner RH 3.2L/4.0L, Vehicles With: Supercharger
(12.65.63)
Upper Oil Pan 3.2L (12.60.48)
Upper Oil Pan 4.0L, Vehicles Without: Supercharger (12.60.48)
Upper Oil Pan 4.0L, Vehicles With: Supercharger (12.60.48)
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