Documente Academic
Documente Profesional
Documente Cultură
XKK 8
4.0L, 4.0L S/C
TABLE OF CONTENTS
1: General 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
General Procedures
Using the Vehicle Jack
Using the Workshop Jack
Description and Operation
Jacking
Safety Precautions
Vehicle Recovery
Emergency Towing
Rear Towing Eye
2: Chassis
204‐00 Suspension System ‐ General Information
Specifications
General Procedures
Front Camber Adjustment
Description of Eccentric Bolt
Installing the Eccentric Bolt
Front Caster Adjustment
Front Camber and Caster Adjustment
Rear Toe Adjustment
Wheel Bearing Circlip Inspection
Wheel Bearing Inspection
Description and Operation
Suspension System
204‐01: Front Suspension
Specifications
Description and Operation
Front Suspension
Removal and Installation
Ball Joint (60.15.02)
Front Lower Arm and Rear Lower Arm Assembly (60.35.02)
Lower Arm Bushing (60.35.45)
Rear Lower Arm (60.35.54)
Shock Absorber and Spring Assembly (60.30.02)
Stabilizer Bar (60.10.01)
Stabilizer Bar Bushing (60.10.04)
Stabilizer Bar Link (60.10.02)
Upper Arm Bushing
Wheel Bearing (60.25.40)
Wheel Hub
Wheel Knuckle (60.25.23)
Wheel Knuckle and Wheel Hub Assembly (60.25.38.90)
Disassembly
Shock Absorber and Spring Assembly (60.30.21)
204‐02: Rear Suspension
Specifications
Description and Operation
Rear Suspension
Removal and Installation
Axle Bump Stop (64.30.15)
Rear Suspension and Axle Assembly (64.25.01)
Shock Absorber (64.30.02)
Spring (64.20.01)
Stabilizer Bar (64.35.08)
Stabilizer Bar Bushing (64.35.18)
Stabilizer Bar Link (64.35.24)
Stabilizer Bar Link Bushing (64.35.25)
Stabilizer Bar Mounting Frame Vehicles Without: Convertible Top (64.25.12)
Stabilizer Bar Mounting Frame Vehicles With: Convertible Top (64.25.12)
Stabilizer Bar Mounting Frame Bushing Vehicles Without: Convertible Top (64.25.13)
Stabilizer Bar Mounting Frame Bushing Vehicles With: Convertible Top (64.25.13)
Wheel Bearing (64.15.14)
Wheel Hub Seal (64.15.15)
Wheel Knuckle Bushing (64.15.24)
204‐04: Wheels and Tires
Specifications
Description and Operation
Wheels and Tires
Diagnosis and Testing
Wheels and Tires
General Notes
Safety Notes
Inspection and Verification
Tread Wear Indicator
Tire Vibration Diagnosis
Torque Sensitive
Vehicle Speed Sensitive
Engine Speed Sensitive
Uneven tire wear.
Tires show excess wear on edge of treads.
Tires show excess wear on edge of treads (with tire pressures correct).
Tires show excess wear in center of tread.
Wheel mounting is difficult.
Wobble or shimmy affecting wheel runout.
Vehicle vibrations from wheels and tires.
Damaged wheel stud threads.
Broken wheel studs.
Corrosion / contamination streaks from wheel stud holes.
Damaged wheel nuts.
Seized wheel nuts.
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
Refer to PDU User Guide
Basic Checks
Removal and Installation
Adaptive Damping Module (86.56.35)
205‐00: Driveline System ‐ General Information
Description and Operation
Driveline System
205‐01: Driveshaft
Specifications
Description and Operation
Driveshaft
Removal and Installation
Driveshaft (47.15.01)
205‐02: Rear Drive Axle/Differential
Specifications
General Procedures
Differential Output Shaft End Float Check
Description and Operation
Rear Drive Axle and Differential
Removal and Installation
Axle Assembly (51.25.13)
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)
206‐00: Brake System ‐ General Information
Specifications
General Procedures
Brake System Bleeding
Front Brake Disc Runout Check
Rear Brake Disc Runout Check
Description and Operation
Brake System
Diagnosis and Testing
Brake System
Inspection and Verification
Component Tests
206‐03: Front Disc Brake
Specifications
Description and Operation
Front Disc Brake
Removal and Installation
Brake Caliper (70.55.02)
Brake Disc (70.10.10)
Brake Pads (70.40.02)
206‐04: Rear Disc Brake
Specifications
Description and Operation
Rear Disc Brake
Removal and Installation
Brake Caliper (70.55.03)
Brake Disc (70.10.11)
Brake Pads (70.40.03)
206‐05: Parking Brake and Actuation
Specifications
General Procedures
Parking Brake Cable Adjustment
Parking Brake Shoe and Lining Adjustment
Description and Operation
Parking Brake
Removal and Installation
Parking Brake Control (70.35.08)
Parking Brake Control Shroud (76.13.63)
Parking Brake Front Cable (70.35.14)
Parking Brake Linkage Lever (70.35.22)
Parking Brake Linkage Lever Mounting Plate Vehicles Without: Convertible Top
(70.35.42)
Parking Brake Linkage Return Springs (70.35.41)
Parking Brake Linkage Rod (70.35.40)
Parking Brake Shoes (70.40.05)
206‐06: Hydraulic Brake Actuation
Specifications
Description and Operation
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)
Brake Pedal
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
Specifications
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
Specifications
Description and Operation
Anti‐Lock Control
Diagnosis and Testing
Anti‐Lock Control
Principle of operation
Inspection and Verification
Diagnostic Drive Cycles
Visual Inspection
Fuse Identification Table
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Removal and Installation
Anti‐Lock Brake System (ABS) Module (70.60.02)
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) (70.60.18)
Rear Wheel Speed Sensor (70.60.04)
Wheel Speed Sensor Ring (70.60.25)
Wheel Speed Sensor Ring Grease Deflector (70.60.26)
211‐00: Steering System ‐ General Information
Specifications
General Procedures
Power Steering System Filling and Bleeding
Fluid Level Indicator
Power Steering System Vacuum Filling and Bleeding
Fluid Hoses
Steering Gear Centralizing
Steering Gear Alignment Markers
Steering Wheel Centralizing
Description and Operation
Steering System
Diagnosis and Testing
Steering System
Inspection and Verification
Steering Relay Harness Connector
Steering Linkage Inspection and Backlash (Freeplay) Check
Power Steering Fluid Condition Check
Power Steering Pressure Test
Steering Fault Diagnosis by Symptom Charts
Description of General Steering System Noises
Description of Specific Steering System Noise Types
Steering System Vibrations and Harshness
Steering Linkage
211‐02: Power Steering
Specifications
Description and Operation
Power Steering
Diagnosis and Testing
Power Steering
Power Steering Pressure Test
Installing Test Equipment
Removing Test Equipment
Power Steering Control Module
Refer to PDU User Guide
Control Module Connections
Removal and Installation
Power Steering Control Valve Actuator (57.10.32)
Power Steering Fluid Cooler (57.15.11)
Power Steering Fluid Reservoir (57.15.08)
Power Steering Fluid Reservoir to Power Steering Pump Supply Hose (57.15.20)
Power Steering Pump (57.20.14)
Power Steering Pump to Steering Gear Pressure Line (57.15.29)
Steering Gear (57.10.01)
Steering Gear Bushing (57.10.30)
Steering Gear to Fluid Cooler Return Hose (57.15.30)
211‐03: Steering Linkage
Specifications
Description and Operation
Steering Linkage
211‐04: Steering Column
Specifications
Description and Operation
Steering Column
Removal and Installation
Steering Column (57.40.02)
Steering Column Control Relay (57.40.34)
Steering Column Lower Shaft (57.40.05)
Steering Wheel (57.60.01)
Tilt /Telescopic Motors (57.40.40)
211‐05: Steering Column Switches
Specifications
Description and Operation
Steering Column Switches
Direction Indicators.
Sidelamps and Dipped Headlamps.
Off Position.
Sidelamps Position.
Headlamps Position.
Headlamp Main Beam Position.
Main Beam Flash.
Message Center Function Button.
Position 'O'. Wipers Off.
Position 'I'. Intermittent Wipe.
Position 'II'. Normal Wiper Operation.
Position 'III'. High Speed Wiper Operation.
Flick Wipe.
Programmed Wash/Wipe.
Removal and Installation
Ignition Switch (86.65.03)
Steering Column Control Switch (57.40.33)
Steering Column Lock Module (86.80.36)
Steering Column Multifunction Switch (86.65.92)
Steering Column Multifunction Switch Mounting Bracket (76.46.33)
3: Powertrain
303‐00: Engine System ‐ General Information
Specifications
Description and Operation
Engine
303‐01: Engine
Specifications
General Procedures
Valve Clearance Adjustment
Valve Clearance Check
Description and Operation
Engine
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 (12.65.76)
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)
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 Vehicles Without: Supercharger (12.65.74)
Exhaust Camshaft Sprocket LH Vehicles With: Supercharger (12.65.74)
Exhaust Camshaft Sprocket RH Vehicles Without: Supercharger (12.65.73)
Exhaust Camshaft Sprocket RH Vehicles With: Supercharger (12.65.73)
Exhaust Manifold LH (30.15.55)
Exhaust Manifold RH (30.15.56)
Flexplate Vehicles Without: Supercharger (12.53.13)
Flexplate Vehicles With: Supercharger (12.53.13)
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 (12.65.67)
Primary Timing Chain RH (12.65.66)
Secondary Timing Chain LH (12.65.69)
Secondary Timing Chain RH (12.65.68)
Secondary Timing Chain Tensioner LH (12.65.64)
Secondary Timing Chain Tensioner RH (12.65.63)
Upper Oil Pan Vehicles Without: Supercharger (12.60.48)
Upper Oil Pan Vehicles With: Supercharger (12.60.48)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
303‐03A: Engine Cooling
General Procedures
Cooling System Draining, Filling and Bleeding Vehicles Without: Supercharger
Drain
Refill
Cooling System Draining, Filling and Bleeding Vehicles With: Supercharger
Drain
Refill
Removal and Installation
Coolant Expansion Tank Vehicles Without: Supercharger (26.15.01)
Coolant Expansion Tank Vehicles With: Supercharger (26.15.01)
Coolant Outlet Pipe (26.31.08)
Cooling Fan Motor (26.25.24)
Cooling Fan Motor and Shroud (26.25.25)
Degas Bottle (26.15.03)
Engine Coolant Level Switch (26.40.11)
Radiator Vehicles Without: Supercharger (26.40.01)
Radiator Vehicles With: Supercharger (26.40.01)
Radiator Lower Hose (26.30.07)
Radiator Upper Hose (26.30.01)
Thermostat Vehicles Without: Supercharger (26.45.07)
Thermostat Vehicles With: Supercharger (26.45.07)
Thermostat Housing Cover (26.45.22)
Thermostat Housing Cover Seal (26.45.20)
Water Pump Vehicles Without: Supercharger (26.50.01)
Water Pump Vehicles With: Supercharger (26.50.01)
Water Pump Pulley Vehicles Without: Supercharger (26.50.05)
Water Pump Pulley Vehicles With: Supercharger (26.50.05)
303‐03B: Supercharger Cooling
Removal and Installation
Water Pump
303‐04: Fuel Charging and Controls
Specifications
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) index
Pinpoint Tests
Removal and Installation
Fuel Injection Supply Manifold Vehicles Without: Supercharger (19.60.13)
Fuel Injection Supply Manifold LH Vehicles With: Supercharger (19.60.05)
Fuel Injection Supply Manifold RH Vehicles With: Supercharger (19.60.04)
Fuel Injector Vehicles Without: Supercharger (18.10.01)
Fuel Injector Vehicles With: Supercharger (18.10.01)
Fuel Injectors Vehicles With: Supercharger (18.10.02)
Throttle Body Vehicles Without: Supercharger (19.70.04)
Throttle Body Vehicles With: Supercharger (19.70.04)
303‐05: Accessory Drive
Description and Operation
Accessory Drive
Crankshaft Pulley
Idler Pulley
Coolant Pump Drive
Power Assisted Steering Pump Drive
Air Conditioning Compressor Drive
Generator Drive
Removal and Installation
Accessory Drive Belt (12.10.40)
Accessory Drive Belt Idler Pulley (12.10.43)
Accessory Drive Belt Tensioner (12.10.41)
Accessory Drive Belt Tensioner Pulley (12.10.42)
Supercharger Belt (18.50.08)
Supercharger Belt Idler Pulley (18.50.09)
Supercharger Belt Tensioner (18.50.24)
303‐06: Starting System
Description and Operation
Starting System
Ignition Switch to ON Position
Ignition Switch at CRANK Position
Diagnosis and Testing
Starting System Vehicles With: Supercharger
Inspection and Verification
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Starting System Vehicles Without: Supercharger
Verification and Inspection
Symptom Chart
Diagnostic Trouble Code (DTC) index
Pinpoint Tests
Removal and Installation
Starter Motor (86.60.01)
303‐07: Engine Ignition
Specifications
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition Vehicles With: Supercharger
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) index
Pinpoint Tests
Engine Ignition Vehicles Without: Supercharger
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Removal and Installation
Ignition Coil‐On‐Plug LH (18.20.44)
Ignition Coil‐On‐Plug RH (18.20.43)
Spark Plugs (18.20.02)
303‐08: Engine Emission Control
Diagnosis and Testing
Engine Emission Control Vehicles Without: Supercharger
Inspection and Verification
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Engine Emission Control Vehicles With: Supercharger
Inspection and Verification
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
303‐12: Intake Air Distribution and Filtering
Removal and Installation
Charge Air Cooler LH (18.50.19)
Charge Air Cooler RH (18.50.18)
Charge Air Cooler Gasket LH (18.50.22)
Charge Air Cooler Gasket RH (18.50.21)
Supercharger (18.50.15)
Supercharger Outlet Pipe (18.50.16)
Supercharger Outlet Pipe Gasket (18.50.17)
Throttle Body Elbow (19.70.28)
Throttle Body Elbow Gasket (19.70.29)
303‐13: Evaporative Emissions
Description and Operation
Evaporative Emissions
Evaporative Emissions Canister Purge Valve
Canister Purge Operation
Vehicles With On‐board Refueling Vapor Recovery.
Operation Of On‐board Refueling Vapor Recovery
Fuel Vapor Vent Valve Housing ‐ Vehicles With On‐Board Refueling Vapor
Recovery
Fuel Vapor Vent Valve Housing ‐ Vehicles Without On‐board Refueling Vapor
Recovery
Diagnosis and Testing
Evaporative Emissions
Preliminary Inspection
Diagnostic Drive Cycles
Diagnostic Trouble Code (DTC) index/Symptom Chart
Pinpoint Tests
Removal and Installation
Evaporative Emission Canister (17.15.13)
Evaporative Emission Canister Purge Valve (17.15.30)
Fuel Vapor Vent Valve Housing (19.55.24)
303‐14: Electronic Engine Controls
Specifications
General Procedures
Engine Control Module (ECM) Adaptation Vehicles Without: Supercharger
When to carry out adaptations
DTCs P1000/P1111
Conditions for adaptation
Fuelling Adaptations Drive Cycle
Diagnostic Monitor Completion
Entry Conditions
Drive Cycle for 40 thou leak test
Drive Cycle for 20 thou leak test (2001 my on only)
Description and Operation
Electronic Engine Controls
Engine Sensors
Electronic Engine Control
Throttle Position (TP) Sensor
Camshaft Position (CMP) Sensor
Crankshaft Position (CKP) Sensor
Engine Coolant Temperature (ECT) Sensor
Knock Sensor (KS)
Heated Oxygen Sensor (HO2S)
Catalyst monitor sensor
Variable Camshaft Timing Oil Control Solenoid ‐ Vehicles Without Supercharger.
Mass Air Flow (MAF) Sensor
Diagnosis and Testing
Electronic Engine Controls Vehicles Without: Supercharger
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Electronic Engine Controls Vehicles With: Supercharger
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Removal and Installation
Camshaft Position (CMP) Sensor LH Vehicles Without: Supercharger (18.31.12)
Camshaft Position (CMP) Sensor LH Vehicles With: Supercharger (18.31.12)
Camshaft Position (CMP) Sensor RH Vehicles Without: Supercharger (18.31.11)
Camshaft Position (CMP) Sensor RH Vehicles With: Supercharger (18.31.11)
Catalyst Monitor Sensor LH (18.30.81)
Catalyst Monitor Sensor RH (18.30.80)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Heated Oxygen Sensor (HO2S) LH (18.30.79)
Heated Oxygen Sensor (HO2S) RH (18.30.78)
Intake Air Temperature (IAT) Sensor (18.30.52)
Knock Sensor (KS) LH Vehicles Without: Supercharger (18.30.92)
Knock Sensor (KS) LH Vehicles With: Supercharger (18.30.92)
Knock Sensor (KS) RH Vehicles Without: Supercharger (18.30.93)
Knock Sensor (KS) RH Vehicles With: Supercharger (18.30.93)
Mass Air Flow (MAF) Sensor (18.30.15)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
307‐01A: Automatic Transmission/Transaxle ‐ Vehicles Without: Supercharger
Specifications
General Procedures
Transmission Fluid Drain and Refill
Removal
Installation
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostic Strategy
Normal transmission operation but fault codes stored
Sport mode will not select
Mode switch state lamp not working
Poor, or reduced shift quality
Out of sequence shift
No torque converter lock‐up
Harsh shifts, engine stalling (torque converter stuck on)
Default to 4th gear
Default to 5th gear
Removal
Transmission ‐ Removal (44.20.01)
Installation
Transmission ‐ Installation (44.20.01)
In Vehicle Repair
Electronic Pressure Control (EPC) Solenoid (44.15.51)
Extension Housing Seal (44.20.18)
Extension Housing O‐Ring Seal (44.20.19)
Main Control Valve Body (44.40.01)
Output Shaft Speed (OSS) Sensor (44.15.41)
Shift Solenoids (SS) (44.15.50)
Transmission Control Module (TCM) (44.15.32)
Transmission Fluid Filter (44.24.07)
Transmission Fluid Pan (44.24.04)
Transmission Fluid Pan Gasket (44.24.05)
Transmission Internal Wiring Harness (44.15.35)
Transmission Internal Wiring Harness Electrical Connector O‐Ring Seals (44.24.20)
Transmission Range (TR) Sensor
Turbine Shaft Speed (TSS) Sensor (44.15.40)
Disassembly/Assembly of subassemblies
Input Shaft Seal (44.32.07)
Torque Converter (44.17.07)
307‐01B: Automatic Transmission/Transaxle ‐ Vehicles With: Supercharger
Specifications
General Procedures
Transmission Fluid Drain and Refill
Removal
Transmission ‐ Removal (44.20.01)
Installation
Transmission ‐ Installation (44.20.01)
In Vehicle Repair
Extension Housing Seal (44.20.18)
Main Control Valve Body (44.40.01)
Transmission Fluid Filter (44.24.07)
Transmission Fluid Pan Gasket (44.24.05)
Transmission Internal Wiring Harness Electrical Connector O‐Ring Seals (44.24.20)
Disassembly/Assembly of subassemblies
Input Shaft Seal (44.32.07)
Torque Converter (44.17.07)
307‐02A: Transmission/Transaxle Cooling ‐ Vehicles Without: Supercharger
Description and Operation
Transmission Cooling
307‐02B: Transmission/Transaxle Cooling ‐ Vehicles With: Supercharger
Description and Operation
Transmission Cooling
307‐05A: Automatic Transmission/Transaxle External Controls ‐ Vehicles Without:
Supercharger
General Procedures
Brake Shift Interlock Actuator Adjustment
Brake Shift Interlock Actuator Manual Override
Kickdown Switch Adjustment
Selector Lever Cable Adjustment
Description and Operation
External Controls
Diagnosis and Testing
External Controls
DTC P0706 Transmission range sensor circuit range / performance
Pinpoint test A: P0706
Removal and Installation
Brake Shift Interlock Actuator (44.15.48)
Kickdown Switch (44.15.23)
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Gate Finish Panel (76.25.24)
Selector Lever Indicator Assembly (44.15.14)
Selector Lever Indicator Disc (44.15.15)
Selector Lever Switch (44.15.52)
Transmission Selector Lever Knob (44.15.06)
Disassembly
Selector Lever (44.15.05)
307‐05B: Automatic Transmission/Transaxle External Controls ‐ Vehicles With:
Supercharger
General Procedures
Brake Shift Interlock Actuator Manual Override
Kickdown Switch Adjustment
Selector Lever Cable Adjustment
Description and Operation
External Controls
Diagnosis and Testing
External Controls
Shift stuck in P
Vehicle rolls on P
R does not engage
N not achieved
D does not engage
Lower ratios will not hold
Shift lever position not visually correct
Shift lever has no effect upon the transmission and resistance cannot be felt
Shift lever position not align correctly following manual selection of lower ratios
Shift lever detent indistinct in 3 causing poor location
Shift may be moved from P without brake pedal operation
Engine may be started in positions other than P or N
Shift lever vibration
Noise / rattle from 'J' gate
Removal and Installation
Brake Shift Interlock Actuator (44.15.48)
Kickdown Switch (44.15.23)
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Gate Finish Panel (76.25.24)
Selector Lever Indicator Disc (44.15.15)
Transmission Control Switch (44.15.12)
Transmission Selector Lever Knob (44.15.06)
309‐00: Exhaust System
Specifications
Description and Operation
Exhaust System
Monitoring Procedure
Heater Resistance Check
Performance Check
Diagnosis and Testing
Exhaust System
DTC P0420 Catalyst system efficiency below threshold (Bank 1)
DTC P0430 Catalyst system efficiency below threshold (Bank 2)
DTC P0131 O2 sensor circuit low voltage (Bank 1 sensor 1)
DTC P0132 O2 sensor circuit high voltage (Bank 1 sensor 1)
DTC P0133 O2 sensor circuit slow response (Bank 1 sensor 1)
DTC P0135 O2 sensor heater circuit malfunction (Bank 1 sensor 1)
DTC P0137 O2 sensor circuit low voltage (Bank 1 sensor 2)
DTC P0138 O2 sensor circuit high voltage (Bank 1 sensor 2)
DTC P0140 O2 sensor circuit no activity detected (Bank 1 sensor 2)
DTC P0151 O2 sensor circuit low voltage (Bank 2 sensor 1)
DTC P0152 O2 sensor circuit high voltage (Bank 2 sensor 1)
DTC P0153 O2 sensor circuit slow response (Bank 2 sensor 1)
DTC P0155 O2 sensor heater circuit malfunction (Bank 2 sensor 1)
DTC P0157 O2 sensor circuit low voltage (Bank 2 sensor 2)
DTC P0158 O2 sensor circuit high voltage (Bank 2 sensor 2)
DTC P0160 O2 sensor circuit no activity detected (Bank 2 sensor 2)
DTC P0430 Catalyst system efficiency below threshold (bank 2)
Pinpoint test A: P0131, P0132, P0135
Pinpoint test B: P0133
Pinpoint test C: P0137, P0138
Pinpoint test D: P0140
Pinpoint test E: P0151, P0152, P0155
Pinpoint test F: P0153
Pinpoint test G: P0157, P0158
Pinpoint test H: P0160
Removal and Installation
Catalytic Converter LH Vehicles Without: Supercharger (17.50.15)
Catalytic Converter LH Vehicles With: Supercharger (17.50.15)
Catalytic Converter RH Vehicles Without: Supercharger (17.50.16)
Catalytic Converter RH Vehicles With: Supercharger (17.50.16)
Catalytic Converter Gasket LH Vehicles Without: Supercharger (17.50.06)
Catalytic Converter Gasket LH Vehicles With: Supercharger (17.50.06)
Catalytic Converter Gasket RH Vehicles Without: Supercharger (17.50.07)
Catalytic Converter Gasket RH Vehicles With: Supercharger (17.50.07)
Front Muffler Vehicles Without: Supercharger (30.10.18)
Front Muffler Vehicles With: Supercharger (30.10.18)
Intermediate Muffler LH (30.10.15)
Intermediate Muffler RH (30.10.16)
Muffler and Tailpipe LH (30.10.22)
Muffler and Tailpipe RH (30.10.52)
310‐00: Fuel System ‐ General Information
General Procedures
Fuel System Pressure Check
Fuel System Pressure Release
All vehicles
Vehicles with supercharger
Vehicles without supercharger
All vehicles
Vehicles without supercharger
Vehicles with supercharger
All vehicles
Description and Operation
Fuel System
310‐01: Fuel Tank and Lines
Description and Operation
Fuel Tank and Lines
Filler Cap and Pipe
Check Valve
Purge Valve
Fuel Lines
Fuel Filter
Fuel Pump
Fuel‐Gauge Sender Unit
Fuel Valves
Fuel Cut-off Inertia Switch
Fuel Tank Earth Strap
Fuel Pump Relay
Monitoring Procedure
Access to Luggage Compartment Components
Removal and Installation
Fuel Filter (19.25.02)
Fuel Level Sensor (88.25.32)
Fuel Pump (19.45.08)
Fuel Pump Relay (19.22.39)
Fuel Tank (19.55.01)
Fuel Tank Access Panel (76.11.32.90)
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
310‐02: Acceleration Control
General Procedures
Accelerator Cable Adjustment
Removal and Installation
Accelerator Cable (19.20.06)
310‐03: Speed Control
Description and Operation
Speed Control
Diagnosis and Testing
Speed Control
Principles of operation
Inspection and Verification
Diagnostic Trouble Code (DTC) index
Pinpoint tests
4: Electrical
412‐00: Climate Control System ‐ General Information
Specifications
General Procedures
Air Conditioning (A/C) System Check ‐ Retail Procedure
Evacuating the Manifold Gauge Set
Connecting the Manifold Gauge Set
Stabilizing the System
Air Conditioning (A/C) System Recovery, Evacuation and Charging
Recover / Reclaim
Evacuation
Charging
Contaminated Refrigerant Handling
Manifold Gauge Set Connection
Parts List
Manifold.
Low Side Pressure Gauge.
High Side Pressure Gauge.
Refrigerant Adding
Refrigerant Oil Adding
Original Compressor
New Compressor
System Components
Refrigerant System Tests
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
Introduction
Functional Check
System symptoms
No cooling
Insufficient cooling
Intermittent cooling
Noisy system
Insufficient heating
412‐01: Air Distribution and Filtering
Description and Operation
Air Distribution and Filtering
Diagnosis and Testing
Air Distribution and Filtering
Removal and Installation
Center Registers (82.20.38)
Driver Side Blower Motor (82.25.56)
Passenger Side Blower Motor (82.25.55)
Pollen Filter (76.10.09)
412‐01: Heating and Ventilation
Description and Operation
Heating and Ventilation
Diagnosis and Testing
Heating and Ventilation
Removal and Installation
Heater Core (80.20.29)
Heater Core and Evaporator Core Housing (82.25.21)
412‐03: Air Conditioning
Description and Operation
Air Conditioning
Diagnosis and Testing
Air Conditioning
Removal and Installation
Air Conditioning (A/C) Compressor (82.10.20)
Condenser Core (82.15.07)
Evaporator Core (82.25.20)
Receiver Drier (82.17.01)
412‐04: Control Components
Description and Operation
Control Components
Diagnosis and Testing
Control Components
Connector Pins Identification
Connector Pin Identity Chart for AC002
Connector Pin Identity Chart for AC003
Connector Pin Identity Chart for AC004
Connector Pin Identity Chart for FC043
Control Panel Communication
Control Panel Inputs / Outputs
A/CCM Connections
System Self‐test
Fault Code Extraction and Deletion Procedure
0 Normal operation no fault codes present
11 Motorized in‐car aspirator malfunction
12 Ambient temperature sensor malfunction
13 Evaporator temperature sensor malfunction
14 Water temperature input malfunction
15 Heater matrix temperature sensor malfunction
21 Solar sensor
22 Compressor lock signal fault
23 Refrigerant pressure switch malfunction
23 Refrigerant pressure low refrigerant charge *
24 Face vent demand potentiometer fault
31 LH fresh / recirc. potentiometer fault
32 RH fresh / recirc. potentiometer fault
33 Cool air by‐pass potentiometer fault
34 Defrost vent potentiometer fault
35 Centre vent potentiometer fault
36 Foot vent potentiometer fault
41 LH fresh / recirc. motor fault
42 RH fresh / recirc. motor fault
43 Cool air by‐pass motor fault
43 Cool Air by‐pass motor fault
44 Defrost vent motor fault
45 Centre vent motor fault
46 Foot vent motor fault
Associated Faults
Panel Communication Check
Actuator Check Procedure
Actuator Fault Codes
Removal and Installation
Air Discharge Temperature Sensor (82.20.64)
Climate Control Assembly (82.20.07)
Cold Air Bypass Blend Door Actuator (82.20.86)
Defrost Vent/Register Blend Door Actuator (82.20.84)
Footwell Vent/Duct Blend Door Actuator (82.20.85)
Instrument Panel Blend Door Actuator (82.20.83)
413‐00: Instrument Cluster and Panel Illumination
Description and Operation
Instrument Cluster and Panel Illumination
Removal and Installation
High Beam Indicator Bulb (86.45.65)
Instrument Cluster Bulb (86.46.22)
Instrument Panel Console Instrument Cluster Bulb (86.46.21)
413‐01: Instrument Cluster
Description and Operation
Instrument Cluster
Diagnosis and Testing
Instrument Cluster
Tests Using the Portable Diagnostic Unit
Replaceable Parts
Removal and Installation
Instrument Cluster (88.20.01)
Instrument Cluster Lens (88.20.28)
Instrument Panel Console Instrument Cluster (88.20.29)
Instrument Panel Console Instrument Cluster Lens (88.20.32)
413‐06: Horn
Description and Operation
Horn
Diagnosis and Testing
Horn
Tests Using the Portable Diagnostic Unit
Removal and Installation
Horn (86.30.02)
413‐07: Clock
Description and Operation
Clock
Diagnosis and Testing
Clock
Tests Using the Portable Diagnostic Unit
413‐08: Information and Message Center
Description and Operation
Information and Message Center
Diagnosis and Testing
Information and Message Center
Tests Using the Portable Diagnostic Unit
414‐00: Charging System ‐ General Information
Description and Operation
Charging System
414‐01: Battery, Mounting and Cables
General Procedures
Battery Connect
Description and Operation
Battery and Cables
Removal and Installation
Battery (86.15.01)
Battery Ground Cable (86.15.19)
Battery Positive Cable (86.15.17)
Battery Retaining Bracket (86.15.12)
414‐02: Generator and Regulator
Description and Operation
Generator
Features
Diagnosis and Testing
Generator
Refer to PDU User Guide
Inspection and Verification
Testing the Battery Circuit
Using a Substitute Battery
Checking Generator Connections
Multiplug Connector
Removal and Installation
Generator (86.10.02)
Voltage Regulator (86.10.28)
415‐01: Audio Unit
Description and Operation
Audio System
Diagnosis and Testing
Audio System
Tests Using the Portable Diagnostic Unit
Removal and Installation
Audio Unit (86.50.03)
Audio Unit Amplifier (86.50.10)
Capacitor (86.10.33)
Compact Disc (CD) Changer (86.50.06)
415‐02: Antenna
Description and Operation
Antenna
Diagnosis and Testing
Antenna
Tests Using the Portable Diagnostic Unit
Removal and Installation
Antenna
Antenna Motor (86.50.21)
415‐03: Speakers
Description and Operation
Speakers
Speaker Location ‐ Convertible
Diagnosis and Testing
Speakers
Tests Using the Portable Diagnostic Unit
Removal and Installation
Door Speaker (86.50.13)
Instrument Panel Tweeter Speaker (86.51.02)
Instrument Panel Tweeter Speaker Grille (86.51.04)
Quarter Panel Speaker Vehicles Without: Convertible Top (86.50.12)
Quarter Panel Speaker Vehicles With: Convertible Top (86.50.12)
Quarter Panel Speaker Grille Vehicles Without: Convertible Top (76.13.70)
Subwoofer Speaker Vehicles Without: Convertible Top (86.51.05)
Subwoofer Speaker Grille (76.13.72)
417‐01: Exterior Lighting
Specifications
Description and Operation
Exterior Lighting
Diagnosis and Testing
Exterior Lighting
Tests Using the Portable Diagnostic Unit
Removal and Installation
Brake Pedal Position (BPP) Switch
Front Fog Lamp (86.40.96)
Front Fog Lamp Bulb (86.40.94)
Front Side Marker Lamp (86.40.59)
Front Side Marker Lamp Bulb (86.40.58)
Front Turn Signal Lamp Bulb (86.40.41)
Headlamp Assembly LH (86.41.33)
Headlamp Assembly RH (86.41.36)
Headlamp Lens (86.41.39)
Headlamp Leveling Motor LH (86.42.09)
Headlamp Leveling Motor RH (86.42.10)
High Beam Headlamp Bulb (86.40.12)
High Mounted Stoplamp Vehicles With: Convertible Top (86.41.01)
License Plate Lamp (86.40.86)
License Plate Lamp Bulb (86.40.85)
Low Beam Headlamp Bulb (86.40.08)
Rear Lamp Assembly (86.41.46)
Rear Lamp Assembly Bulb (86.40.73)
Rear Side Marker Lamp (86.41.08)
Rear Side Marker Lamp Bulb (86.41.07)
Side Lamp Bulb (86.40.27)
Side Turn Signal Lamp Bulb (86.41.42)
Side Turn Signal Lamp LH (86.40.54)
Side Turn Signal Lamp RH (86.40.53)
417‐02: Interior Lighting
Specifications
Description and Operation
Interior Lighting
Diagnosis and Testing
Interior Lighting
Tests Using the Portable Diagnostic Unit
Removal and Installation
Door Courtesy Lamp (86.40.38)
Door Courtesy Lamp Bulb (86.40.47)
Door Lock Control Switch Bulb (86.46.23)
Footwell Lamp (86.46.20)
Footwell Lamp Bulb (86.46.24)
Front Interior Lamp (86.45.12)
Glove Compartment Lamp (86.45.08)
Glove Compartment Lamp Bulb (86.45.07)
Luggage Compartment Lamp (86.45.16)
Luggage Compartment Lamp Bulb (86.45.15)
Map Reading Lamp Bulb (86.45.09)
Rear Interior Lamp Bulb Vehicles Without: Convertible Top (86.45.06)
Vanity Mirror Lamp (76.10.50)
Vanity Mirror Lamp Bulb (86.45.95)
417‐04: Daytime Running Lamps (DRL)
Description and Operation
Daytime Running Lamps (DRL)
Diagnosis and Testing
Daytime Running Lamps (DRL)
Tests Using the Portable Diagnostic Unit
418‐00: Module Communications Network
Description and Operation
Communications Network
Diagnosis and Testing
Communications Network
Principles of Operation
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) index
Power Supply/Ground test index
Pinpoint tests
Removal and Installation
Auxiliary Junction Box (86.70.55)
Battery Junction Box (BJB) (86.70.69)
Central Junction Box (CJB) LH (86.70.57)
Central Junction Box (CJB) RH (86.70.56)
419‐07: Navigation System
Description and Operation
Navigation System
Removal and Installation
Navigation System Antenna (86.62.06)
Navigation System Compact Disc (CD) Unit (86.62.05)
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05)
419‐01: Multifunction Electronic Modules
Removal and Installation
Driver Door Module (DDM) (86.80.29)
Driver Seat Module (DSM) (86.75.28)
Multifunction Electronic Module (86.80.31)
Passenger Door Module (PDM) (86.80.30)
Passenger Seat Module (PSM) (86.75.16)
5: Body and Paint
501‐00: Body System ‐ General Information
Description and Operation
Body
501‐02: Front End Body Panels
Specifications
Description and Operation
Front End Body Panels
Removal and Installation
Bulb Access Panel (76.10.91)
Cowl Panel Grille (76.10.01)
Cowl Vent Screen (76.10.01)
Fender Splash Shield (76.10.90)
Radiator Grille Opening Cross Brace Vehicles Without: Supercharger (76.10.03)
Radiator Grille Opening Cross Brace Vehicles With: Supercharger (76.10.03)
Radiator Grille Opening Panel (76.10.06)
Radiator Splash Shield (76.22.90)
501‐03: Body Closures
General Procedures
Luggage Compartment Lid Alignment
Description and Operation
Body Closures
Doors
Hood
Trunk Lid
Removal and Installation
Door Opening Lower Weatherstrip Vehicles Without: Convertible Top (76.40.30)
Door Opening Upper Weatherstrip (76.40.01)
Fuel Filler Door (76.10.25)
Hood (76.16.01)
Hood Insulation (76.16.06)
Hood Strut (76.16.15)
Luggage Compartment Lid (76.19.01)
Luggage Compartment Lid Opening Weatherstrip (76.19.06)
Luggage Compartment Lid Strut (76.19.27)
501‐05: Interior Trim and Ornamentation
Description and Operation
Interior Trim
Removal and Installation
A‐Pillar Trim Panel (76.13.31)
Coat Hanger (76.10.54)
Cowl Side Trim Panel (76.13.30)
Door Trim Panel (76.34.01)
Driver Side Floor Covering (76.49.09)
Headliner (76.64.01)
Luggage Compartment Front Trim Panel (76.19.31)
Luggage Compartment Rear Trim Panel (76.19.44)
Luggage Compartment Side Trim Panel (76.19.22)
Parcel Shelf Vehicles Without: Convertible Top (76.67.06)
Passenger Air Bag Module Finish Panel (76.47.40)
Passenger Side Floor Covering (76.49.10)
Rear Quarter Panel Armrest Vehicles Without: Convertible Top (76.13.66)
Rear Quarter Panel Armrest and Speaker Grille Vehicles Without: Convertible Top
(76.13.71)
Rear Quarter Trim Panel (76.13.73)
Rear Quarter Upper Trim Panel Vehicles With: Convertible Top
Scuff Plate Trim Panel (76.13.22)
Sun Visor (76.10.48)
Sun Visor Retaining Clip (76.10.58)
Door Window Control Switch Finish Panel (76.47.33)
501‐08: Exterior Trim and Ornamentation
Description and Operation
Exterior Trim
Removal and Installation
Door Moulding (76.43.72)
Door Window Moulding (76.43.04)
Fender Moulding (76.43.73)
Hood Grille (76.16.37)
License Plate Housing (76.43.22)
Luggage Compartment Lid Moulding (76.43.79)
Radiator Grille (76.55.03)
Rear Quarter Window Moulding (76.43.81)
Rear Window Moulding Vehicles Without: Convertible Top (76.43.46)
Roof Moulding Vehicles Without: Convertible Top (76.43.11)
501‐09: Rear View Mirrors
Description and Operation
Rear View Mirrors
Removal and Installation
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 (76.10.57)
Interior Mirror (76.10.51)
Interior Mirror Mounting Block (76.10.62)
501‐10: Seating
Specifications
Description and Operation
Seats
Removal and Installation
Front Seat (76.70.01)
Front Seat Backrest Cover (76.70.15)
Front Seat Backrest Heater Mat (86.75.14)
Front Seat Backrest Trim Panel (76.70.03)
Front Seat Height Adjustment Motor (86.75.29)
Front Seat Recliner Motor (86.75.04)
Front Seat Track Motor (86.75.33)
Lumbar Motor (86.75.12)
Rear Seat Backrest (76.70.38)
Rear Seat Cushion (76.70.37)
Seat Control Switch (86.75.23)
501‐11: Glass, Frames and Mechanisms
General Procedures
Door Window Glass Adjustment
Description and Operation
Glass, Frames and Mechanisms
Removal and Installation
Automatic Window Control Switch (86.65.97)
Door Window Glass (76.31.01)
Door Window Glass Weatherstrip (76.31.55)
Door Window Glass Weatherstrip Vehicles With: Convertible Top (76.31.55)
Door Window Regulator Motor (86.25.57)
Driver Door Window Control Switch (86.25.03)
Passenger Door Window Control Switch (86.25.06)
Rear Quarter Window Glass (76.31.31)
Rear Quarter Window Glass Weatherstrip Vehicles With: Convertible Top (76.40.33)
Rear Quarter Window Glass Lower Weatherstrip (76.40.32)
Rear Quarter Window Glass Upper Weatherstrip (76.40.31)
Rear Quarter Window Regulator Motor Vehicles With: Convertible Top (86.25.11)
Rear Window Glass Vehicles Without: Convertible Top (76.81.11)
Rear Window Glass Vehicles With: Convertible Top (76.81.11)
Windshield Glass (76.81.40)
Windshield Moulding (76.43.40)
501‐12: Instrument Panel and Console
Specifications
Description and Operation
Instrument Panel and Instrument Panel Console
Removal and Installation
Audio Unit Housing (76.25.15)
Floor Console (76.25.01)
Floor Console Ashtray (76.25.25)
Floor Console Finish Panel (76.47.26)
Floor Console Stowage Compartment (76.25.16)
Floor Console Stowage Compartment Lid (76.25.18)
Glove Compartment (76.52.03)
Glove Compartment Lid (76.52.02)
Instrument Cluster Finish Panel (76.47.24)
Instrument Panel (76.46.01)
Instrument Panel Finish Panel (76.47.06)
Instrument Panel Lower Trim Panel (76.46.11)
Overhead Console (76.13.69)
Rear Cup Holder (76.25.27)
Steering Column Lower Shroud (76.46.03)
501‐14: Handles, Locks, Latches and Entry Systems
Description and Operation
Handles, Locks, Latches and Entry Systems
Removal and Installation
Door Ajar Switch (86.65.98)
Door Ajar Warning Indicator Switch (86.65.96)
Door Latch (76.37.12)
Door Latch Cable (76.37.67)
Door Lock Actuator (86.65.16)
Door Lock Control Switch (86.80.32)
Door Lock Cylinder (76.37.71)
Exterior Driver Door Handle (76.58.07)
Exterior Passenger Door Handle (76.58.08)
Glove Compartment Lid Lock Cylinder (76.52.23)
Hood Ajar Switch (86.65.99)
Ignition Lock Cylinder (57.40.29)
Luggage Compartment Lid and Fuel Filler Door Release Switch (86.65.95)
Luggage Compartment Lid Latch (76.19.25)
Luggage Compartment Lid Latch Actuator (76.19.25)
Luggage Compartment Lid Lock Cylinder (76.19.19)
Luggage Compartment Lid Warning Indicator Switch (86.65.93)
501‐16: Wipers and Washers
Specifications
Description and Operation
Wipers and Washers
Removal and Installation
Headlamp Washer Jet (84.20.08)
Rain Sensor (86.56.62)
Rain Sensor Module (86.56.60)
Windshield Washer Pump and Headlamp Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.01)
Windshield Wiper Motor (84.15.13)
Wiper Pivot Arm (84.15.03)
501‐18: Convertible Top
Description and Operation
Convertible Top
Removal and Installation
Convertible Top Assembly (76.86.15)
Convertible Top Headliner (76.86.16)
Convertible Top Hydraulic Lift Cylinder (76.86.17)
Convertible Top Hydraulic Lift Cylinder Hoses (76.86.24)
Convertible Top Hydraulic Pump (76.86.06)
Convertible Top Latch (76.86.19)
Convertible Top Latch Hydraulic Cylinder (76.86.21)
Convertible Top Latch Hydraulic Cylinder Hoses (76.86.22)
Convertible Top Material (76.86.12)
Header Rail Lower Trim Panel (76.64.16.70)
Header Rail Upper Trim Panel (76.86.20)
Header Rail Weatherstrip
501‐19: Bumpers
Specifications
Description and Operation
Bumpers
Removal and Installation
Bumper Bracket (76.22.87)
Bumper Isolator (76.22.88)
Front Bumper (76.22.08)
Front Bumper Cover (76.22.78)
Front Bumper Isolator (76.22.31)
Rear Bumper (76.22.27)
Rear Bumper Cover (76.22.77)
Rear Bumper Isolator (76.22.70)
501‐20A: Safety Belt System
Specifications
Description and Operation
Safety Belt System
Removal and Installation
Front Safety Belt Retractor LH (76.73.10)
Front Safety Belt Retractor RH (76.73.21)
Rear Safety Belt Retractor Vehicles Without: Convertible Top (76.73.18)
Rear Safety Belt Retractor Vehicles With: Convertible Top (76.73.18)
501‐20B: Supplemental Restraint System
Specifications
Description and Operation
Air Bag Supplemental Restraint System (SRS)
Removal and Installation
Air Bag Control Module LHD (76.73.41)
Air Bag Control Module RHD (76.73.41)
Crash Sensor (76.73.55)
Driver Air Bag Module (76.73.39)
Passenger Air Bag Module (76.73.37)
501‐25: Body Repairs ‐ General Information
Description and Operation
Body Repairs
502‐00: Uni‐Body, Subframe and Mounting System
Removal and Installation
Front Axle Crossmember
Front Axle Crossmember Front Bushing (60.35.24)
Front Axle Crossmember Rear Bushing (60.35.26)
Rear Axle Crossmember (64.25.16)
Rear Axle Crossmember Bushing (64.25.02)
Emergency Towing
1999 XK RANGE - General Information - 100-00
Safety Notice
Appropriate service methods and proper 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 nor vehicle integrity is compromised from choices of methods, tools or parts.
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.
Copyright Statement
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., Service Department, Browns Lane, Coventry, CV5 9DR, England.
This manual incorporates descriptive, diagnostic, and repair information to help trained Jaguar technicians
complete service and rectification procedures. The information can be accessed by choosing the appropriate five
digit section number. For example, Section <<412-03>> covers air conditioning, which is part of the Climate
Control System.
The manual is organized into six groups covering generic aspects of the vehicle systems; the first digit of the
section number represents a group selected from the following:
1. General Information.
2. Chassis.
3. Powertrain.
4. Electrical.
6. Routine Maintenance.
Each of the six groups comprises sections relating to specific areas of the vehicle.
The second and third digits of the section number indicate the vehicle system.
The last two digits of the section number define the system covered, more specifically.
Specification
1 2012-07-21
1999 XK RANGE - General Information - 100-00
General specifications (including setting-up information, capacities, lubricants, fluids, sealants and
adhesives).
Torque specifications.
Description and Operation
A general illustration and parts list to identify the components which comprise a particular system or
assembly.
A brief description of the system operating characteristics or description of the assembly.
A description of each component and its function.
Diagnosis and Testing
General maintenance procedures, including adjustment, alignment, bleeding and filling, with illustrated
steps and supporting text.
Tightening torque specifications, shown in the illustrations.
Removal and Installation
Component removal and installation maintenance procedures, with illustrated steps and supporting text.
Tightening torque specifications, shown in the illustrations.
An illustrated tool chart for each procedure requiring the use of special tools.
Disassembly and Assembly
Component disassembly and assembly maintenance procedures, with illustrated steps and supporting
text.
Tightening torque specifications, shown in the illustrations.
An illustrated tool chart for each procedure requiring the use of special tools.
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 ensure that the accessory and its fitted
location on the vehicle conform to mandatory requirements existing in their 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.
2 2012-07-21
1999 XK RANGE - General Information - 100-00
Patched Fasteners
Two types of patched fastener are essentially used on certain suspension, steering and other critical components,
where operational movement of the component necessitates positive thread locking. Standard patched fasteners
have part numbers bearing the suffix letter M. For identification of special patched fasteners, refer to the list of
patched fasteners below, or the relevant component drawings.
Jaguar Specification JFS 02.01.02 patched fasteners incorporate a micro-encapsulated adhesive which is
released into the mating threads during tightening. Following final tightening, the adhesive in this type of patched
fastener must be allowed a period to cure before the component/vehicle is used. On removal, this type of fastener
must be discarded and a new patched fastener of the same specification fitted. All mating threads must be
thoroughly cleaned prior to fitting of the new fastener.
Jaguar Specification JFS 02.01.04 patched fasteners incorporate a plastic/polyester on the thread. Acting as a
wedge between the mating threads, this compound imposes a prevailing torque during tightening. Whilst this type
of patched fastener can be re-used, the imposed torque diminishes. It is therefore recommended that following
third removal, this type of patched fastener is discarded and a new fastener of the same specification is fitted.
Special fasteners bearing the following part numbers are of the micro-encapsulated adhesive type and following
removal, must be discarded and replaced by new items of the same specification:
CAC 8223
JZH 100027.
JZS 100082; JZS100087; JZS 100088; JZS 100089; JZS 100090; JZS 100118; JZS 100157; JZS 100164; JZS
100166.
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 ensure 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.
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 for this range of vehicles.
References to the left- or right-hand side of the vehicle are made as if viewing from the driver's seat.
3 2012-07-21
1999 XK RANGE - General Information - 100-00
With the engine installed in the vehicle, the right-hand cylinder bank is designated Bank A, and the left-hand
cylinder bank is designated Bank B.
Special Tools
Any special tools and equipment required to perform a maintenance procedure, are shown at the beginning of
each maintenance procedure.
Torque Specifications
Torque specifications are shown in maintenance procedure illustrations and also in the torque specifications chart
located at the front of the relevant section.
Owing to the electronic components used on the vehicle, it is important that the battery is disconnected when
specified in a maintenance procedure.
When the battery is connected, the specified procedure must be followed, to ensure the correct operation of all
vehicle systems; refer to Section <<414-01>>.
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 ensure 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.
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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.
Ensure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure
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 ensure that the correct part has been obtained.
Inspection
Before inspecting a component for wear or performing a dimensional check, ensure 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.
Safety Precautions
WARNING:
WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE
ATMOSPHERE. FUEL VAPOUR 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
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Do not disconnect any pipes of the 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.
Health Protection
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.
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Environmental Protection
In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into water courses. The
burning of used engine oil in small space heaters or boilers is not recommended unless emission control
equipment is 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.
Vehicles use programmed electronic control systems to provide engine management and emission regulation,
automatic transmission operation and anti-lock braking control. These control systems have an integral On-Board
Diagnostics (OBD) facility for use in conjunction with either Jaguar diagnostic equipment or a scan tool which is
capable of retrieving DTCs, PIDs and performing active commands.
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 vehicles without recourse to the portable diagnostic unit (PDU).
General Information
Engine Management System
Automatic Transmission
Anti-lock Braking System
Where appropriate a section comprises the following sub-sections:
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 and details of connectors, splices,
fuses, wire gauge and colors. See Circuit Diagrams.
Diagnosis and Testing (dedicated to fault analysis and rectification)
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tightening torques.
Circuit Diagrams
To understand the relationship between the vehicle electrical system and the system circuit diagrams, refer to the
appropriate Electrical Guide.
The diagnostic trouble codes (DTCs) are listed in Section <<303-00>> under Diagnostic Trouble Codes and
include, where applicable, the corresponding manual section reference.
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Terminology Glossary
This glossary of terms is intended to cover 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.
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Diagnostic Test Mode DTM A level of capability in an OBD system. May include different functional
states 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
Diagnostic Trouble DTC An alpha/numeric identifier for a fault condition identified by the On-Board
Code Diagnostic (OBD) system
Dial test indicator DTI A mechanical measuring instrument, with a rotary indicating pointer
connected to a linear operating probe
Differential pressure Pressure difference between two regions e.g. between intake manifold
and atmospheric pressures
Differential Pressure DPFE An EGR system that monitors differential EGR pressure across a remote
Feedback EGR orifice to control EGR flow
Direct current dc Current which flows in one direction only, though it may have appreciable
pulsations in its magnitude
Dual linear switch DLS J-gate switch connected to the TCM on SC vehicles
E
EGR Temperature EGRT EGRT Sensing EGR function based on temperature change
Sensor
EGR Vacuum EVR Controls EGR flow by changing vacuum to the EGR valve
Regulator
EGR Valve Position EVP An EGR system that directly monitors EGR valve position to control EGR
flow
Electrically Erasable EEPROM
Programmable
Read-Only Memory
Electrically EPROM
Programmable
Read-Only memory
Electronic Secondary Air EAIR A pump-driven system for providing secondary air using an electric air
Injection pump
Engine Control ECM
Module
End of dash EOD Referring to a vehicle fascia, eg EOD air vent
Engine Coolant Level ECL
Engine Coolant ECT
Temperature
ECT Sensor ECTS Thermistor which provides engine coolant temperature signal to the ECM
to trigger enrichment circuits which increase injector 'on' time for cold start
and warm-up
Engine speed RPM
Environmental Protection EPA
Agency
Evaporative Emission EVAP System designed to prevent fuel vapor from escaping into the
atmosphere. Typically includes a charcoal filled canister to absorb fuel
vapor
Evaporative Emission EVAPP
Control Valve
Exhaust Gas EGR System which reduces NOx emissions by adding exhaust gases to the
Recirculation incoming fuel/air charge
Exhaust Gas EGRS
Recirculation Solenoid
Vacuum Valve
Exhaust Gas EGRT Sensor
Recirculation
Temperature Sensor
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K
Kilogramme (mass) kg
Kilogramme (force) kgf
Kilogramme force per kgf/cm2
square centimeter
Kilometer km
Kilometer per hour km/h
Kilopascal kPa
Kilovolt kV
Knock Sensor KS Sensor which detects the onset of detonation, and signals the ECM to
retard the ignition
L
Left-hand LH
Left-hand drive vehicle LHD
Left-hand thread LH Thd
Light Emitting Diode LED Light-emitting semiconductor diode used in alphanumeric displays and as
an indicator lamp
Liquid Crystal Display LCD Optical digital display system, applied voltage to which varies the way the
crystals reflect light, thereby modifying the display
Liter L
Low tension lt Primary circuit of the ignition system, linking the battery to the primary
winding in the ignition coil
M
Malfunction Indicator MIL A required on-board indicator to alert the driver of an emission related
Lamp malfunction
Manifold Absolute MAP Absolute pressure of the intake manifold air
Pressure
Manifold Absolute MAPS Sensor located in the ECM and ported to the intake manifold
Pressure Sensor
Manifold Surface MST
Temperature
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Mass Air Flow MAF System which provides information on the mass flow rate of the intake air
to the engine
Mass Air Flow Sensor MAFS Hot-wire sensor which monitors air flow into the intake manifold for fueling
and ignition control
Maximum max.
Meter (measurement) m
Metric (screw thread, e.g. M
M8)
Microfarad MFD Unit of electrical capacitance, one millionth of a farad
Millimeter mm
Millimeter of mercury mmHg
Millisecond ms
Minimum min.
Minute minute
Model Year MY
Module M Self contained group of electrical/electronic components which is
designed as a single replaceable unit
Modulating signal MD A shift process signal to the TCM on SC vehicles
Motorized In-Car MIA Device which constantly samples cabin temperature by passing air over a
Aspirator sensor, and communicates with the A/CCM to modify A/C system
performance to suit
Multi Protocol Adaptor MPA An interpreter for the various data languages present on a vehicle
N
National Institute of NIOSH
Occupational Safety and
Health (US)
Newton N SI unit of force. 1 N = 0.2248 pounds force
Newton meter Nm SI unit of torque. Must not be confused with nm (nanometer)
Nitrous Oxide NOx Compounds of nitrogen and oxygen formed at high temperatures. Major
source of exhaust-gas air pollution
Non-Volatile Random NVRAM RAM which retains memory even if power supply is interrupted
Access Memory
Normally aspirated Fueling system using intake air at atmospheric pressure; not
supercharged or turbocharged
Normally Closed NC
Normally Open NO
North American NAS Vehicles for sale in the USA and Canadian markets
Specification
Number No.
O
Occupational Safety and OSHA
Health Administration
(US)
On-Board Diagnostic OBD A system that monitors some or all computer input and output control
signals. Signal(s) outside the pre-determined limits imply a fault in the
system or a related system
On-Board Refueling ORVR
Vapor Recovery
Original Equipment OEM
Manufacturer
Output O/P An electrical output signal from a controlling device
Outside diameter o. dia
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R
Random Access RAM Fast access memory store which is accessible for entry or extraction of
Memory data
Read-Only Memory ROM Fast access memory in which data is fixed and may not be changed
Reservoir RES Container, usually for oils, coolants or hydraulic fluids
Return RTN A dedicated sensor ground circuit
Revolutions Per RPM Shaft speed of a device, usually an engine or motor
Minute
Right-hand RH
Right-hand drive RHD
vehicle
S
Scan Tool ST Device that interfaces with and communicates information on a data link
Seat Control Module SCM Module controlling the seat motor systems (not electric raise/lower-only
seats)
Secondary Air Air provided to the exhaust system
Secondary Air AIR System used for a period of time each time the engine is started, unless
Injection certain temperature criteria are met. Pumps air directly into the exhaust
system which generates extra heat and reduces the time taken for the
catalytic converters to reach operating temperature
Secondary Air Injection AIRB Vents secondary air to atmosphere
Bypass
Secondary Air Injection AIRC Valve which prevents back-flow of exhaust gas to the AIR system when
Check Valve the system is inoperative
Secondary Air Injection AIRD Diverts secondary air to either the catalyst or exhaust manifold
Diverter
Secondary Air Injection AIRPC Clutch mounted on the AIRP drive shaft
Magnetic Clutch
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Secondary Air Injection AIRP Mechanically driven rotary vane pump, driven through the AIRPC
Pump
Secondary Air Injection AIRR Controls the injection of air into the exhaust system
Relay
Secondary Air Injection AIRS Vacuum operated valve backing-up the AIRC
Switching Valve
Security and Locking SLCM Module controlling the vehicle's security and closure-locking functions
Control Module
Sensor S Generic name for a device that senses either the absolute value or a
change in a physical quantity such as temperature, pressure or flow rate,
and converts that change into an electrical quantity signal
Service Repair Operation SRO Number generated by Jaguar Methods and Techniques system which
(number) relates to the time allowed to complete a repair operation. Further
information on the system can be found in the separate Jaguar
Publications (for each model range) entitled 'Repair Operation Times'
Shift signal SD A shift process signal to the TCM on SC vehicles
Shift Solenoid SS Controls shifting in an automatic transmission
Signal return SIG RTN
Sliding Roof Control SRCM
Module
Society of Automotive SAE
Engineers
Speed Control Control SCCM Module controlling Speed Control System
Module
Square centimeter cm2
Standard std
Standard Corporate SCP A high-speed, serial communications system linking all body system
Protocol control modules. Control messages and data are passed between
modules at up to 786 messages per second
Supercharger SC An intake system which utilizes a supercharger (mechanically driven
device that pressurizes intake air, thereby increasing density of charge air
and the consequent power output from a given displacement)
Supercharger Bypass SCB
Switch SW
T
Tachometer TACH A circuit that provides input for an electronic tachometer display
Thermal Vacuum TVV Controls vacuum levels or routing based on temperature
Valve
Throttle Body TB Device containing the throttle
Throttle Position TP
Throttle Position TPS Interprets throttle position and movement to identify idle, acceleration and
Sensor full-power demands
Top Dead Center TDC
Torque Converter TCC
Clutch
Total indicator reading TIR The total indicated movement on a DTI with the test piece rotated through
360°
Transmission Control TCM Controls the shifting pattern of the (automatic) transmission
Module
Transmission Control TCS Modifies the operation of electronically controlled transmissions
Switch
Transmission Oil TOT Indicates temperature of transmission fluid
Temperature
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Identification Codes
Engine Number
The engine number (10 digits) is stamped on a raised pad on the front of the engine block near the thermostat housing. The piston
grade reference (8 digits) is also shown.
The serial number of the transmission unit is displayed on a metal or bar code label attached to the LH side of the transmission
casing.
Vehicle Identification
The VIN and other information according to market, is displayed on a label located on the LH door post above the door striker plate,
visible when the door is open. For certain markets, the VIN appears on a bar code label referred to as the Certification Label and
additionally carries the month and year of manufacture, vehicle weight data and paint and trim codes. The VIN is also displayed on
a plate visible through the windshield. It is essential that the vehicle identification number (VIN) is quoted when ordering parts and in
all associated correspondence.
Item Description
GVWR Gross Vehicle Weight Rating
GAWR F Gross Front Axle Weight Rating
GAWR R Gross Rear Axle Weight Rating
Paint Paint Code
Trim Trim Code
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Item Description
1 Gross Vehicle Weight
2 Maximum Permitted Front Axle Loading
3 Maximum Permitted Rear Axle Loading
ANTI-THEFT LABELS
For some markets, anti-theft labels bearing the VIN printed on a special anti-forgery background are positioned on certain body
components. An additional anti-theft label is positioned on the LH side of the engine/automatic transmission casing. Anti-theft labels
must not be removed from a vehicle unless necessitated by component renewal.
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1. WARNING:
ENSURE THAT THE VEHICLE IS STANDING ON FIRM, LEVEL GROUND.
Position the jack at one of the four vehicle jacking points.
Put the parking brake ON and the transmission in Park.
Chock the wheels to prevent movement of the vehicle.
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Jacking
The vehicle jack and wheel chock are stored in the trunk as part of the vehicle toolkit.
Use of the vehicle jack and workshop jacks is described in the general procedures in this section.
Jacking Points
Are situated below the body side members on the sill flange.
Consist of a reinforced plate, profiled to provide positive engagement with the vehicle jack.
Are located behind the front wheels for lifting the front of the vehicle.
Are located in front of the rear wheels for lifting the rear wheels.
Provide the support points for the four lifting pads of a wheel-free lift.
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Safety Precautions
The following safety precautions must be observed when raising the vehicle to perform service operations:
Never rely on a jack alone to support a vehicle; use suitable vehicle stands to provide rigid support.
When working beneath a vehicle, whenever possible use a ramp or inspection pit instead of a jack and
vehicle stands.
Ensure 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 transmission into Park if possible.
Check that any lifting equipment used has adequate capacity for the load being lifted and is in proper working
order.
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Vehicle Recovery
NOTE:
Prior to recovery, ensure that the vehicle keys are available and the security system disarmed.
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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.
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 at one of the front towing eye positions.
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The front towing eye screws into the front lower body crossmember at the left- or right-hand side of the vehicle, after
the removal of a blanking plug.
The rear towing eye is a welded double loop on the right-hand side of the trunk floor. This eye must not be used for
towing another vehicle.
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Unit Specification
Loctite 270
Grease Shell Retinax 'A'
Grease Castrol 'NTR'
Component Dimension
Hub face - maximum run-out 0.038 mm
Component Dimension
Hub face - maximum run-out 0.057 mm
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Wheel Alignment - Front Camber
1997 onwards Units Camber
VIN - 001246 to
current
' ' Left - Hand Right - Balance (RH -
Hand LH)
' ' Min Max Min Max Min Max
All Right-Hand drive and Degrees/minutes -1° 17' -0° 17' -0° 45' +0° 14' -0° 11' +1° 13'
Japan
' Decimal degrees -1.28° -0.28° -0.76° +0.24° -0.19° +1.21°
USA, Canada and Degrees/minutes -1° 11' -0° 11' -1° 18' -0° 18' -0° 50' +0° 34'
Mexico
' Decimal degrees -1.18° -0.18° -1.30° -0.30° -0.83° +0.57°
Rest of World Degrees/minutes -1° 14' -0° 14' -1° 17' -0° 17' -0° 44' +0° 40'
' Decimal degrees -1.24° -0.24° -1.28° -0.28° -0.74° +0.66° All the above figures are at 'showroom' height.
(See ride height section above).
Tires must be inflated to normal pressure.
<<204-04>>
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Wheel Alignment - Front Toe
1997 onwards Units Total Toe
VIN - 001246 to current
' ' Min Max
All Right-Hand drive and Japan Degrees/minutes +0° 05' +0° 25'
' Decimal degrees +0.08° +0.42°
USA, Canada and Mexico Degrees/minutes +0° 05' +0° 25'
' Decimal degrees +0.08° +0.42°
Rest of World Degrees/minutes +0° 05' +0° 25'
' Decimal degrees +0.08° +0.42° All the above figures are at 'showroom' height. (See ride height section above).
Tires must be inflated to normal pressure. <<204-04>>
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1. The front suspension on vehicles up to VIN 031302 does not provide the facility to adjust the camber angle.
This can only be achieved by replacing the original rear fulcrum-bolt of the lower-wishbone, with an eccentric
fulcrum-bolt. The eccentric bolt should only be fitted when directed by Jaguar Technical Support. See operation
(<<57.65.02>>). Eccentric fulcrum bolts are supplied by Jaguar Cars Ltd.
1. Both ends of the eccentric fulcrum bolt, i.e. the threaded section and the head are concentric with the holes in
the crossbeam fulcrum flanges. However, the center section of the bolt (arrowed), which retains the wishbone
rear bush, is eccentric to the two ends of the bolt. When the bolt is installed; rotation of the bolt will cause the
lower-wishbone rear arm to move in and out. A raised strip (arrowed) on the bolt head flange indicates the
position of the bolts eccentric section, to aid positioning when adjusting the camber.The function of the eccentric
bolt when it is rotated, is to increase or decrease the distance between the lower-wishbone fulcrum center at
the crossbeam and the ball joint center, therefore altering the camber angle.
Removal
1. 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. See
section <<100-00>> for information.
NOTE:
An eccentric bolt must be fitted to both front lower wishbones.
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Installation
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4. NOTE:
Make sure steering wheel and road wheels are in the central position before fitting steering column.
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6. Rotate eccentric bolt until the raised indicator strip on the bolt head flange is in the 6 o'clock position. This
position will set the camber angle to its original setting.
Repeat procedure on opposite-side eccentric bolt.
Adjusting Camber
NOTE:
Both eccentric bolts should now be in the position as detailed above, i.e. with the indicator strip in the 6 o'clock
position.
Rotating the eccentric bolt through 90 degrees from the 6 o'clock position, so that the indicator strip is
outboard of the bolt center will cause the lower-wishbone rear fulcrum to move outward. This will,
depending on original camber angle, either decrease the positive camber or increase the negative camber.
Rotating the eccentric bolt through 90 degrees from the 6 o'clock position, so that the indicator strip is
inboard of the bolt center will cause the lower-wishbone rear fulcrum to move inward. This will, depending
on original camber angle, either increase the positive camber or decrease the negative camber.
1. Adjust the camber angle to the correct setting. Refer to <<204-01>> specifications for settings.
2. After adjustment of the camber angle, measure the suspension geometry, record the results and re-adjust if
necessary.
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CAUTION:
If a vehicle has a suspension geometry problem, all geometry settings must be investigated and corrected
before making any adjustments to the caster setting.
1. If a suspension problem is suspected the 'Suspension Geometry Record Form' provided by Jaguar Technical
Support must be completed, and Technical Support consulted, before any adjustments are carried out. See
operation (<<57.65.02>>).
2. NOTE:
Alteration of the caster setting will affect the camber and toe settings.
5. CAUTION:
Do not allow the weight of the vertical link to hang on the brake hose.
NOTE:
Note the position of the shims before removing the fulcrum bolt.
6. CAUTION:
The total number of shims fitted to each fulcrum bolt must always remain the same, regardless of
adjustment to the front and rear packs, i.e. no shims are to be added or removed from the fulcrum
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bolt.
Caster angle is adjusted by interchanging the shims between the front and rear arm of each wishbone. See
<<204-01>> specifications for settings.
7. Use the illustration and table below to calculate the required positioning of the shims needed to set the caster
angle.
8. NOTE:
Caster specification is subject to market variations, as shown in the following table, which is the result of
differing road surfaces and market preferences.
To increase positive caster, the shim thickness at the front of the wishbone 1 or 3 must be decreased, and the
rear 2 or 4 increased by the same amount.
9. To decrease positive caster, the shim thickness at the front of the wishbone 1 or 3 must be increased and the
rear 2 or 4 decreased by the same amount.
The thick shim is 1.6 mm thick, paint code blue, it will effect caster by 0.4 degrees.
The thin shim is 0.9 mm thick, paint code red, it will effect caster by 0.2 degrees.
The total number of shims allocated to each wishbone fulcrum bolt is 2 thick and 2 thin shims.
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15. Check camber and toe settings and adjust if necessary. See specification section.
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1. The close tolerance machined alloy subframe installed on NA vehicles with VIN up to 031302, precludes the
necessity for adjustment of front suspension geometry during vehicle manufacture. Eccentric lower wishbone
fulcrum bolts are available as service items, but should only be fitted when directed by Jaguar Technical
Support.On RHD and Japan market LH drive SC vehicles with VIN up to 031302, eccentric fulcrum bolts
securing the lower wishbone to the front crossbeam, facilitate adjustment of wheel camber.All RH drive and
Japan market LH drive vehicles from VIN 031302, incorporate a long upper wishbone on the RH side of the
vehicle and a short upper wishbone on the LH side. There is a 2mm difference between the two wishbones,
measured from the centers of the ball joint location and the fulcrum bolt location. The longer wishbone is
identified by a countersunk hole in the upper surface adjacent to the ball joint location. All other LH drive vehicles
from VIN 031302 onward are fitted with the shorter upper wishbone on both sides. These measures counter the
effects of road camber on steering and eliminate the necessity for adjustment of suspension geometry.NOTE:
The vehicle must be checked to establish that it conforms to the Jaguar original specification, e.g. wheels,
tires, tire pressures, etc.
NOTE:
The 'space saver' wheel must not be installed on any of the hubs when measuring suspension geometry.
NOTE:
The vehicle must be unladen and the fuel tank full when measuring suspension geometry.
Whilst fulcrum bolts remain available as service items, a suspected suspension problem must be reported to
Jaguar Technical Support on the 'Suspension Geometry Record Form' provided and Technical Support
consulted, before any adjustments are carried out.
2. Road test the vehicle to establish the exact nature of the complaint, e.g. pulling to one side, wander.
3. Measure the suspension geometry, fill in the 'Suspension Geometry Record Form', and contact Jaguar
Technical Support for assistance.
4. Technical Support will give advice on the course of action to be taken to rectify the problem.
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1. NOTE:
The vehicle should be unladen and at curb weight with a full fuel tank when checking and adjusting wheel
alignment.
NOTE:
Wheel alignment must not be carried out with a space saver wheel installed on any of the hubs.
NOTE:
Before carrying out any checking or adjustment of wheel alignment, ensure that the vehicle wheels, tires and
tire pressures are to Jaguar specification.
NOTE:
Before checking or adjusting rear wheel alignment, examine the vehicle for curb impact damage on wheels
and subsequent damage to suspension components.
Position alignment checking equipment on road wheels and following equipment manufacturer's instructions,
check and if necessary adjust rear wheel alignment to Specifications in Section <<204-02>>.
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1. When installing the bearing circlips in the vertical link ensure that the ears are located at the lowest position to
permit water drainage.To achieve this, a perpendicular line drawn through the suspension upper ball-joint will
indicate the position of the gap between the circlip ears. This procedure makes an allowance for the caster
angle prior to installing the vertical link.
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1. During use, a small amount of surplus grease may appear around the bearing seal, this does not indicate a
failed bearing or seal. The grease should not be removed as this will act as an additional barrier to the ingress
of water or foreign matter.Excessive end float or bearing rumble will indicate a failed bearing; for maximum
permissible end float see specification section. Take care not to confuse suspension ball joint or upper or lower
fulcrum bush movement for bearing end float.If the hub is removed for any reason, a new bearing assembly
must be installed. Never attempt to re-use a bearing.
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Suspension System
Details of the Suspension System (including Wheels and Tires) can be found in Sections <<204-01>>, <<204-02>>,
204-03 and <<204-04>>.
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Unit Specification
Loctite 270
Grease Shell Retinax 'A'
Grease Castrol 'NTR'
Press-In Loads
Component Load
Ball Joint-lower 25 - 50 Kn
Ball Joint-upper 25 - 50 Kn
Torques
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. See section <<100-00>> for
information.
Component Nm
Nut - ball joint-upper 60-80
Nut - ball joint-lower 60-80
Bolt - brake disc shield 9-11
Bolt - crossbeam front mounting bracket to body 77-103
Bolt - crossbeam rear mounting to body 77-103
Bolt - crossbeam to rear mounting 26-34
Bolt - crossbeam to engine mounting 34-46
Nut - hub rotor nut 270-330
Nut - shock absorber lower pivot 60-80
Nut - shock absorber upper stud (non-adaptive damping) 30-40
Nut - shock absorber upper stud (adaptive damping) 16-18
Nut - spring and shock absorber upper-mounting to body 26-34
Bolt - stabilizer bar bracket to crossbeam 22-28
Nut - stabilizer bar to link 60-80
Nut - stabilizer bar link to lower wishbone 39-55
Bolt - wishbone lower front arm to rear arm 128-172
Nut - wishbone upper fulcrum 98-132
Bolt - wishbone lower front-fulcrum 113-153
Bolt - wishbone lower rear-fulcrum 113-153
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Front Suspension
Item Description
1 Crossbeam
2 Shock Absorber and Spring Assembly
3 Upper Wishbone
4 Vertical Link
5 Lower Wishbone
6 Stabilizer Bar Link
7 Lower Ball Joint
8 Upper Ball Joint
9 Stabilizer Bar
10 Hub
11 Hub Rotor Nut
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Crossbeam
Item Description
1 Upper Wishbone Mounting
2 Lower Wishbone Mounting
3 Front Mounting Bush Location
4 Engine Mounting Location
5 Rear Mounting Location
6 Power Steering Rack Mounting
CAUTION:
Do not attempt to weld or repair the aluminum crossbeam. If it is damaged, a new one must be installed.
CAUTION:
Do not use the crossbeam as a jacking point, as damage can occur to the crossbeam, steering rack and
brake pipes.
The crossbeam is a lightweight aluminum casting which is bolted at four points to the vehicle's longitudinal members,
through metal-to-rubber bonded mountings. Bushes which are pressed into the crossbeam are used at the front, and
mountings which are bolted to the crossbeam are used at the rear.
Wishbone Assemblies
Both upper and lower wishbone assemblies are attached to the crossbeam by fulcrum bolts. The upper wishbone is a
single-piece steel forging, which is fitted with a press-fit ball joint, and two slipflex bushes to each arm. A single
fulcrum bolt attaches the upper wishbone to the crossbeam. Shims installed with the upper fulcrum bolt are used to
adjust the caster setting.
The wide-base lower wishbone comprises two steel forged arms bolted together. The front wishbone arm is tapped
to accept the two bolts which secure the two wishbone arms together. Additionally the two bolts also secure the
shock absorber mounting brackets to the wishbone. Each lower wishbone arm is fitted with a metal-to-rubber bonded
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fulcrum bush which is attached to the crossbeam by an independent fulcrum bolt. The rear wishbone arm has a press
fit ball joint installed.
The camber setting is adjusted by rotating the lower-wishbone rear fulcrum bolt, which has an eccentric shaft.
However, in some markets the eccentric bolt is not fitted and the original fulcrum bolt has to be substituted with an
eccentric bolt to enable adjustment. The eccentric bolt is supplied by Jaguar Cars Ltd.
Stabilizer Bar
The stabilizer bar, is attached to the crossbeam in two positions by rubber bushes and clamps. The outer ends of the
stabilizer bar are attached to links which are connected the lower wishbones. The stabilizer bar provides the required
stiffness to prevent excessive body roll and fore-and-aft motion.
Vertical link
The vertical link swivels on the upper and lower wishbones via the ball joints, and carries the
hub,
cartridge wheel bearing - which is greased for life, has integral seals, and is non-adjustable,
hub rotor nut (hub nut and ABS rotor combined),
wheel speed sensor,
brake caliper,
and brake disc and shield.
The position of the vertical link is determined by the movement of the steering rack, which is connected to the vertical
link's integral steering arm by the tie-rod-end.
The shock absorber and spring is a coaxial assembly, installed between the lower wishbone and vehicle body. The top
spring mounting is attached to the vehicle's inner fender and the shock absorber is attached to a bracket on the lower
wishbone. The spring is compressed between the upper mounting and the lower spring pan which is held in position by
a circlip attached to the shock absorber.
Springs come in various ratings depending on the vehicle's suspension specification The suspension specification also
determines the number of packers fitted between the lower spring pan and the spring.
Shock absorbers and CATS (adaptive damping): see section 204-03 Description and Operation.
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Removal CAUTION:
Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
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1999 XK RANGE - Front Suspension - 204-01
vehicle. These devices restrict the number of times a nut or bolt can be used. See section <<100-00>> for
information.
CAUTION:
The ball joint must be returned for warranty purposes, care must therefore be exercised to avoid damaging it
during removal. Any damage incurred during removal must be noted and recorded.
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6. CAUTION:
Do not use special tool 211-098 in the following procedure as this will damage the ball joint gaiter.
7. Raise upper wishbone to release ball joint pin from vertical link.
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8. To prevent damage to lower ball joint, secure vertical link to road spring using strong wire.
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10. CAUTION:
When removing wishbone from suspension beam, retain and note positions of castor adjustment
shims.
Remove upper wishbone from suspension beam and retain adjustment shims.
12. Using a hacksaw, partially cut through two diametrically opposite segments of ball joint flange.
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13. Carefully chisel through and remove the two ball joint flange segments to permit installation between press
bed plates.
14. Remove wishbone from vise and thoroughly clean to remove swarf and road deposits.
15. For warranty purposes, paint positions of spring clip ends on ball joint housing and rubber gaiter.
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16. NOTE:
Any gaiter damage incurred during removal must be recorded for warranty purposes.
17. Invert wishbone and position on press with ball joint flange between press bed plates.
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18. Install special tool 204-200 on ball joint and operate press to release joint from wishbone.
21. Ensuring that their relative positions are clearly marked, place ball joint, rubber gaiter and retaining clip in a
clean plastic bag and return for warranty purposes.
22. Thoroughly clean wishbone paying particular attention to ball joint and pivot bolt locations.
Installation
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Using ball joint plastic cover to align, position mandrel of special tool 204-199 on ball joint
Align assembly with press ram and operate press to fully seat ball joint in wishbone.
5. Installing castor shims in positions noted during removal, assemble wishbone to suspension beam.
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8. Position wishbone to facilitate engagement of ball joint taper pin in vertical link.
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9. Install nut securing ball joint to vertical link and tighten nut to 60-80Nm.
10. Position wheel speed sensor harness on wishbone and secure with new tie straps.
13. Check and as necessary adjust front wheel alignment. Refer to 57.65.01.
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Removal 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. See section <<100-00>> for
information.
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3. Remove nut and bolt securing stabilizer bar link-rod to lower wishbone.
4. To prevent damage to upper ball joint, secure vertical link to road spring using strong wire.
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6. CAUTION:
Do not use special tool 211-098 in the following procedure as this will damage the ball joint gaiter.
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9. Remove nut and bolt securing lower wishbone front arm to cross-beam.
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10. Remove nut and bolt securing lower wishbone rear arm to cross-beam
13. Check that ball joint gaiter is free from cuts or abrasions.
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Installation
2. Install but do not tighten wishbone rear arm to cross beam pivot nut and bolt.
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3. Install but do not tighten wishbone front arm to cross beam pivot nut and bolt.
4. Install nut securing lower ball joint to vertical link and tighten to 60-80Nm.
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5. Align lower end of shock absorber with wishbone, install nut and bolt and tighten to 60-80Nm.
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9. Align stabilizer bar link rod with lower wishbone, install nut and bolt and tighten to 39-55Nm.
11. Raise vehicle, remove stands and lower vehicle. Refer to Section <<100-02>>.
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Removal
1. 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. See
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5. CAUTION:
Do not allow the weight of the vertical link to hang on the upper ball-joint. Support the weight of the
vertical link through-out the procedure, to prevent damage to the upper ball-joint.
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Remove nut from lower ball joint.
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11. CAUTION:
Do not allow the weight of steering rack to hang on the PAS pipes.
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12. CAUTION:
Note the position of the fulcrum bolts, as some vehicles are fitted with an eccentric bolt to the rear
wishbone arm. See General Procedures section <<204-01>> for information.
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14. NOTE:
For assembly reference, note orientation of bush.
15. NOTE:
For assembly reference, note orientation of bush.
Installation CAUTION:
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The front and rear wishbone bushes are different lengths, make sure the bushes are fitted to the correct
arms.
1. NOTE:
Fit bush into arm in the same orientation as noted in the removal section.
2. NOTE:
Fit bush into arm in the same orientation as noted in the removal section.
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8. CAUTION:
Make sure the fulcrum bolts are fitted in their original positions as noted in removal.
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11. NOTE:
Make sure steering wheel and road wheels are in the central position before fitting the steering column.
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Removal 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. See section <<100-00>> for
information.
6. Thoroughly clean wishbone front arm and shock absorber lower mounting brackets.
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Installation
4. Install wishbone rear arm and shock absorber mounting brackets to wishbone front arm.
1. Position shock absorber mounting brackets and wishbone securing bolts on rear arm.
2. Position wishbone front arm on bolts.
Install but do not tighten bolts.
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7. Release wishbone assembly from vise and remove plastic transit cover from ball joint.
10. Raise front of vehicle, remove stands and lower vehicle. Refer to Section <<100-02>>.
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1999 XK RANGE - Front Suspension - 204-01
1. 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. See
section <<100-00>> for information.
4. CAUTION:
The suspension must remain supported by the jack throughout this operation, to prevent damage
to the upper and lower ball-joints.
Place a jack under the lower wishbone, raise the jack until the weight of the suspension is supported.
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6. Remove nut securing shock absorber to lower mounting, DO NOT remove bolt at this stage.
7. Carefully lower the jack supporting the suspension, while guiding the shock absorber, upper mounting studs
through the body. Stop lowering the jack when the studs have passed through the body.
8. CAUTION:
For installation reference, note position of washers and shims before removing fulcrum shaft.
Release upper wishbone from crossbeam, to provide access for the removal of the shock absorber and spring
assembly.
1. Remove nut.
2. Remove fulcrum shaft.
3. Collect washers and shims.
4. Release upper wishbone from crossbeam.
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9. CAUTION:
Do not stretch the brake hose when removing shock absorber and spring assembly.
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Installation
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2. Release upper wishbone to provide access for the fitting of the shock absorber and spring assembly.
1. Remove fulcrum shaft.
2. Release upper wishbone.
3. CAUTION:
Do not stretch brake-hose when fitting shock absorber and spring assembly.
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5. CAUTION:
Make sure the adaptive damping electrical connector is correctly aligned. Failure to follow these
instructions may cause damage to the electrical connector.
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1. 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. See
section <<100-00>> for information.
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9. Remove undertray.
1. Remove and discard eight scrivets.
2. Remove screws.
3. Remove undertray.
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11. Raise front of vehicle and support on stands. Refer to section <<100-02>>.
14. CAUTION:
Place a wooden block between the jack and crossbeam, to prevent damage to the crossbeam.
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Installation
2. CAUTION:
Make sure the Casrol NTR grease is only applied to the inner surface of the mounting bush. Failure
to follow this instruction may affect the retention of the bush in the retaining bracket.
NOTE:
Make sure bushes are seated correctly in the stabilizer bar's retaining bosses and crossbeam recesses.
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4. Raise crossbeam.
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8. Fit front engine mounting bolts, but DO NOT tighten at this stage.
Repeat procedure on opposite-side mounting.
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10. Lower and remove the jack from beneath the crossbeam.
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21. Connect battery ground cable. Refer to section <<414-01>>, Battery Reconnection Procedure.
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1999 XK RANGE - Front Suspension - 204-01
1. 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. See
section <<100-00>> for information.
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Installation
1. CAUTION:
Make sure the Castrol NTR grease is only applied to the inner surface of the mounting bush. Failure
to follow this instruction may affect the retention of the bush in the retaining bracket.
NOTE:
Make sure bushes are seated correctly in the stabilizer bar's retaining bosses and crossbeam recesses.
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1. 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. See
section <<100-00>> for information.
4. Remove link.
Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting.
1. Remove nut.
2. Remove nut and bolt.
3. Remove link from stabilizer bar.
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1999 XK RANGE - Front Suspension - 204-01
Installation
1. Fit link .
1. Align link to lower wishbone and fit bolt.
2. Fit and tighten nut.
Use an open-ended spanner on the ball-pin flats to prevent the dust cover from twisting.
3. Fit and tighten nut.
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1999 XK RANGE - Front Suspension - 204-01
Removal
1. 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. See
section <<100-00>> for information.
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1999 XK RANGE - Front Suspension - 204-01
Reposition harness.
6. CAUTION:
Do not allow the weight of the vertical link to hang on the brake hose.
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7. CAUTION:
For installation reference, note the position of washers and shims before removing fulcrum bolt.
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Installation
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5. Repeat the previous three pictorial-procedures to fit other bush into wishbone.
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Hub Remover
204-193 (JD 224)
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Hub Replacer
204-196 (JD 236)
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Circlip Pliers
18G 1004
Removal
1. 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. See
section <<100-00>> for information.
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3. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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8. Remove and discard the inboard circlip from the vertical link.
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10. Using a hydraulic press, remove wheel bearing from vertical link.
NOTE:
Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible.
1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on
the press-bed.
2. Position special tool on top of bearing.
3. Operate press to remove bearing from vertical link, discard bearing.
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Installation
1. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
2. Using a hydraulic press, fit wheel bearing into the vertical link.
1. Position vertical link on the press bed with outboard side of the vertical link face down.
2. Position wheel bearing to vertical link.
3. Position special tool on top of wheel bearing.
4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating
load.
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3. CAUTION:
To prevent damage to the integral wheel-bearing seal, select a set of ends for the circlip pliers
which do not protrude through the circlip ears.
4. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore,
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
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6. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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7. NOTE:
The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before
this number must be fitted with a deflector ring when the rotor nut is removed for repair purposes. Deflector
rings can be obtained from Jaguar Parts.
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9. CAUTION:
Do not slacken the rotor nut to engage the spring clip.
11. Fit vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>.
12. Check wheel alignment and adjust if necessary. Refer to operation 57.65.01.
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Wheel Hub
Special Service tools
Hub Remover
204-193 (JD 224)
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Hub Replacer
204-196 (JD 236)
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Circlip Pliers
18G 1004
Removal
1. 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. See
section <<100-00>> for information.
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3. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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CAUTION:
Removing the hub from the vertical link damages the wheel bearing. A new wheel bearing MUST be
fitted to the vertical link.
8. Remove and discard the inboard circlip from the vertical link.
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10. Using a hydraulic press, remove the wheel bearing from the vertical link.
NOTE:
Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible.
1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on
the press-bed.
2. Position special tool on top of bearing.
3. Operate press to remove bearing from vertical link, discard bearing.
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1999 XK RANGE - Front Suspension - 204-01
Installation
1. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
2. Using a hydraulic press, fit the wheel bearing into the vertical link.
1. Position vertical link on the press bed with outboard side of the vertical link face down.
2. Position wheel bearing to vertical link.
3. Position special tool on top of wheel bearing.
4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating
load.
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1999 XK RANGE - Front Suspension - 204-01
3. CAUTION:
To prevent damage to the integral wheel-bearing seal, select a set of ends for the circlip pliers
which do not protrude through the circlip ears.
4. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore,
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
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1999 XK RANGE - Front Suspension - 204-01
6. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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1999 XK RANGE - Front Suspension - 204-01
7. NOTE:
The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before
this number must be fitted with a deflector ring when the rotor nut is removed for repair purposes. Deflector
rings can be obtained from Jaguar Parts.
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1999 XK RANGE - Front Suspension - 204-01
9. CAUTION:
Do not slacken the rotor nut to engage the spring clip.
11. Fit vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>.
12. Check wheel alignment and adjust if necessary. Refer to operation 57.65.01.
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1999 XK RANGE - Front Suspension - 204-01
Hub Remover
204-193 (JD 224)
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1999 XK RANGE - Front Suspension - 204-01
Hub Replacer
204-196 (JD 236)
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1999 XK RANGE - Front Suspension - 204-01
Circlip Pliers
18G 1004
Removal
1. 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. See
section <<100-00>> for information.
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1999 XK RANGE - Front Suspension - 204-01
3. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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CAUTION:
Removing the hub from the vertical link damages the wheel bearing. A new wheel bearing MUST be
fitted to the vertical link.
8. Remove and discard the inboard circlip from the vertical link.
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1999 XK RANGE - Front Suspension - 204-01
10. Using a hydraulic press, remove wheel bearing from vertical link.
NOTE:
Make sure the vertical link is level, and the supports are situated as near to the bearing bore as possible.
1. Position the vertical link so that the inboard side of the bearing bore is resting on suitable supports on
the press-bed.
2. Position special tool on top of bearing.
3. Operate press to remove bearing from vertical link, discard bearing.
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1999 XK RANGE - Front Suspension - 204-01
Installation
1. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
2. Using a hydraulic press, fit wheel bearing into the vertical link.
1. Position vertical link on the press bed with outboard side of the vertical link face down.
2. Position wheel bearing to vertical link.
3. Position special tool on top of wheel bearing.
4. Operate press to fit bearing, make sure that the bearing is fully seated by applying a three-ton seating
load.
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1999 XK RANGE - Front Suspension - 204-01
3. CAUTION:
To prevent damaging the integral wheel-bearing seal, select a set of ends for the circlip pliers which
do not protrude through the circlip ears.
4. NOTE:
The gap between the ears of the circlip must be positioned so that it is in the lowest position of the bore,
when the vertical link is fitted to the vehicle. Refer to General Procedures for further information.
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1999 XK RANGE - Front Suspension - 204-01
6. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Fit and tighten wheel nuts.
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1999 XK RANGE - Front Suspension - 204-01
7. NOTE:
The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before
this number must be fitted with a deflector ring when the rotor nut is removed for repair purposes. Deflector
rings can be obtained from Jaguar Parts.
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1999 XK RANGE - Front Suspension - 204-01
9. CAUTION:
Do not slacken the rotor nut to engage the spring clip.
11. Fit vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>.
12. Check wheel alignment and adjust if necessary. Refer to operation 57.65.01.
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1999 XK RANGE - Front Suspension - 204-01
Removal
1. 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. See
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1999 XK RANGE - Front Suspension - 204-01
4. CAUTION:
Do not allow the brake caliper to hang on the brake hose.
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1999 XK RANGE - Front Suspension - 204-01
9. CAUTION:
Do not allow the weight of the vertical link to hang on the lower ball joint, after releasing the upper
ball joint.
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1999 XK RANGE - Front Suspension - 204-01
12. Remove the vertical link and hub assembly from the vehicle.
Installation
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1999 XK RANGE - Front Suspension - 204-01
Disassembly
1. 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.
<<100-00>>
2. WARNING:
MAKE SURE THE SHOCK ABSORBER IS SECURED BY FULLY INSERTING THE LOCKING PIN IN TO
THE SPECIAL TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Install the shock absorber and spring assembly to the special tool as shown.
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1999 XK RANGE - Front Suspension - 204-01
3. WARNING:
AS THE SPRING IS UNDER EXTREME TENSION CARE MUST BE TAKEN AT ALL TIMES. FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Clamp the road spring.
Rotate the handle until spring pressure is released.
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E43415.GIF"
4. Remove the shock absorber retaining nut.
Remove and discard the retaining nut.
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1999 XK RANGE - Front Suspension - 204-01
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E33739.GIF"
7. Remove the gaiter assembly from the upper mounting.
1. Disengage the gaiter from the upper mounting.
2. Remove the spring assister from the gaiter.
Assembly
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E32295.GIF"
1. NOTE:
To ease fitting apply a suitable lubricant to the spring assister and gaiter.
NOTE:
Make sure the gaiter assembly is seated securely and squarely into the upper mounting.
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1999 XK RANGE - Front Suspension - 204-01
2. CAUTION:
Make sure circlip on the shock absorber abuts with the lower spring pan.
CAUTION:
Make sure the spring ends butt correctly against the spring seats.
Install the shock absorber and spring assembly to the special tool.
3. WARNING:
AS THE SPRING IS UNDER EXTREME TENSION CARE MUST BE TAKEN AT ALL TIMES. FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Clamp the road spring.
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E43415.GIF"
4. Vehicles without adaptive damping.
Install a new retaining nut.
Tighten to 40 Nm.
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E43415.GIF"
5. Vehicles with adaptive damping.
Install a new retaining nut.
Tighten to 18 Nm.
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1999 XK RANGE - Front Suspension - 204-01
7. Remove the shock absorber and spring assembly from the special tool.
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1999 XK RANGE - Rear Suspension - 204-02
Unit Specification
Loctite 270
Grease Shell Retinax 'A'
Grease Castrol 'NTR'
Torques
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. See section <<100-00>> for
information.
Component Nm
Bolt - ABS Sensor to Hub Carrier 8-10
Bolt - bump stop to body 26-34
Nut - differential stud to pendulum 149-201
Nut - hub 304-336
Nut - link assembly to differential 68-92
Bolt - link assembly to subframe mounting bracket 88-118
Bolt - monostrut to body bracket 88-118
Bolt - support plate to subframe mounting bracket 40-54
Nut - shock absorber lower-pivot 77-103
Nut - shock absorber upper-stud (non-adaptive damping) 30-40
Nut - shock absorber upper-stud (adaptive damping) 16-18
Nut - spring and shock absorber assembly, upper-mounting to body 17-23
Stud - spring and shock absorber assembly, upper-mounting to body 15-19
Bolt - stabilizer-bar bracket to wishbone-tie 40-54
Nut - stabilizer bar to link 30-40
Nut - stabilizer-bar link to wishbone 30-40
Bolt - suspension subframe to differential 88-118
Nut - suspension subframe front flange to subframe mounting bracket 68-92
Bolt - suspension subframe to mounting-bush bracket (through bush) 88-118
Bolt - suspension-subframe mounting-bush bracket to body 88-118
Tie-stud (front) - to differential 350-430
Nut - wishbone-tie to monostrut 77-103
Nut - wishbone-tie to differential 88-118
Nut - wishbone inner fulcrum 77-103
Nut - wishbone outer fulcrum 88-118
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1999 XK RANGE - Rear Suspension - 204-02
Rear Suspension
Parts List
Item Description
1 Lower wishbone
2 Suspension spring
3 Damper
4 Upper spring seat
5 Hub carrier
6 'A' Frame
7 Wide mounting frame
8 Wishbone tie assembly
9 Pendulum
10 Wishbone fulcrum pin
11 Stabilizer bar
12 Bump stop
13 Monostrut
14 Upper link assembly
The independent rear suspension uses co-axial spring and damper units, an 'A' frame, wishbone tie, pendulum
assembly, wide mounting frame, monostrut and cast wishbones. Positive location of the suspension is provided by the
'A' frame, wide mounting bracket and monostrut. Each wishbone inner is pivoted on a fulcrum bolt which passes
through the wishbone tie and pendulum assembly.
The wishbone tie and pendulum assemblies are installed at the front and rear of the final drive housing. The monostrut
is also attached to wishbone tie assembly and two further tie rods are installed between the front of the 'A' frame and
the top of the final drive housing.
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1999 XK RANGE - Rear Suspension - 204-02
The outer end of the wishbone is bolted to the hub carrier assembly using a pivot bolt, allowing for toe-in adjustment.
When the pivot bolt is correctly seated in a groove on the wishbone arm, it has small clearance at the sides but full
clearance at the top and bottom. Rotation of the bolt, with the eccentric constrained between vertical faces, causes
the bolt shank to be moved in the horizontal plane, thus moving the hub carrier and effecting wheel alignment
adjustment.
The axle-shaft acts as the the upper wishbone and the hub carrier as a vertical link.
A snubber is installed above the hub carrier to prevent the carrier contacting the vehicle body.
The suspension spring is co-axial with the damper unit and is installed between the wishbone integral spring seat and
the upper spring seat mounted on the vehicle body. The damper lower end is attached to the wishbone by a bolt which
forms the damper lower pivot.
A stabilizer bar is mounted at the rear of the wishbone tie assembly and its outer ends are connected to the
wishbones by short links.
As the road wheel rises, the movement is transmitted through the hub carrier assembly to the wishbone and
axle-shaft, which also rise. As the wishbone rises, it causes the suspension spring to be compressed and the damper
to move through part of its travel. The spring absorbs the shock and the damper damps any unwanted spring
frequencies.
When cornering, weight is transferred to the outer wheel with a natural tendency for the inner wheel to lift. The
stabilizer bar helps to minimise this by transferring some of the apparent rise of the outer wheel to the inner wheel
through the links to the wishbones, helping to provide a more level ride. Adaptive damping may also be specified as an
option.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
1. 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.
<<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>>
3. CAUTION:
Do not suspend the caliper from the brake hose as this will damage the hose.
NOTE:
Right-hand shown, left-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
4. NOTE:
Right-hand shown, left-hand similar
5. NOTE:
Right-hand shown, left-hand similar
Remove and discard the tie straps securing the wheel speed sensor harnesses to the brake hose clips.
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1999 XK RANGE - Rear Suspension - 204-02
7. NOTE:
Right-hand shown, left-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
8. Fully slacken but do not remove the parking brake cable adjuster nut.
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1999 XK RANGE - Rear Suspension - 204-02
10. Withdraw the left-hand parking brake cable through the equalizer.
11. Mark the position of the drive shaft coupling to the flexible coupling.
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1999 XK RANGE - Rear Suspension - 204-02
12. Remove the drive shaft from the differential drive coupling.
Remove the drive shaft to differential drive coupling bolts.
Carefully withdraw and lower the drive shaft from the differential coupling.
13. CAUTION:
Position a suitable piece of wood between the jack and the rear suspension and axle assembly.
Failure to follow this instruction may result in damage to the vehicle.
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1999 XK RANGE - Rear Suspension - 204-02
14. NOTE:
Left-hand shown, right-hand similar
15. NOTE:
Right-hand shown, left-hand similar
Remove and discard the subframe front mounting brackets to body bolts.
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1999 XK RANGE - Rear Suspension - 204-02
16. NOTE:
Right-hand shown, left-hand similar
17. NOTE:
Left-hand shown, right-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
18. WARNING:
WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING REMOVAL.
FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Remove the rear suspension and axle assembly.
Ensure that the hydraulic pipes, brake calipers, harnesses and the drive shaft will not obstruct the rear
suspension and axle assembly during removal.
Carefully lower the rear suspension and axle assembly and traverse clear of vehicle.
20. With assistance, position the rear suspension and axle assembly on to a bench.
21. Clean the subframe mounting bushes and corresponding body locations.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
1. Apply a thin coat of grease to the subframe bushes and place the shims in position.
2. WARNING:
WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING
INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
CAUTION:
Position a suitable piece of wood between the jack and the rear suspension and axle assembly.
Failure to follow this instruction may result in damage to the vehicle.
3. WARNING:
WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING
INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Position the rear suspension and axle assembly under the vehicle.
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1999 XK RANGE - Rear Suspension - 204-02
4. WARNING:
WITH ASSISTANCE, SUPPORT THE REAR SUSPENSION AND AXLE ASSEMBLY DURING
INSTALLATION. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Raise the trolley jack to position the rear suspension and axle assembly to the vehicle.
5. NOTE:
Right-hand shown, left-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
6. NOTE:
Right-hand shown, left-hand similar
7. NOTE:
Right-hand shown, left-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
8. NOTE:
Right-hand shown, left-hand similar
9. NOTE:
Right-hand shown, left-hand similar
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
14. Route the left hand parking brake cable through the equalizer.
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1999 XK RANGE - Rear Suspension - 204-02
17. CAUTION:
Make sure the adaptive damping electrical connector is correctly aligned. Failure to follow these
instructions may cause damage to the electrical connector.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
20. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip.
22. Remove the axle stands and lower the vehicle. <<100-02>>
23. Check and adjust the rear wheel alignment as necessary. <<204-00>>
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1999 XK RANGE - Rear Suspension - 204-02
Spring Compressors
204-179 (JD 199)
Removal
1. 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.
<<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>>
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1999 XK RANGE - Rear Suspension - 204-02
3. CAUTION:
Do not suspend the caliper from the brake hose as this will damage the hose.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. Remove and discard the tie strap securing the wheel speed sensor harness to the brake hose clip.
6. Mark the wishbone at the pivot pin eccentric flange marker to aid installation.
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
8. CAUTION:
To prevent damage to the parking brake cable, the hub carrier must be supported on removal from
the wishbone.
4 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
9. CAUTION:
Note the position of the shims during removal. They must be returned to their original position
during installation.
Noting their positions, remove the shim from each end of the pivot pin sleeve.
10. WARNING:
ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING
AND THE ARMS ARE CORRECTLY SEATED .
WARNING:
WHEN COMPRESSING THE SPRING, TIGHTEN THE SPECIAL-TOOL ADJUSTMENT BOLTS EVENLY.
Compress the spring.
Install and align the special tools 204-179 diametrically opposite on the spring.
Evenly tighten the special tool tensioning bolts to compress the spring.
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1999 XK RANGE - Rear Suspension - 204-02
11. Remove the shock absorber to wishbone mounting nut and bolt.
12. Remove the nuts securing the shock absorber and spring upper mounting to the body.
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1999 XK RANGE - Rear Suspension - 204-02
13. Using the special tools 204-179-1, secure the upper mounting to the spring.
14. Using a jack, retract the shock absorber through the wishbone aperture.
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1999 XK RANGE - Rear Suspension - 204-02
15. Position a bolt through the spring coils and shock absorber lower-bush, to temporarily locate the shock
absorber.
16. Partially lower the jack for access to the top of the shock absorber.
19. Remove the shock absorber and spring assembly from the vehicle and place the assembly on a work bench.
8 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
21. Remove the pigtail seat and clean the wishbone lower spring location.
22. With assistance, manually compress the shock absorber and withdraw the bolt from the spring coils.
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1999 XK RANGE - Rear Suspension - 204-02
24. Remove the special tools 204-179-1 and remove the upper mounting from the spring.
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1999 XK RANGE - Rear Suspension - 204-02
25. Remove the shock upper mounting assembly from the spring.
Remove the spring upper isolator.
Remove the upper spring pan.
Remove the packing ring.
Installation
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1999 XK RANGE - Rear Suspension - 204-02
3. Ensuring the correct orientation, secure the upper mounting to the spring using the special tools 204-179-1.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
6. Manually retract the shock absorber and place a bolt through the spring coils and the shock absorber
lower-bush.
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1999 XK RANGE - Rear Suspension - 204-02
9. With assistance, manually retract the shock absorber and remove the temporary securing bolt.
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1999 XK RANGE - Rear Suspension - 204-02
11. Align the shock absorber lower bush to the wishbone and install the mounting bolt.
1. Install but do not tighten the nut.
12. CAUTION:
Make sure the adaptive damping electrical connector is correctly aligned. Failure to follow these
instructions may cause damage to the electrical connector.
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1999 XK RANGE - Rear Suspension - 204-02
14. Ensuring that the spring is seated on the isolator and spring pan, position the upper spring pan on to the
body studs.
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1999 XK RANGE - Rear Suspension - 204-02
17. Fully seat and secure the upper spring pan to the body.
Ensure the spring pan is correctly seated in the body location.
Install the nuts securing the spring pan to the body studs.
Tighten to 17-23 Nm.
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1999 XK RANGE - Rear Suspension - 204-02
19. Install the shims on the pivot pin sleeve in the positions noted during removal.
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1999 XK RANGE - Rear Suspension - 204-02
22. Release the tie strap securing the brake caliper to the suspension mounting bracket.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
25. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip.
27. Remove the axle stands and lower the vehicle. <<100-02>>
28. Check and adjust the rear wheel alignment as necessary. <<204-00>>
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1999 XK RANGE - Rear Suspension - 204-02
Spring 64.20.01
Special Service tools
Spring Compressors
204-179 (JD 199)
Removal
1. 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.
<<100-00>>
Raise the rear of the vehicle and support on axle stands. <<100-02>>
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1999 XK RANGE - Rear Suspension - 204-02
3. CAUTION:
Do not suspend the caliper from the brake hose as this will damage the hose.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. Remove and discard the tie strap securing the wheel speed sensor harness to the brake hose clip.
6. Mark the wishbone at the pivot pin eccentric flange marker to aid installation.
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
8. CAUTION:
To prevent damage to the parking brake cable, the hub carrier must be supported on removal from
the wishbone.
4 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
9. CAUTION:
Note the position of the shims during removal. They must be returned to their original position
during installation.
Noting their positions, remove the shim from each end of the pivot pin sleeve.
10. WARNING:
ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING
AND THE ARMS ARE CORRECTLY SEATED .
WARNING:
WHEN COMPRESSING THE SPRING, TIGHTEN THE SPECIAL-TOOL ADJUSTMENT BOLTS EVENLY.
Compress the spring.
Install and align the special tools 204-179 diametrically opposite on the spring.
Evenly tighten the special tool tensioning bolts to compress the spring.
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1999 XK RANGE - Rear Suspension - 204-02
11. Remove the shock absorber to wishbone mounting nut and bolt.
12. Remove the nuts securing the shock absorber and spring upper mounting to the body.
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1999 XK RANGE - Rear Suspension - 204-02
13. Using the special tools 204-179-1, secure the upper mounting to the spring.
14. Using a jack, retract the shock absorber through the wishbone aperture.
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1999 XK RANGE - Rear Suspension - 204-02
15. Position a bolt through the spring coils and shock absorber lower-bush, to temporarily locate the shock
absorber.
16. Partially lower the jack for access to the top of the shock absorber.
19. Remove the shock absorber and spring assembly from the vehicle and place the assembly on a work bench.
8 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
21. Remove the pigtail seat and clean the wishbone lower spring location.
22. With assistance, manually compress the shock absorber and withdraw the bolt from the spring coils.
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1999 XK RANGE - Rear Suspension - 204-02
24. Remove the special tools 204-179-1 and remove the upper mounting from the spring.
10 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
25. Remove the shock upper mounting assembly from the spring.
Remove the spring upper isolator.
Remove the upper spring pan.
Remove the packing ring.
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1999 XK RANGE - Rear Suspension - 204-02
27. CAUTION:
The type and number of packers fitted to rear springs is dependent upon spring rating. Some
springs are fitted without any packers. The original packer(s) must therefore be retained on
removal.
28. WARNING:
WHEN RELEASING THE SPRING TENSION, SLACKEN THE SPECIAL-TOOL ADJUSTMENT BOLTS
EVENLY.
Evenly slacken the adjuster bolts on special tools 204-179 and remove the tools from the spring.
12 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Installation
2. WARNING:
ENSURE THE SPECIAL TOOLS ARE POSITIONED DIAMETRICALLY OPPOSITE ON THE SPRING
AND THE ARMS ARE CORRECTLY SEATED .
WARNING:
TIGHTEN THE SPECIAL TOOL ADJUSTMENT BOLTS EVENLY WHEN COMPRESSING THE SPRING.
Using the special tools 204-179 compress the spring.
1. Fit and align the arms of the special-tools to the spring reference marks.
2. Tighten the special-tool adjustment bolts evenly to compress the spring.
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1999 XK RANGE - Rear Suspension - 204-02
5. Ensuring the correct orientation, secure the upper mounting to the spring using the special tools 204-179-1.
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1999 XK RANGE - Rear Suspension - 204-02
8. Manually retract the shock absorber and place a bolt through the spring coils and the shock absorber
lower-bush.
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1999 XK RANGE - Rear Suspension - 204-02
10. Position the shock absorber and spring assembly to the vehicle.
11. With assistance, manually retract the shock absorber and remove the temporary securing bolt.
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1999 XK RANGE - Rear Suspension - 204-02
13. Align the shock absorber lower bush to the wishbone and install the mounting bolt.
1. Install but do not tighten the nut.
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1999 XK RANGE - Rear Suspension - 204-02
14. CAUTION:
Make sure the adaptive damping electrical connector is correctly aligned. Failure to follow these
instructions may cause damage to the electrical connector.
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1999 XK RANGE - Rear Suspension - 204-02
16. Ensuring that the spring is seated on the isolator and spring pan, position the upper spring pan on to the
body studs.
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1999 XK RANGE - Rear Suspension - 204-02
19. Fully seat and secure the upper spring pan to the body.
Ensure the spring pan is correctly seated in the body location.
Install the nuts securing the spring pan to the body studs.
Tighten to 17-23 Nm.
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1999 XK RANGE - Rear Suspension - 204-02
21. Install the shims on the pivot pin sleeve in the positions noted during removal.
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1999 XK RANGE - Rear Suspension - 204-02
24. Release the tie strap securing the brake caliper to the suspension mounting bracket.
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1999 XK RANGE - Rear Suspension - 204-02
27. Using a new tie strap, secure the wheel speed sensor harness to the brake hose clip.
29. Remove the axle stands and lower the vehicle. <<100-02>>
30. Check and adjust the rear wheel alignment as necessary. <<204-00>>
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1999 XK RANGE - Rear Suspension - 204-02
1. 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. See
section <<100-00>> for information.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
1. CAUTION:
Make sure the Castrol NTRgrease is only applied to the inner surface of the mounting bushes.
Failure to follow this instruction may affect the retention of the bushes in the retaining brackets.
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1999 XK RANGE - Rear Suspension - 204-02
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4 2012-07-21
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1. 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. See
section <<100-00>> for information.
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Installation
1. CAUTION:
Make sure the Castrol NTR grease is only applied to the inner surface of the mounting bushes.
Failure to follow this instruction may affect the retention of the bushes in the retaining brackets.
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1999 XK RANGE - Rear Suspension - 204-02
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
4 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
1. 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. See
section <<100-00>> for information.
2. Remove link.
1. Remove nut securing link to wishbone.
2. Remove lower bush.
3. Remove nut and bolt securing link to stabilizer bar.
4. Remove link from wishbone.
5. Remove upper-bush from link.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
1. Fit link.
1. Fit upper bush to link.
2. Fit link to wishbone.
3. Fit and tighten nut and bolt securing link to stabilizer bar.
4. Fit lower bush to link.
5. Fit and tighten nut securing link to wishbone.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
1. 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. See
section <<100-00>> for information.
2. Remove link.
1. Remove nut securing link to wishbone.
2. Remove lower bush.
3. Remove nut and bolt securing link to stabilizer bar.
4. Remove link from wishbone.
5. Remove upper-bush from link.
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Installation
1. Fit link.
1. Fit upper bush to link.
2. Fit link to wishbone.
3. Fit and tighten nut and bolt securing link to stabilizer bar.
4. Fit lower bush to link.
5. Fit and tighten nut securing link to wishbone.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
1. 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. See
section <<100-00>> for information.
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. CAUTION:
To prevent damage to the axle assembly, position a piece of wood between the jack and axle
assembly.
Position a suitable jack under the suspension subframe, and support the weight of the axle assembly.
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1999 XK RANGE - Rear Suspension - 204-02
9. Lower axle assembly sufficiently (approximately 25mm), to allow for the removal of the monostrut.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
2. Fit bolts securing monostrut to body brackets, DO NOT tighten bolts at this stage.
3. Raise axle assembly on jack, and guide monostrut into wishbone-tie assembly brackets.
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7 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
1. 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. See
section <<100-00>> for information.
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
6. CAUTION:
To prevent damage to the axle assembly, position a piece of wood between the jack and the axle
assembly.
Position a suitable jack under the suspension subframe, and support the weight of the axle assembly.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
10. Lower axle assembly sufficiently (approximately 25mm), to allow for the removal of the monostrut.
Installation
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1999 XK RANGE - Rear Suspension - 204-02
2. Fit bolts securing monostrut to body brackets, DO NOT tighten bolts at this stage.
3. Raise axle assembly on jack, and guide monostrut into wishbone-tie assembly brackets.
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1999 XK RANGE - Rear Suspension - 204-02
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Stabilizer Bar Mounting Frame Bushing Vehicles Without: Convertible Top 64.25.13
Special Service tools
Adaptor Ring
204-116-01 (JD 143-1)
Anvil Adaptor
204-116-02 (JD 143-2)
Remover/Replacer Adaptor
204-116-08 (JD 143-8)
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Removal
1. 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. See
section <<100-00>> for information.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Stabilizer Bar Mounting Frame Bushing Vehicles With: Convertible Top 64.25.13
Special Service tools
Adaptor Ring
204-116-01 (JD 143-1)
Anvil Adaptor
204-116-02 (JD 143-2)
Remover/Replacer Adaptor
204-116-08 (JD 143-8)
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Removal
1. 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. See
section <<100-00>> for information.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Hub Puller
204-011 (JD 1D)
Rear-Hub Remover
204-113 (JD 132)
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1999 XK RANGE - Rear Suspension - 204-02
Driver Handle
100-013 (18G-134)
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Removal 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. See section <<100-00>> for
information.
1. Release handbrake.
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1999 XK RANGE - Rear Suspension - 204-02
3. Fully slacken but do not remove parking brake cable adjuster nut.
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1999 XK RANGE - Rear Suspension - 204-02
5. Withdraw parking brake cable through equalizer (LH side cable only).
7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>.
9. Position special tool 204-195 on hub studs and install securing nuts.
5 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
10. Slacken but do not remove hub to axle shaft securing nut.
11. Remove securing nuts and withdraw special tool (204-195) from hub.
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1999 XK RANGE - Rear Suspension - 204-02
15. Sever and discard wheel speed sensor harness tie strap and position harness for access.
7 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
24. Remove hub and carrier from wishbone and axle shaft.
Withdraw pivot pin and remove hub and carrier assembly.
25. CAUTION:
Note position of shims during removal. They must be returned to their original positions during
installation.
Noting positions, remove shim from each end of pivot pin sleeve.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
30. Remove outer seal and bearing assembly from hub carrier.
Using a drift, remove and discard outer seal.
Remove and discard outer bearing.
Remove bearing spacer.
Remove bearing shim.
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1999 XK RANGE - Rear Suspension - 204-02
14 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Installation
1. Place hub carrier on press bed and insert inner bearing cup.
15 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
2. Using a hydraulic press, install new inner bearing cup in hub carrier.
Install special handle 18G134 to tool 204-118/2.
Align special tool 204-118/2 to bearing cup.
Align assembly to ram, and operate press to fully seat bearing cup.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
9. CAUTION:
Do not allow press load to be directed on to hub studs.
10. CAUTION:
Do not use excessive force when levering hub.
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1999 XK RANGE - Rear Suspension - 204-02
11. Using hydraulic press, remove hub and outer bearing assembly from carrier.
1. Position large section of special tool JD132 on press bed, with recess in tool upper most.
2. Position hub carrier on tool, ensuring parking brake cable housing locates in tool recess.
3. Position small section of special tool JD132 on hub.
Align assembly to press-ram, and operate press to remove hub from hub carrier.
12. Remove ABS rotor and inner bearing from hub carrier.
Remove ABS rotor.
Remove inner bearing.
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1999 XK RANGE - Rear Suspension - 204-02
14. Pack new inner and outer bearings with Shell Retinax 'A' grease.
15. Install outer bearing and using special tool 205-234, fully seat seal in hub carrier.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
20. Place block of wood on hydraulic press-bed and position hub carrier on block.
21. CAUTION:
Do not allow press load to be directed on to hub studs.
Align ABS rotor to hub and operate press to fully seat rotor on hub.
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1999 XK RANGE - Rear Suspension - 204-02
23. Install shims on pivot pin sleeve in positions noted during removal.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
26. Install washer and nut on pivot pin, but DO NOT tighten nut.
26 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
28. Install locating collar and hub nut on axle shaft, but DO NOT tighten hub nut.
27 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
31. Using new tie strap, secure wheel speed sensor harness to hub carrier.
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1999 XK RANGE - Rear Suspension - 204-02
34. Position special tool 204-195 on hub studs and install nuts.
36. Remove securing nuts and withdraw special tool 204-195 from hub.
38. Remove stands and lower vehicle onto wheels. Refer to section <<100-02>>.
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1999 XK RANGE - Rear Suspension - 204-02
40. Route parking brake cable through suspension mounting bracket and secure with clip.
30 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
31 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Hub Puller
204-011 (JD 1D)
Rear-Hub Remover
204-113 (JD 132)
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Removal 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. See section <<100-00>> for
information.
3. Fully slacken but do not remove parking brake cable adjuster nut.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. Withdraw parking brake cable through equalizer (LH side cable only).
7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>.
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
9. Position special tool (204-195) on hub studs and install securing nuts.
10. Slacken but do not remove hub to axle shaft securing nut.
11. Remove nuts and withdraw special tool (204-195) from hub.
4 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
15. Sever and discard wheel speed sensor harness tie strap and position harness for access.
5 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
6 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
7 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
8 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
24. Remove hub and carrier from wishbone and axle shaft.
Withdraw pivot pin and remove hub and carrier assembly.
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1999 XK RANGE - Rear Suspension - 204-02
25. CAUTION:
Note position of shims during removal. They must be returned to their original positions during
installation.
Noting positions, remove shim from each end of pivot pin sleeve.
10 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
30. Remove outer seal and bearing assembly from hub carrier.
Using a drift, remove and discard outer seal.
Remove outer bearing.
Remove bearing spacer.
Remove bearing shim.
12 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Installation
1. Grease bearings.
Pack inner and outer bearing races with Shell Retinax 'A' grease:
Apply a film of shell Retinax 'A' grease to bearing cups
2. Install outer bearing in hub carrier and fully seat new seal using special tool 205-234.
3. Apply a thin film of Shell Retinax 'A' grease to hub shaft and install hub in carrier/bearing assembly.
13 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. Place block of wood on hydraulic press-bed and position hub carrier on block.
6. CAUTION:
Do not allow press load to be directed onto hub studs.
Align ABS rotor to hub and operate press to fully seat rotor on hub.
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1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
10. Install washer and nut on pivot pin, but DO NOT tighten nut.
16 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
12. Install locating collar and hub nut on axle shaft, but DO NOT tighten hub nut.
17 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
15. Using new tie strap, secure wheel speed sensor harness to hub carrier.
18. Position special tool (204-195) on hub studs and install securing nuts.
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1999 XK RANGE - Rear Suspension - 204-02
20. Remove securing nuts and withdraw special tool (204-195) from hub.
22. Raise rear of vehicle, remove stands and lower vehicle. Refer to section <<100-02>>.
24. Route parking brake cable through suspension mounting bracket and secure with clip.
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1999 XK RANGE - Rear Suspension - 204-02
25. Route parking brake cable through equalizer (LH side cable only).
21 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Hub Puller
204-011 (JD 1D)
Driver Handle
100-013 (18G 134)
1 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
Removal 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. See section <<100-00>> for
information.
3. Fully slacken but do not remove parking brake cable adjuster nut.
2 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
5. Withdraw parking brake cable through equalizer (LH side cable only).
7. Raise rear of vehicle to working height and support on stands. Refer to section <<100-02>>.
3 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
9. Position special tool (204-195) on hub studs and install securing nuts.
10. Slacken but do not remove hub to axle shaft securing nut.
11. Remove nuts from studs and withdraw special tool (204-195) from hub.
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1999 XK RANGE - Rear Suspension - 204-02
15. Remove wheel speed sensor harness tie strap and position harness for access.
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1999 XK RANGE - Rear Suspension - 204-02
6 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
7 2012-07-21
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1999 XK RANGE - Rear Suspension - 204-02
31. Repeat procedure to remove opposite end bearing cup and discard both cups.
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1999 XK RANGE - Rear Suspension - 204-02
Installation
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1999 XK RANGE - Rear Suspension - 204-02
13 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
9. Using 3.905mm shim and pre-load measurements as a datum, select two new shims of equal thickness to
provide a pre-load measurement of 0.076 mm.
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1999 XK RANGE - Rear Suspension - 204-02
12. Remove nut, tube and pivot pin from hub carrier.
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1999 XK RANGE - Rear Suspension - 204-02
16 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
16. Install locating collar and hub nut on axle shaft, but DO NOT tighten hub nut.
17 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
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1999 XK RANGE - Rear Suspension - 204-02
19. Using new tie strap, secure wheel speed sensor harness to hub carrier.
19 2012-07-21
1999 XK RANGE - Rear Suspension - 204-02
24. Remove nuts and withdraw special tool (204-195) from hub studs.
26. Raise rear of vehicle, remove stands and lower vehicle. Refer to section <<100-02>>.
28. Route parking brake cable through equalizer (LH side cable only).
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1999 XK RANGE - Rear Suspension - 204-02
21 2012-07-21
1999 XK RANGE - Wheels and Tires - 204-04
Torques
Component Nm
Wheel nut - steel wheel 68 - 82
Wheel nut - alloy wheel 88 - 102
Spare wheel retainer - temporary or full size spare 3
Inflation Pressures for Recommended Tires - Maximum Comfort Speeds up to 160 km/h (100 mph)
CAUTION:
Only check tire pressures when the tires are cold, (when the tires have been operational wait until the tires
have cooled to ambient temperature before checking the pressures).
CAUTION:
Do not exceed 80km/h (50mph) when the temporary spare wheel is installed.
Tires other than those recommended must be inflated to the following cold inflation pressure (front and Rear): 3.0
bar, 44lbf/in2
When using non-Jaguar approved winter tires, inflate to the recommended tire pressure and do not exceed the tire's
speed capability.
Wheel Application
NOTE:
Refer to (<<204-04>>) Description and Operation Section for Wheel Designs.
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1999 XK RANGE - Wheels and Tires - 204-04
Recommended Tires
CAUTION:
The 9J X 18 rear wheels and tires MUST NOT be installed to the front of the vehicle.
CAUTION:
Only use winter tires in complete sets of the same type and size.
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1999 XK RANGE - Wheels and Tires - 204-04
Item Description
1 Standard 8J X 17 Alloy Wheel
2 Optional 8J X 18 Alloy Wheel - Front Optional 9J X 18 Alloy Wheel - Rear
Item Description
- 8J X 18 Alloy Wheel - Front
- 9J X 18 Alloy Wheel - Rear
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1999 XK RANGE - Wheels and Tires - 204-04
Wheel Changing
CAUTION:
Do not allow grease to contaminate the wheel stud threads and wheel nut to wheel mating surface, as this
may cause the nuts to loosen.
NOTE:
When installing the wheel, smear a thin layer of grease onto the hub mounting face and spigot; and wheel
mounting face and spigot hole, to prevent the wheel corroding on to the hub.
2 2012-07-21
1999 XK RANGE - Wheels and Tires - 204-04
Item Description
One locking wheel nut is fitted to each road wheel and can only be removed by using the correctly coded socket. For
road wheels with exposed wheel nuts, each locking wheel nut is provided with a cover, which is removed using the
cover removal tool.
Locking wheel nuts have different coded keyway combinations with corresponding coded sockets. The correct socket,
and cover removal tool are supplied with the vehicle toolkit. Sets of sockets are available to Jaguar dealers.
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.
NOTE:
When using this type of spare wheel note that:
Tires
The radial ply tires shown in the <<204-04>> Specification Section are recommended by Jaguar to 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.
All recommended tires, including winter tires, must be inflated to the pressures shown in the <<204-04>> Specification
Section. Inflation pressures must only be checked when the tires are cold.
When renewal of tires 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.
No attempt must be made to interchange wheels from the front to the rear or vice-versa, as wear produces a
characteristic pattern on each tire depending upon its position on the vehicle. If this position is changed after wear has
occurred, the performance of the tire will be adversely affected.
It should be remembered that new tires must be balanced before installing to the vehicle.
Winter Tires
NOTE:
Speed must not exceed 210 km/h (131 mph) when winter tires are installed.
Jaguar recommended winter tires as specified in <<204-04>> Specification Section must only be fitted in complete
four-wheel sets of the same type and size.
3 2012-07-21
1999 XK RANGE - Wheels and Tires - 204-04
Jaguar recommended snow chains, must only be installed when using 17 inch wheels with 245/50 R17 winter tires.
The Jaguar recommended spike spider traction system can be used on all wheel and tire sizes, except the temporary
spare wheel.
NOTE:
When using snow chains or the spike spider traction system, note that:
Snow chains and the spike spider traction system must only be fitted to the rear wheels.
Only Jaguar recommended snow chains or spike spider traction system must be used.
The maximum permissible speed with winter tires, and snow chains or spike spider traction system fitted is
48 km/h (30 mph).
Traction control (where fitted) must be switched OFF when using snow chains or the spike spider traction
system.
Snow chains and the spike spider traction system must not be used on roads which are clear of snow.
Asymmetric Tires
Some tires recommended by Jaguar are asymmetric. Inner and outer markers embossed on the tire walls must be
observed to ensure the correct installation of the tire to the wheel.
Rotational Indicators
Some tires recommended by Jaguar are directional, these tires have an embossed arrow on the tire wall to show the
direction of rotation of the tire when installed.
NOTE:
Tire condition must comply with prevailing local legislation.
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.
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1999 XK RANGE - Wheels and Tires - 204-04
General Notes
1. Factory installed tires and wheels are designed to provide optimum ride and handling characteristics when
inflated to the recommended inflation pressures, with vehicle loads not exceeding the full-rated load capacity.
2. 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.
4. The use of any other size or type of wheel / tire may seriously affect:
Safety.
Ride.
Handling.
Speedometer / odometer calibration.
Vehicle ground clearance.
Tire clearance between body and chassis.
Wheel bearing life.
Brake cooling.
Safety Notes
WARNING:
DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE, HANDLING MAY BE SERIOUSLY
AFFECTED RESULTING IN LOSS OF CONTROL.
WARNING:
DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE, HANDLING MAY BE SERIOUSLY
AFFECTED RESULTING IN LOSS OF CONTROL.
WARNING:
CORRECT TIRE ROTATIONAL DIRECTION IS IMPORTANT, OBSERVE THE DIRECTION OF THE
SIDEWALL MOLDED INDICATORS.
WARNING:
A TIRE AND WHEEL MUST ALWAYS BE CORRECTLY MATCHED. WIDER OR NARROWER TIRES THAN
RECOMMENDED COULD CAUSE DANGER THROUGH SUDDEN DEFLATION.
WARNING:
WHEN USING THE TEMPORARY SPARE WHEEL, SPEED MUST NOT EXCEED 80 KM/H (50 MPH). DRIVE
WITH CAUTION AND REPLACE WITH THE SPECIFIED WHEEL / TIRE ASSEMBLY AS SOON AS POSSIBLE.
WARNING:
TRACTION CONTROL (IF AVAILABLE) MUST NOT BE ENGAGED WITH THE TEMPORARY SPARE WHEEL
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1999 XK RANGE - Wheels and Tires - 204-04
FITTED.
WARNING:
WHEN CHANGING A WHEEL, ENSURE THAT THE VEHICLE CANNOT MOVE. ALWAYS APPLY THE PARK
BRAKE AND SELECT TRANSMISSION 'P' POSITION.
WARNING:
NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING THE
WHEEL. THE VEHICLE COULD MOVE.
WARNING:
TIGHTEN THE WHEEL NUTS TO SPECIFICATION. WHEELS MAY COME LOOSE IF OVER OR UNDER
TIGHTENED.
WARNING:
USE WHEELS AND WHEEL NUTS DESIGNED FOR XK SERIES VEHICLES ONLY. AFTERMARKET WHEELS
OR WHEEL NUTS MAY NOT FIT OR FUNCTION PROPERLY AND COULD CAUSE INJURY OR DAMAGE.
To maximize tire performance, inspect the tires frequently for signs of:
Uneven wear.
Incorrect tire pressure.
Wheel imbalance.
Cuts.
Abrasions.
Bulges (blister).
Ply separation.
Embedded objects.
Impact damage.
Inspection should be more frequent when:
NOTE:
Tire condition must comply with prevailing local legislation.
New tires must be installed if the wear indicators are exposed or if there is severe shoulder wear. Shoulder wear is
usually caused by either excessive camber or toe on tires.
A tire vibration diagnostic procedure always begins with a road test. The road test and the customer interview (if
available) will provide much of the information needed to find the source of 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:
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1999 XK RANGE - Wheels and Tires - 204-04
Torque Sensitive
This means that the condition can be improved or made worse by accelerating, decelerating, coasting, maintaining a
steady vehicle speed, or applying engine torque.
This means that the vibration always occurs at the same vehicle speed and is not affected by engine torque, engine
speed or gear selection.
This means that the vibration occurs at varying vehicle speeds when a different gear is selected. It can 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 tires.
If the road test indicates that there is tire wine, 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 is flat or has soft spots making a noise as they slap the roadway. Tire
whine can be distinguished from axle noise, as tire whine remains the same over a range of speeds.
Symptom Chart
Condition(s):
Action(s) to take:
Correct to specification.
Possible Source(s):
Excessive radial and lateral runout.
Action(s) to take:
Renew tire or wheel.
Possible Source(s):
Out of specification steering geometry.
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1999 XK RANGE - Wheels and Tires - 204-04
Action(s) to take:
Realign steering geometry: Refer to Section <<204-00>>.
Possible Source(s):
Worn ball joint.
Action(s) to take:
Renew damaged component, realign steering geometry.
Possible Source(s):
Worn tie-rod end.
Action(s) to take:
Renew component, realign steering geometry.
Possible Source(s):
Incorrect tire / wheel usage.
Action(s) to take:
Install correct tire and wheel combination.
Possible Source(s):
Loose or leaking shock absorbers.
Action(s) to take:
Tighten or Renew as necessary: Refer to Section <<204-00>>.
Possible Source(s):
Suspension geometry out of alignment.
Action(s) to take:
Check and adjust: Refer to Section <<204-00>>.
Possible Source(s):
Loose, worn or damaged suspension components.
Action(s) to take:
Inspect, Repair or Renew 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 Renew as required.
Action(s) to take:
Correct pressure to specification.
Possible Source(s):
Vehicle overloaded.
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1999 XK RANGE - Wheels and Tires - 204-04
Action(s) to take:
Correct to specification.
Tires show excess wear on edge of treads (with tire pressures correct).
Possible Source(s):
Incorrect toe setting.
Action(s) to take:
Set to specification: Refer to Section <<204-00>>.
Action(s) to take:
Correct pressure to specification
Action(s) to take:
Follow the manufacturer's specifications. Clean or Renew.
Action(s) to take:
Inspect wheel rims for damage and runout. Renew as required.
Action(s) to take:
Install correct tire / wheel combination.
Possible Source(s):
Inflation pressure too high or low.
Action(s) to take:
Correct pressure to specification
Possible Source(s):
Uneven tire wear.
Action(s) to take:
Refer to Diagnosis and Testing in this section.
Possible Source(s):
Wheel and tire assembly imbalance.
Action(s) to take:
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1999 XK RANGE - Wheels and Tires - 204-04
Possible Source(s):
Brake disc imbalance.
Action(s) to take:
Check brake disc cooling fins for mud and foreign material. Check for damage or disc heavy
spot. Refer to Section <<206-00>>.
Possible Source(s):
Damaged or distorted wheel.
Action(s) to take:
Renew wheel.
Possible Source(s):
Excessive radial run-out of wheel or tire.
Excessive lateral run-out of wheel or tire.
Action(s) to take:
Renew wheel or tire.
Possible Source(s):
Incorrectly seated tire.
Action(s) to take:
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 Renew worn or damaged parts. Clean mounting surfaces.
Possible Source(s):
Defective wheel bearings.
Action(s) to take:
Renew worn or damaged bearing sets: Refer to Section <<204-00>>.
Possible Source(s):
Water in tires.
Action(s) to take:
Remove water.
Action(s) to take:
Renew wheel studs.
Action(s) to take:
Renew wheel studs.
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1999 XK RANGE - Wheels and Tires - 204-04
Action(s) to take:
Check complete assembly. Renew damaged parts. Apply correct torque setting.
Action(s) to take:
Renew wheel nuts. Apply correct torque setting.
Action(s) to take:
CAUTION:
Do not permit lubricant to contaminate wheel hub stud holes or wheel nut seats.
If corrosion is light, wire brush away corrosion. If corrosion is excessive renew wheel studs and
wheel nuts. Lubricate the first three threads of wheel studs with a graphite based lubricant.
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1999 XK RANGE - Wheels and Tires - 204-04
Removal CAUTION:
Do not use heat to loosen a seized wheel nut: heat will change the metal's properties and damage wheel
bearing and brake caliper seals.
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1999 XK RANGE - Wheels and Tires - 204-04
Installation
1. CAUTION:
Do not allow grease to contaminate the wheel stud threads and wheel nut to wheel mating
surface, as this may cause the nuts to loosen.
NOTE:
To prevent the wheel corroding on to the hub, smear a thin layer of grease onto the hub mounting face
and spigot; and wheel mounting face and spigot hole.
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Damping System
Description
Movement of each road spring is independently damped by a telescopic, hydraulically-controlled shock absorber.
Each shock absorber is installed coaxially within the road spring. Front springs are located between spring seats
on the shock absorber body and rod, rear springs are located between seats on the shock absorber and the lower
wishbone.
Item Description
1 Shock Absorber
2 Road Spring
3 Adaptive Damper Harness Connector
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Item Description
1 Shock Absorber
2 Road Spring
3 Lower Wishbone
4 Spring Upper seat
Operation
As a shock absorber rod rises and falls in unison with road spring movement, that movement is damped by
controlling the flow of fluid from one end of a chamber to the other within each shock absorber. Any increase in
the restriction of fluid flow within a shock absorber results in a corresponding increase in damping action and a
firmer ride.
Description
The Adaptive Damping System available as an option, matches damping effect with vehicle driving forces, to
provide optimum ride and handling performance.
The system which is completely automatic and requires no drive input, comprises the following components:
Four adaptive damping units installed in the normal shock absorber positions. These are identified by a
harness connector incorporated in the top of each unit.
An adaptive damping control module (ADCM) installed in the trunk adjacent to the battery.
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Two vertical movement sensors (accelerometers), one installed on the bulkhead below the air
conditioning unit, the other in the trunk below the fuel tank.
A lateral movement sensor (accelerometer) installed within the RH side false bulkhead.
Operation
The four adaptive damping units are simultaneously switched to either firm or soft setting to suit circumstances.
When the vehicle is stationary, the system adopts the firm setting to minimize vehicle pitch during initial
acceleration. From 8km/h (5mph) upwards, the system reverts to the soft setting until otherwise switched by the
ADCM.
On detecting cornering forces, the lateral sensor transits signals to the ADCM, which in turn switches the damping
units to the firm setting, reducing vehicle roll-rate and improving wheel control.
On detection of a bump or depression in the road, the vertical sensors transmit signals to the ADCM, which in turn
switches the damping units to the firm setting to minimize vehicle body movement.
Under braking conditions, the ACDM, on receipt of a signal, commences calculation of vehicle deceleration.
When deceleration exceeds a pre-determined threshold, the ADCM switches the damping units to the firm setting,
reducing vehicle pitch rate and improving wheel control.
Following completion of a cornering manoeuvre, negotiation of road surface undulations, or heavy braking, that
has necessitated switching to the firm setting, the ADCM always returns the damping units to the soft setting.
In the event of failure of the Adaptive Damping System, the damping units automatically revert to the Firm setting,
ensuring that the vehicle remains safe to drive under all circumstances. The driver will be alerted to such a failure
by illumination of a 'SUSPENSION FAULT' warning on the fascia message center and the amber warning light in
the instrument cluster.
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Item Description
1 Adaptive Damper Unit Front-Right Hand
2 Accelerometer-Lateral
3 Accelerometer Vertical-Front
4 Adaptive Damper Unit Rear-Right Hand
5 Electronic Control Module (ADCM)
6 Accelerometer Vertical-Rear
7 Adaptive Damper Unit Rear-Left Hand
8 Adaptive Damper Unit Front-Left Hand
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Item Description
1 Power
2 Ignition Supply
3 Ground
4 Vertical Accelerometer - Front
5 Vertical Accelerometer - Rear
6 Lateral Accelerometer
7 Brake Operation Signal
8 Vehicle Speed Signal
9 Output to Fascia Message Centre
10 Damper Control Signals
Three accelerometers sense vehicle body movement and generate an analogue voltage (+5V max.) output, which
is proportional to the vehicle body movement. These voltages are supplied to the Adaptive Damping Control
Module (ADCM).
At 0g. (no movement of the body) each vertical accelerometer outputs approximately 2.5V steady voltage. The
lateral accelerometer outputs approximately 1.5V. The voltage output due to body movement is proportional to
acceleration in the acceleration axis, up to approximately 4.5V and down to approximately 0.5V.
The ADCM is hardwired to the Instrument Cluster. Should a fault occur, the ADCM grounds the System Error line
which switches on the amber warning lamp and displays the message SUSPENSION FAILURE on the message
centre.
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Refer to the PDU User Guide for details of diagnosing and testing the Adaptive Damping System. The PDU
interrogates the ADCM directly via the K and L lines to the diagnostic socket.
The PDU will give an indication of the integrity of each electronic and electrical component. It will indicate, for
example, that the accelerometers are not broken, but not that they functioning correctly when the vehicle is in
motion. However, it is exceptional for an accelerometer to function incorrectly in its dynamic mode if it is proved to
be functioning when static.
Basic Checks
Before changing any component, refer to the circuit diagrams of the manual and check the continuity of relevant
harness circuits; in some instances, the PDU will not differentiate between a faulty component and a damaged
connection or wiring.
Check the System Error line from the ADCM to the Instrument Cluster - Fascia Harness pin FC025/006. Check
the Road Speed Output from the Instrument Cluster to the ADCM - Fascia Harness pin FC026/007.
Check any relevant connections to confirm that the connection is electrically sound and that a terminal pin has not
been pushed back into the connector shell, ie. not making a connection to its mating pin / socket.
Check the following fuses in the luggage compartment fusebox: Fuse No. 2 (20A) and Fuse No. 4 (5A).
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Vehicle Dynamic Suspension - 204-05
Installation
3. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Driveline System - General Information - 205-00
Driveline System
Details of the Driveline System can be found in sections <<205-01>> and <<205-02>>.
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1999 XK RANGE - Driveshaft - 205-01
Torques
Component Nm
Bolt M12 - Jurid flexible coupling to transmission flange 75-88
Bolt M10 - Driveshaft to final drive unit flange 51-69
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1999 XK RANGE - Driveshaft - 205-01
Driveshaft
Item Description
1 Jurid flexible coupling
2 Sliding joint
3 Hookes joint
The one-piece aluminum driveshaft incorporates a flexible (Jurid) drive coupling at the transmission flange, a
sliding joint aft of the transmission and a Hookes joint at the differential.
The drive couplings and sliding joint allow for variations in the driveshaft alignment due to the relative movement
of components.
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1999 XK RANGE - Driveshaft - 205-01
Driveshaft 47.15.01
Special Service tools
Removal
2. Torque wrench setting using may be achieved using one of the following methods:
1. Torque wrench calibration machine ; apply the specified torque at the calibrator (using the adaptor)
and note the corresponding reading at the torque wrench
2. Formula to calculate the effect of the added length
RS = (W x T) / (W + L)WhereRS = Torque wrench settingW = Effective length of the torque
wrenchT = Torque specificationL = Length of adaptor
3. Using a torque wrench 330 mm (0,33 m) long and an adaptor 50mm (0,05 m) long, calculate as follows
for a specified torque of 60Nm:
RS = (0,33 x 60) / (0,33 + 0,05)
= 52,1Nm
Removal 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 problem, 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.
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1999 XK RANGE - Driveshaft - 205-01
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Installation
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1999 XK RANGE - Driveshaft - 205-01
2. NOTE:
See 'Special tool' notes
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Unit Specification
Final Drive Shell Spirax Super TS 90
Hub spline to Axle shaft Loctite 270 Studlock or equivalent
Capacities
Unit Liters
Final Drive 1,80
Torques
Component Nm
Bolt - Final drive nose plate 39 - 51
Bolt - 'A' frame to final drive 90 - 110
Nut 'A' frame to rear mounting bracket 85 - 115
Nut - Axle shaft to final drive flange 81 - 99
Nut - Axle shaft to hub 304 - 336
Nut - Damper lower fixing 80 - 100
Bolt M12 - Jurid flexible coupling to transmission 75 - 88
Bolt M10 - Driveshaft to final drive unit flange 51 - 69
Nut - Lower fulcrum 90 - 110
Nut - Pendulum to final drive 160 - 200
Nut - Stabilizer to wishbone 30 - 40
Nut - Tie rod to final drive 85 - 105
Nut - Tie rod to wide mounting bracket 85 - 115
Nut - Wishbone pivot 80 - 100
Nut - Wishbone tie to final drive 85 - 105
Nut 'A' frame to wide mounting bracket 85 - 105
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
3. Mount a dial test indicator (DTI) to the differential housing with the probe resting on the axle shaft flange
(the DTI probe must be parallel to the output shaft center line and NOT the axle shaft)
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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Parts List
Item Description
1 Final Drive Unit
2 Wide Mounting Bracket
3 Pendulum Assembly
4 Wishbone Tie Assembly
5 'A' Frame
The type 14 HU final drive assembly is a hypoid unit with the pinion arranged on the cross-car cenerline. It utilizes
a cassette type pinion oil seal and sealed output shaft bearings.
The differential unit is mounted between the wide mounting bracket, pendulum assembly and the wishbone tie
assembly. Two tie rods are fitted between top rear of the final drive casing and the front of the wide mounting
bracket.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Removal
5. CAUTION:
Do not lift the assembly by the driveshafts, this may cause damage
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
7. Tighten the spring compressor evenly to release the spring load on the damper
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
14. Position the axle assembly on its LH side and support it on wooden blocks
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
19. Position the assembly for access to the 'A' frame to final drive fixings, noting that oil may issue from the
breather
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Installation
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
3. Locate the 'A' frame rear bracket and 'A' frame assembly
1. Fit the 'A' frame rear bracket
2. Fit the 'A' frame assembly
3. Loose assemble the 'A' frame to final drive fixings
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
7. NOTE:
Ensure the correct orientation of the flat sided washers
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12. Ensure that the spring pan and wishbone location reflects the original condition
14. Check and adjust as required, the final drive unit oil level
15. Check and adjust as required, the rear wheel alignment, <<204-02>>.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Hub remover
204-011
Thread protector
JD 1D / 7
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Removal
2. Support the vehicle at the rear and remove the appropriate rear road wheel
3. Remove and discard the hub nut, apply the brakes to prevent rotation
4. Remove the brake caliper in accordance with <<70.55.03>>, but do not disconnect the hydraulics
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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CAUTION:
Take care not to introduce debris into the hub bearings, or damage the seal
Using service tool 204 - 011, push the axle shaft through the hub
9. NOTE:
In the wheel-free condition, the axle is in tension and the flanges will separate as the nuts are withdrawn
10. NOTE:
The axle shaft nuts may damage the studs upon removal; check the thread condition by engaging a new
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Inspect the output flange studs and renew if there is evidence of damage / distortion
11. Clean all traces of thread locking agent from the hub splines (and axle shaft if it is to be re-used)
Installation
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
5. Check and adjust as required, the final drive unit oil level
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Removal
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3. NOTE:
In the wheel-free condition, the axle is in tension and the flanges will separate as the nuts are withdrawn
4. Thoroughly clean the area around the output shaft housing and differential case
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
CAUTION:
Do not drill into the output shaft, it is not necessary to break the inside diameter of the collar
2. Drill 3 off holes 4,0 mm dia equally spaced, to a MAXIMUM depth of 5,0 mm
CAUTION:
There is no need to split the collar when chiselling
With a suitable chisel strike the collar across the three drilled holes (along the axis of the output shaft)
to relieve tension within the steel
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
8. CAUTION:
The original bearing must NOT be reused
Using a suitable press remove and discard the bearing, collar and circlip
Installation
1. Inspect the output shaft for damage and corrosion, replace as necessary
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
CAUTION:
If the gap CANNOT be achieved, contact Jaguar Service
2. A gap smaller than specified will indicate an improperly fitted circlip. This may be rectified by refitting
or by the application of radial pressure around the inner circumference of the circlip
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Removal
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
2. WARNING:
MAKE SURE NO DAMAGE OCCURS TO THE INPUT SHAFT.
Release the peened collar of the drive pinion flange retaining nut.
3. WARNING:
MAKE SURE NO DAMAGE OCCURS TO THE INPUT SHAFT THREADS.
Using the special tool, remove and discard the drive pinion flange retaining nut.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
4. Using the special tool, remove and discard the drive pinion flange.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
Installation
1. Slide the drive pinion oil seal and ryton ring against the shoulder of the drive pinion flange.
1. Position the ryton ring to the drive pinion oil seal.
2. Slide the drive pinion oil seal and ryton ring against the shoulder of the drive pinion flange.
2. NOTE:
Apply a suitable amount of clean differential oil to lubricate the outer diameter of the drive pinion oil seal.
Loosely install the drive pinion flange assembly to the differential case.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
3. Slide the drive pinion flange assembly into position until the drive pinion oil seal is adjacent to the differential
case.
4. NOTE:
Install a new drive pinion flange retaining nut.
NOTE:
Make sure the ryton ring has remained correctly positioned to the drive pinion oil seal.
Using the special tool, tighten the drive pinion flange retaining nut to 203 - 223 Nm.
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1999 XK RANGE - Rear Drive Axle/Differential - 205-02
5. Peen the collar of the drive pinion flange retaining nut to the drive pinion.
7. Check the differential oil level, and if necessary, fill the differential with oil to the lower edge of the fill hole.
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1999 XK RANGE - Brake System - General Information - 206-00
Unit Specification
Brake fluid ITT Super Dot 4
Component Dimension
Brake disc - diameter 305 mm
Brake disc - thickness (new) 19.5 - 20 mm
Brake disc - minimum thickness 18.5 mm
Brake disc - minimum wall thickness 4.9 mm
Brake disc - maximum run-out 0.15 mm
Caliper piston diameter 42 mm
Parking brake drum - maximum diameter 181 mm
Brake pad - minimum thickness 2 mm
Parking brake shoes - minimum thickness 2 mm
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1999 XK RANGE - Brake System - General Information - 206-00
WARNING:
WASH HANDS AFTER HANDLING BRAKE FLUID. IF BRAKE FLUID COMES INTO CONTACT WITH THE
EYES, FLUSH EYES WITH COLD RUNNING WATER. IF IRRITATION PERSISTS SEEK MEDICAL
ATTENTION. IF BRAKE FLUID IS TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET
MEDICAL ATTENTION IMMEDIATELY.
CAUTION:
Remove brake fluid spillage immediately from paint work with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. NOTE:
Make sure the brake-fluid level does not fall below the fluid reservoir 'MIN' (minimum) mark when bleeding
the brake system.
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1999 XK RANGE - Brake System - General Information - 206-00
7. Following the procedure above, bleed the brakes in the order shown:
1. Left-Hand Front,
2. Right-Hand Front,
3. Left- Hand Rear,
4. Right-Hand Rear.
8. CAUTION:
Remove brake fluid spillage immediately from paint work with clean water.
9. Start engine.
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1999 XK RANGE - Brake System - General Information - 206-00
11. Apply brake pedal and check around vehicle for brake fluid leaks.
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1999 XK RANGE - Brake System - General Information - 206-00
2. Remove wheel.
3. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
4. Make sure that wheel bearing end-float is correct. Refer to specification section <<204-01>>.
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1999 XK RANGE - Brake System - General Information - 206-00
6. If the brake disc run-out exceeds specification, reposition the brake disc on the hub and repeat the above
procedure. Continue repositioning the brake disc until the run-out is within specification.
7. If the brake disc run-out still exceeds specification, check the hub face run-out.
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10. NOTE:
Make sure the brake disc and hub mating surfaces are clean.
If the hub run-out is within specification replace brake discs. Refer to procedure 70.10.12.
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2. Remove wheel.
3. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
4. NOTE:
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Measurement of the brake disc run-out, must be carried-out with the disc and hub parking-brake
adjuster-holes aligned.
Make sure that wheel bearing end-float is correct. Refer to specification section <<204-02>>.
6. If the brake disc run-out exceeds specification, check the hub face run-out.
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9. NOTE:
Make sure the brake disc and hub mating surfaces are clean.
If the hub run-out is within specification replace brake discs. Refer to procedure 70.10.13.
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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 hand operated control.
NOTE:
Prior to carrying out any diagnosis, make sure that the brake system warning indicator is functional.
Visually examine the front and rear tire and wheel 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
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
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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.
Condition(s):
Brakes noisy
Possible Source(s):
Brake pads.
Brake discs.
Action(s) to take:
GO to <<Pinpoint Test A>>.
Action(s) to take:
Go to <<Pinpoint Test B>>.
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Action(s) to take:
GO to <<Pinpoint Test C>>.
Action(s) to take:
GO to <<Pinpoint Test D>>.
Action(s) to take:
GO to <<Pinpoint Test E>>.
Action(s) to take:
Go to <<Pinpoint Test F>>.
Action(s) to take:
GO to <<Pinpoint Test G>>.
Action(s) to take:
GO to <<Pinpoint Test H>>.
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Brakes drag
Possible Source(s):
Parking brake control applied/malfunction.
Seized parking brake cables.
Seized caliper slide pins.
Seized caliper.
Brake booster.
Pedal gear.
Action(s) to take:
GO to <<Pinpoint Test I>>.
Action(s) to take:
GO to <<Pinpoint Test J>>.
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.
Action(s) to take:
RELEASE and ADJUST the parking brake. For additional information, refer to<<206-05>>.
Possible Source(s):
Electrical circuit.
Action(s) to take:
For additional information, refer to PDU for analysis/rectification of the concern.
Action(s) to take:
GO to <<Pinpoint Test K>>.
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A : BRAKES NOISY
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
Goto <<A2>>
-> 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.
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.
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
If the vibration is from the front of the vehicle
Goto <<B3>>
If the vibration is from the rear of the vehicle or can not be diagnosed between front or rear of the vehicle
Goto <<B6>>
-> No
Vehicle is OK.
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1. Check the condition of the front suspension bushes and ball joints <<204-01>> Check the condition of the steering
linkage components <<211-02>><<211-03>>
Do any of the front suspension components or steering components require replacement?
-> Yes
INSTALL new components as necessary <<204-01>><<211-02>><<211-03>> Road test the vehicle
between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal. If vibration still exists
Goto <<B4>>
-> No
Goto <<B4>>
1. Check the condition of the front brake pads and front brake discs.
Does excessive brake disc runout or brake disc thickness variation exist?
-> Yes
Goto <<B5>>
-> No
Goto <<B6>>
1. Check to see if the vehicle has recently been repaired for brake vibration problems by the installation of new front
brake discs and pads.
Has vehicle has recently been repaired for brake vibration problems by the installation of new front
brake discs and pads.
-> Yes
INSTALL new front wheel hubs <<204-01>> INSTALL new front brake discs and front brake pads
<<206-03>> TEST the system for normal operation.
-> No
INSTALL front brake discs and front brake pads <<206-03>> CHECK for excessive brake disc runout If
excessive brake disc runout exists INSTALL new front wheel hubs <<204-01>> TEST the system for normal
operation.
1. Check the condition of the rear brake pads and rear brake discs.
Does excessive brake disc runout or brake disc thickness variation exist?
-> Yes
INSTALL rear brake discs and rear brake pads <<206-04>> CHECK for excessive brake disc runout. If
excessive brake disc runout exists INSTALL new rear wheel hubs. TEST the system for normal operation.
-> No
REPEAT road test and re-check for a vibration concern. If vibration exists
Goto <<B3>>
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C3 : CHECK 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
INSTALL new calipers as necessary. TEST the system for normal operation.
-> No
Goto <<C4>>
1. Check the brake discs for excessive damage, thickness variation or runout. For additional information, refer to
General Procedures in this section.
Does excessive damage or runout exist?
-> Yes
INSTALL new brake discs and brake pads as necessary. TEST the system for normal operation.
-> No
Goto <<C5>>
1. Check the front hub and wheel bearing assembly. For additional information, refer to<<204-00>>.
Are the wheel bearings OK?
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-> Yes
Goto <<C6>>
-> No
INSTALL new wheel bearings. For additional information, refer to<<204-01>>. TEST the system for normal
operation.
1. Pump the brake pedal 10 times and hold on the final application.
Does the brake pedal feel firm on final application?
-> Yes
Goto <<D3>>
-> No
BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the
system for normal operation.
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.
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-> Yes
BLEED the brake system. For additional information, refer to General Procedures in this section. TEST the
system for normal operation. REPEAT road test.
-> No
Goto <<E4>>
1. Check for external brake system leaks. For additional information, refer to 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 in this section. TEST the system for normal operation. REPEAT road test.
-> No
System is OK.
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
Goto <<F2>>
-> No
Goto <<F3>>
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 in this section. TEST the system for normal operation.
-> No
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System is OK.
1. Check the brake pads for wear, contamination, correct installation, damage and type.
Are any concerns found?
-> 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
Goto <<G2>>
G2 : CHECK VACUUM
G3 : INSPECT SYSTEM
1. Switch the engine off.
2. Reconnect the vacuum hose.
3. Inspect the brake booster, rubber grommet, and all vacuum plumbing for cracks, holes, damaged connections, or
missing clamps.
4. Pump the brake pedal several times to exhaust the vacuum. Push down on the brake pedal and hold.
Does the brake pedal move down when the engine is started?
-> Yes
Vacuum system is OK.
-> No
Goto <<G4>>
1. Check the brake booster valve. For additional information, refer to Brake Booster in this section.
Is the power brake booster valve OK?
-> Yes
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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.
1. Road test the vehicle and apply the brake pedal lightly.
Do the brakes lockup?
-> Yes
Goto <<H2>>
-> No
Vehicle is OK.
1. Inspect brake pads for contamination, correct installation, damage and type.
Are any concerns found?
-> 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
Goto <<H3>>
I : BRAKES DRAG
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Goto <<I2>>
I2 : CHECK 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
Goto <<I3>>
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.
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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?
-> Yes
Goto <<J4>>
-> No
CHECK the vacuum to the brake booster. For additional information, refer to<<206-07>>.
1. Check the front hub and bearing assembly. For additional information, refer to<<204-01>>.
Are the front wheel bearings loose?
-> Yes
INSTALL a new front wheel bearing if damaged. For additional information, refer to<<204-01>>. TEST the
system for normal operation.
-> No
CHECK the front brake discs for thickness variances. For additional information, refer to General
Procedures in this section.
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
Goto <<K2>>
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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.
3. With the transmission in PARK, 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. For additional information, refer to
General Procedures in this section.
Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In
diagnosing the condition of the brake master cylinder, check pedal feel as evidence of a brake concern. Check for
brake warning lamp illumination and the brake fluid level in the brake master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder is in need of
repair.
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.
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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, an incorrectly
adjusted parking brake, 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.
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 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 reservoir mounting seals. Repair such a leak by installing new seals and
make sure that the reservoir retaining bolt is correctly installed.
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1999 XK RANGE - Front Disc Brake - 206-03
Unit Specification
Brake fluid ITT Super Dot 4
Torques
Component Nm
Bolt - caliper carrier to vertical link 120-160
Guide Pin - caliper housing to caliper carrier 25-30
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. See section <<100-00>> for
information.
Component Nm
Bleed nipple - front 4-6
Bleed nipple - rear 8-11
Hose to front caliper 10-14
Hose banjo to rear caliper 30-40
M10 hose locknut 15-20
M10 brake tube female-nut 13-17
M10 brake tube male-nut 13-17
M12 brake tube male-nut 15-20
Bolt - 3-way tube connector to body 9-12
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Components
Item Description
1 Brake Disc
2 Caliper Housing
3 Caliper Carrier
4 Brake Pads
5 Guide Pins
6 Dust Covers
7 Anti-rattle Spring
8 Dust Shield
9 Brake Hose
10 Bleed Nipple
The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through
the center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions.
The caliper carrier, which is secured to the vertical link by two bolts, carries the single-piston caliper housing. The
caliper housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are
applied the caliper-housing piston pushes the brake pad in front of it, towards the brake disc. This movement forces
the caliper housing to move along the guide-pins, in the opposite direction of the piston, to apply the second brake
pad. The brake disc is therefore gripped between the two pads. As brake pressure is increased the grip on the brake
disc is increased to slow-down the rotation of the road wheel.
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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:
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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
CAUTION:
A new brake hose must be installed when replacing a front brake caliper.
CAUTION:
The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of
the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
1. Open engine compartment and fit paint work protection covers to fenders.
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5. NOTE:
The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting
the brake hose.
6. Depress and hold down brake pedal at the specified measurement using the special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
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8. CAUTION:
A new brake hose must be installed when replacing a front brake caliper.
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11. NOTE:
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
13. Remove brake dust and clean caliper mating surfaces. See Warning above.
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Installation
2. NOTE:
Clean caliper piston to pad mating surface .
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4. NOTE:
The brake hose must only be installed with the vehicle's body supported and the suspension hanging in the
straight ahead position.
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5. NOTE:
Make sure the brake hose does not twist when tightening the hose lock-nut.
8. NOTE:
Make sure the brake hose is routed correctly.
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Removal WARNING:
BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS.
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:
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. See section <<100-00>> for
information.
1. Open engine compartment and install paint work protection covers to fenders.
4. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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5. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
6. CAUTION:
Always install new brake pads, irrespective of the condition of the original pads, when renewing
brake discs.
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NOTE:
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
10. Remove brake dust from calipers and clean mating surfaces, see WARNING above.
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11. Thoroughly clean the area of the hubs where they mate against the brake discs.
Installation
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4. CAUTION:
Always install new brake pads, irrespective of the condition of the original pads, when renewing
brake discs.
CAUTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage
immediately from paint work, with clean water.
NOTE:
Clean caliper piston to pad mating surface.
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9. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
10. Remove paint work protection covers, and close engine compartment.
11. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
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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:
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. See section <<100-00>> for
information.
1. Open engine compartment and fit paint work protection covers to fenders.
4. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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5. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
6. NOTE:
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
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7. Clean all mating surfaces and remove brake dust, see WARNING above.
Installation
1. CAUTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage
immediately from paint work, with clean water.
NOTE:
Clean caliper piston to pad mating surface.
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6. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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8. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
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1999 XK RANGE - Rear Disc Brake - 206-04
Unit Specification
Brake fluid ITT Super Dot 4
Torques
Component Nm
Bolt - caliper carrier to hub carrier 54-66
Guide Pin - caliper housing to caliper carrier 25-30
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. See section <<100-00>> for
information.
Component Nm
Bleed nipple - front 4-6
Bleed nipple - rear 8-11
Hose to front caliper 10-14
Hose banjo to rear caliper - bolt 30-40
M10 hose locknut 15-20
M10 brake tube female-nut 13-17
M10 brake tube male-nut 13-17
M12 brake tube male-nut 15-20
3-way tube connector to body 9-12
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1999 XK RANGE - Rear Disc Brake - 206-04
Components
Item Description
1 Brake Disc
2 Caliper Housing
3 Caliper Carrier
4 Brake Pads
5 Guide Pins
6 Dust Covers
7 Anti-rattle Spring
8 Dust Shield
9 Brake Hose
10 Bleed Nipple and Cap
The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through
the center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions.
The caliper carrier, which is secured to the hub carrier by two bolts, carries the single-piston caliper housing. The
caliper housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are
applied the caliper-housing piston pushes the brake pad in front of it, towards the brake disc. This movement forces
the caliper housing to move along the guide-pins, in the opposite direction of the piston, to apply the second brake
pad. The brake disc is therefore gripped between the two pads. As brake pressure is increased the grip on the brake
disc is increased to slow-down the rotation of the road wheel.
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1999 XK RANGE - Rear Disc Brake - 206-04
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:
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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
CAUTION:
The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of
the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
1. Open luggage compartment lid and fit suitable paintwork protection equipment.
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5. NOTE:
The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting
the brake hose.
6. Depress and hold down brake pedal at the specified measurement using the special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
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10. NOTE:
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
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12. Clean all mating surfaces and remove brake dust. See Warning above.
Installation
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Removal WARNING:
BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS.
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:
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. See section <<100-00>> for
information.
1. Open engine compartment and fit paint work protection covers to fenders.
4. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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5. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
6. CAUTION:
Always install new brake pads, irrespective of the condition of the original pads, when renewing a
brake disc.
NOTE:
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The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
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11. Remove brake dust from calipers, and from area of parking brake shoes, see WARNING above.
13. Thoroughly clean the area of both hubs where they mate against the brake discs.
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Installation
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5. CAUTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage
immediately from paint work, with clean water.
6. CAUTION:
Always install new brake pads, irrespective of the condition of the original pads, when renewing a
brake disc.
NOTE:
Clean caliper piston to pad mating surface.
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11. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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12. Remove paint work protection covers, and close engine compartment.
13. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
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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:
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. See section <<100-00>> for
information.
1. Open engine compartment and fit paint work protection covers to fenders.
4. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
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1999 XK RANGE - Rear Disc Brake - 206-04
5. CAUTION:
Tie caliper housing aside. Do not allow the caliper housing to hang on the hydraulic hose, as this
will damage the hose.
6. NOTE:
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.
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7. Clean all mating surfaces and remove brake dust. See Warning above.
Installation
1. CAUTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid spillage
immediately from paint work, with clean water.
2. NOTE:
Clean caliper piston to pad mating surface.
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Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back
of inner pad into caliper piston.
7. CAUTION:
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Remove brake fluid spillage immediately from paint work, with clean water.
9. Start the engine and repeatedly press the brake pedal until brake pressure is evident.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Dimensions
NOTE:
When a component reaches its maximum / minimum limit the component must be replaced. Care must be taken
when refinishing brake drums that the limits are not exceeded.
Component Dimension
Parking brake drum - maximum diameter 181 mm
Parking brake shoes - minimum thickness 2 mm
Torques
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. See section <<100-00>> for
information.
Component Nm
Bolt - parking brake lever to body 22-28
Bolt - pivot to body 22-28
Bolt - relay lever mounting plate to body 22-28
Bolt - relay lever to mounting plate 22-28
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4. CAUTION:
Make sure that the rear wheels rotate freely when the parking brake lever is released.
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3. Make sure that the parking brake lever is released, and the gear selector lever is in the neutral (N) position.
5. Using a flat-bladed screwdriver rotate the adjuster counter-clockwise until the brake disc cannot be rotated.
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6. NOTE:
The brake shoe return-spring next to the adjuster prevents the adjuster from rotating under normal operating
conditions. Make sure that the spring is seated between the adjuster spokes, when brake adjustment is
complete.
Rotate the adjuster gradually clockwise until the brake disc rotates freely.
Install plug to access hole.
8. CAUTION:
Make sure that the rear wheels rotate freely when the parking brake lever is released.
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Parking Brake
Item Description
1 Hand Lever
2 Front Cable
3 Relay Lever Mounting Plate
4 Relay Lever
5 Cable Adjuster Rod
6 Equalizer
7 Rear Cable RH
8 Rear Cable LH
9 Warning-Light Switch
The parking-brake hand lever is mounted on the inner sill and incorporates the ratchet mechanism and release button.
The front cable is routed from the hand lever, under the carpet through to an abutment bracket adjacent to the
transmission tunnel, and then connected to the relay lever. The relay lever is attached to a mounting plate by a center
bolt on which it rotates The relay lever mounting plate straddles the transmission tunnel, the plate is secured by four
bolts on the coupe, and eight bolts on the convertible which has a longer plate. The relay lever acts as a center pull
system to transmit the force from the hand lever to the rear brakes shoes. The equalizer which is positioned in the
center of the rear brake cables balances the force that is applied to the rear brakes.
The rear brake cables are linked together: each cable passes through the suspension subframe and rear hub carrier
and connects to a brake shoe expander lever. Application of the parking brake causes the rear cables to pull on the
expander levers, the expander lever mechanism rotates on a pivot pin to force the brake shoes outwards to contact
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The parking brake cables are adjusted by the rotation of a nut on the adjuster rod. The parking brake shoes are
adjusted by means of a manual adjustment mechanism at each set of shoes. Refer to General Procedures in section
<<206-05>>.
If the vehicle is driven above 5 km/h with the parking brake applied, a warning lamp and text message will appear on
the message center. The message clears when the brake is released or the speed drops below 3 km/h.
Item Description
1 Adjuster Mechanism
2 Retaining Pins
3 Brake Shoes
4 Upper Return Spring
5 Lower Return Spring
6 Expander Lever Mechanism
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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:
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. See section <<100-00>> for
information.
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5. NOTE:
Spacers and washers (if installed) are used to seat the hand lever. For installation purposes note the
number and position of the washers that are removed from each bolt.
6. NOTE:
For installation purposes note the number of washers (if installed) that are removed from the bolt.
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Installation
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3. Release cover trim securing clip from brake lever and remove cover trim.
Installation
1. With parking brake lever in the fully up position, install cover trim on lever.
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Removal 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. See section <<100-00>> for
information.
4. Remove the lower slider bar of the driver side seat belt.
1. Remove bolt.
2. Remove slider bar from body grommet and seat belt loop.
3. Collect spacer and card washer.
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5. Raise rear seat cushion on driver's side of vehicle for access to carpet.
Remove nuts securing seat cushion to body
Raise seat cushion.
7. Raise vehicle.
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Installation
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1999 XK RANGE - Parking Brake and Actuation - 206-05
4. Raise vehicle.
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8. Lower vehicle.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
11. Install the lower slider bar of the driver side seat belt.
1. Insert slider bar through seat belt loop and body grommet.
2. Position spacer and card washer.
3. Install bolt and tighten to 34-46 Nm.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Removal 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. See section <<100-00>> for
information.
3. Remove equalizer.
1. Remove adjustment nut.
2. Remove equalizer from adjustment rod and cable.
3. Remove damper.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
5. CAUTION:
Be aware of the spring torsion when removing components from the relay lever.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Installation
1. NOTE:
Make sure return-spring legs are located correctly after installation.
NOTE:
Apply grease to clevis pins and relay lever.
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2. Tighten bolts.
1. Tighten bolts to 22-28 Nm.
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Parking Brake Linkage Lever Mounting Plate Vehicles Without: Convertible Top 70.35.42
Removal 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. See section <<100-00>> for
information.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
4. CAUTION:
Be aware of the spring torsion when removing components.
Installation
1. NOTE:
Make sure return-spring legs are located correctly after installation.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
2. Tighten bolts.
1. Tighten bolts to 22-28 Nm.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Removal 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. See section <<100-00>> for
information.
1 2012-07-21
1999 XK RANGE - Parking Brake and Actuation - 206-05
4. CAUTION:
Be aware of the spring torsion when removing components.
Installation
1. NOTE:
Make sure return-spring legs are located correctly after installation.
2. Tighten bolts.
1. Tighten bolt to 22-28 Nm.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Removal 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. See section <<100-00>> for
information.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
Installation
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1999 XK RANGE - Parking Brake and Actuation - 206-05
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:
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. See section <<100-00>> for
information.
1. Open engine compartment and fit paint work protection covers to fenders.
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10. Remove brake shoes from parking brake lever-mechanism and remove shoes from vehicle.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
12. Remove brake dust and clean components, see WARNING above.
13. Repeat procedure to remove parking brake shoes on opposite side of vehicle.
Installation
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3. NOTE:
Make sure retaining pin is seated correctly in backing plate.
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1999 XK RANGE - Parking Brake and Actuation - 206-05
6. NOTE:
Make sure retaining pin is seated correctly in backing plate.
7. Make sure brake shoes are seated correctly in adjuster and lever mechanism.
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Unit Specification
Brake fluid ITT Super Dot 4
Torques
Component Nm
Nut - master cylinder to brake booster 21-29
Nut - brake pedal pivot-pin to pedal housing 15-20
Nut - brake switch to pedal housing 3
Bolt - pedal housing to body 15-20
Nut - pedal housing to body 15-20
Nut - brake booster to pedal housing 22-28
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. See section <<100-00>> for
information.
Component Nm
Bleed nipple - front 4-6
Bleed nipple - rear 8-11
Hose to front caliper 10-14
Hose banjo to rear caliper - bolt 30-40
M10 hose locknut 15-20
M10 brake tube female-nut 13-17
M10 brake tube male-nut 13-17
M12 brake tube male-nut 15-20
Bolt - 3-way tube connector to body 9-12
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Item Description
1 Pedal Housing / Booster - refer to <<206-07>>
2 Vacuum Hose - refer to <<206-07>>
3 Master Cylinder / Reservoir
4 Primary Brake Circuit
5 Secondary Brake Circuit
6 Hydraulic Pump / Motor Unit - refer to <<206-09>>
7 Valve Block - refer to <<206-09>>
8 ABS/Traction Control Control Module (ABS/TCCM) - refer to <<206-09>>
6/7/8 Brake Control Modulator
9 Brake Disc - refer to <<206-03>> or <<206-04>>
10 Brake Caliper: refer to <<206-03>> / <<206-04>>
11 Wheel Speed Sensor - refer to <<206-09>>
12 ABS Warning Lamp - refer to <<206-09>>
13 Brake Fluid Level Warning-Lamp
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The tandem master cylinder contains two independent pistons, fluid pressure to each brake circuit is controlled by its
own individual piston. Brake fluid is supplied to the master cylinder by the reservoir, which is divided into two sections
to prevent total fluid loss should one of the circuits fail. A port situated at the bottom of each section of the reservoir
supplies the fluid to each piston.
The fluid reservoir has a fluid-level indicator switch installed, which operates when the fluid level is low, causing the
brake fluid level warning-lamp to illuminate.
Brake Calipers
The brake calipers are of the single piston type. The caliper carrier, which is secured to the vertical link by two bolts,
carries the single-piston caliper housing. The caliper housing is secured to the caliper carrier by two guide-pins and a
anti-rattle spring. When the brakes are applied, the caliper-housing piston pushes the brake pad in front of it, towards
the brake disc. This movement forces the caliper housing to move along the guide-pins, in the opposite direction of the
piston, to apply the second brake pad.
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Remove reservoir filler cap and empty residual brake fluid into a container. Refit cap.
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Installation
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3. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
5. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
6. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
4 2012-07-21
1999 XK RANGE - Hydraulic Brake Actuation - 206-06
Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, refer to operation <<86.15.19>> for further information).
4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
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Installation
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5. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
8. Connect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
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Brake Pedal
Removal
4. Clean components.
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Installation
CAUTION:
Make sure the BPP switch ratchet adjuster is fully released before installing.
3. Install the brake booster and brake master cylinder assembly. <<206-07>>
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Remove brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
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Installation
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3. Install brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
4. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
6. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
7. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
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Brake Pedal and Bracket, Brake Booster and Brake Master Cylinder 70.35.39
Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
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7. Position absorbent cloth underneath master cylinder to collect brake fluid spillage.
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9. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
11. Remove pedal housing, brake booster and master cylinder assembly from vehicle.
Remove nuts and bolts.
Remove assembly from vehicle.
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Installation
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2. CAUTION:
Make sure no pipes or cables become trapped when fitting the pedal housing assembly.
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8. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
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10. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
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1999 XK RANGE - Power Brake Actuation - 206-07
Unit Specification
Brake fluid ITT Super Dot 4
Torques
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. See section <<100-00>> for
information.
Component Nm
Nut - master cylinder to brake booster 21-29
Nut - brake pedal pivot-pin to pedal housing 15-20
Nut - brake switch to pedal housing 3
Bolt - pedal housing to body 15-20
Nut - pedal housing to body 15-20
Nut - brake booster to pedal housing 21-29
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. See section <<100-00>> for
information.
Component Nm
Bleed nipple - front 4-6
Bleed nipple - rear 8-11
Hose to front caliper 10-14
Hose banjo to rear caliper - bolt 30-40
M10 hose locknut 15-20
M10 brake tube female-nut 13-17
M10 brake tube male-nut 13-17
M12 brake tube male-nut 15-20
Bolt - 3-way tube connector to body 9-12
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Brake Booster
Item Description
1 Master Cylinder / Reservoir - refer to <<206-06>>
2 Booster
3 Pedal Box - refer to <<206-06>>
4 Vacuum Hose
5 Non-Return Valve
The brake booster provides assistance by reinforcing the driver's effort when braking. The reinforced
assistance provided by the booster is proportional to the driver's effort applied to the brake pedal.
The brake force applied by the driver is increased by the booster in a ratio of 6.5:1.
The vacuum used to operate the booster is formed in the engine's intake manifold. The booster is connected
to the intake manifold by a hose.
The booster is fail-safe therefore, if a fault develops in the vacuum unit, the braking system will still function.
However, the driver will have to apply a greater force to the brake pedal to slow down the vehicle.
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Remove brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
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Installation
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3. Install brake booster and master cylinder assembly. Refer to operation <<70.50.18>>.
4. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
6. Install windshield wiper arm and blade assembly. Refer operation 84.15.44.90.
7. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
2. Open engine compartment and fit paint work protection covers to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
4. Remove windshield wiper arm and blade assembly for access. Refer to operation 84.15.44.90.
6. Remove pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Remove reservoir filler cap and pour residual brake fluid into a container. Refit cap.
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10. Separate brake booster and master cylinder assembly from pedal housing.
Remove nuts.
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Installation
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2. Align brake booster assembly to pedal housing, make sure push-rod fork straddles brake pedal.
Install nuts and tighten to 22-28 Nm.
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5. Install pedal housing, brake booster and master cylinder assembly. Refer to operation <<70.35.39>>.
7. Install windshield wiper arm and blade assembly. Refer to operation 84.15.44.90.
8. Reconnect battery ground cable (IMPORTANT, see operation <<86.15.15>> for further information).
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Unit Specification
Brake fluid ITT Super Dot 4
Torques
Component Nm
Bolt - front wheel speed sensor 8-10
Bolt - rear wheel speed sensor 8-10
Bolt - hydraulic control unit to bracket 8-10
Hub rotor nut 270-330
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. See section <<100-00>> for
information.
Component Nm
Bleed nipple - front 4-6
Bleed nipple - rear 8-11
Hose to front caliper 10-14
Hose banjo to rear caliper - bolt 30-40
M10 hose locknut 15-20
M10 brake tube female-nut 13-17
M10 brake tube male-nut 13-17
M12 brake tube male-nut 15-20
Bolt - 3-way tube connector to body 9-12
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Anti-Lock Control
Component Location
Item Description
1 Pedal Housing / Booster - refer to <<206-07>>
2 Vacuum Hose - refer to <<206-07>>
3 Master Cylinder / Reservoir - refer to <<206-06>>
4 Primary Brake Circuit - refer to <<206-06>>
5 Secondary Brake Circuit - refer to <<206-06>>
6 Hydraulic Pump / Motor Unit
7 ABS/Traction Control Control Module (ABS/TCCM)
8 Hydraulic Control Unit (HCU)
6/7/8 Brake Control Modulator
9 Brake Disc - refer to <<206-03>> or <<206-04>>
10 Brake Caliper - refer to <<206-03>>/<<206-04>>
11 Wheel Speed Sensor
12 ABS Warning Lamp
13 Brake Fluid Level Warning-Lamp - refer to <<206-06>>
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Each wheel is monitored by a wheel speed sensor, to detect the speed of movement of a toothed gear that is driven
by the wheel. Signal's generated by the toothed gear passing the sensor are sent to the ABS/TCCM to communicate
the speed of wheel rotation and any rapid change of wheel speed.
The frequency of the sinusoidal output voltage signal from the sensor, is proportional to road wheel rotational speed
and the number of teeth on the toothed gear. The amplitude of the voltage is dependent upon the 'air gap' between
the sensor and toothed wheel, therefore it is important that this preset gap remains clear and undisturbed.
a ABS/TCCM
a hydraulic control unit,
an electrically driven hydraulic pump,
two low pressure accumulators and damping chambers.
ABS/TCCM
The ABS/TCCM is integrated with the hydraulic control unit. It houses the solenoids that operate the hydraulic control
unit's input and return valves; the valve stems locate into the ABS/TCCM's solenoids. There is no electrical connection
between the ABS/TCCM and the hydraulic control unit.
The ABS/TCCM constantly monitors the brake electronic system by passing self-checking electrical pulses around the
circuit. The self check procedures carried-out by the ABS/TCCM are listed below:
1. Monitoring of the operating voltage: the control module will shut-down should the voltages not be
(approximately) in the range of 9 to 19V.
3. Monitoring for disturbance, where a failure may be caused by external radio frequency interference, internal
leakage current, defective valve transistor or a faulty valve.
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5. The controller area network (CAN) micro-controller checks for correct operation of the communication
network and performs a RAM self-check.
CAUTION:
Disconnection of ABS/TCCM connectors may introduce other fault codes. Following rectification and
reconnection, ensure that no induced codes exist.
Signals processed by the ABS/TCCM are also sent to the CAN for vehicle use, such as the instrument cluster speed
display, cruise control and stability/traction control.
Control of the fluid pressure to the front and rear brakes is by means of the valves contained in the hydraulic control
unit. The valves are operated by solenoids housed in the ABS/TCCM.
Hydraulic Pump
It is a reciprocating two-circuit pump in which one brake circuit is assigned to each pump circuit.
It supplies the fluid pressure and volume to supply the brake circuits under ABS and Traction control.
The pump is driven by an electric motor, with the pump housing incorporating two low pressure accumulators
and damping chambers for each brake circuit.
The accumulator stores the pressure and smooths out the output pulses from the pump.
The system will be set in a fail-safe mode if a problem is detected; a warning lamp on the instrument panel will notify
the driver there is a problem.
The ABS components are combined with an hydraulic booster and a tandem master cylinder to provide a two circuit
braking system. The system comprises, four wheel speed sensors, a brake control modulator and an ABS warning
lamp.
Should a wheel start to lock-up during braking a signal transmitted from the wheel speed sensor to the brake control
modulator will start the hydraulic pump. The brake control modulator will close the input valve of the line connected to
the locked-wheel to stop any increase in fluid pressure to the brake caliper. If this fails to prevent the wheel locking,
the pressure in the caliper will be decreased by opening the return valve until the wheel starts accelerating again. The
fluid pressure from the return valve is directed into the low pressure accumulator, housed in the pump.
From the low pressure accumulator, fluid is pumped through the damping chamber to the brake master cylinder. The
pressure to the brake caliper will then be increased in small steps to maintain maximum adhesion between the tire and
road surface. This is achieved by closing the return valve, and opening the input valve and using the hydraulic pump to
increase the pressure.
Although the system senses all four wheels independently, the rear wheels are regulated as a pair. If a sensor on a
rear wheel detects a wheel decelerating rapidly, then the fluid pressure to both wheels is reduced. The fluid pressure
is then dictated by the wheel having the lowest adhesion with the road surface.
The ABS system will be set in a fail-safe mode if a problem is detected; a warning lamp on the instrument panel will
notify the driver there is a problem. The brake system will still operate conventionally and with the same standard of
performance as a vehicle not equipped with ABS.
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Automatic Stability Control (ASC)
The ASC utilizes the ABS sensing arrangement to provide the maximum traction force to propel the vehicle.
The ASC is switched on when the engine is started. The system can be switched off by pressing the 'ASC OFF' (the
switched is marked 'TRAC OFF' on vehicles fitted with traction control). The switch, which is situated in the center
console switchpack, lights up to warn that the system is switched off. An 'ASC' amber warning light flashes on the
instrument panel when the system detects a spinning wheel.
The ASC system uses engine intervention to reduce the torque delivered to the drive wheels to prevent them spinning.
Torque reductions are then requested from the engine control module (ECM) through the CAN. The throttle is then
positioned to provide the target torque, which has been calculated to prevent wheel spin. During the transient phase of
torque reduction the fuel is cut-off and the ignition retarded Both the fuel cut-off and ignition retard will be restored to
normal when the throttle is set to its new position.
The ASC uses a brake control modulator with six solenoid valves: three normally open inlet valves and three normally
closed outlet valves.
Traction Control
Traction control has the same capabilities as ASC but with the added ability to actuate the brakes of the spinning
wheel. This enhances ASC by improving acceleration particularly on surfaces with uneven friction , e.g. one wheel on
ice the other on tarmac.
When wheelspin occurs, brake line pressure to the slipping wheel is generated, to operate that wheel's brake. The
BCM achieves this by closing the cut-off solenoid valve and operating the hydraulic pump. Brake fluid is then drawn
from the reservoir through the non-actuated master cylinder to the brake caliper.
A 'TRAC' amber warning light flashes on the instrument panel when the system detects a spinning wheel.
The traction control system uses a brake control modulator with nine solenoid valves: four normally open inlet valves
and four normally closed outlet valves and one special isolating valve. The outlet valves control the brakes of each
each rear wheel individually on the traction control system.
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Rear Wheel Speed Sensors and ABS/TCCM Circuit Diagram
Item Description
1 ABS / TCCM
2 Engine compartment fuse-box
3 TCM (supercharged)
4 ECM
5 TCM (normally aspirated)
6 Left rear wheel speed sensor
7 Right rear wheel speed sensor
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Anti-Lock Control
Principle of operation
The ABS components are combined with a hydraulic booster and a tandem master cylinder to provide a two circuit
braking system. The system consists of; four wheel speed sensors, a brake control modulator, and an ABS warning
lamp.
Should a wheel start to lock up during braking, a signal transmitted from the wheel speed sensor to the brake control
modulator will start the hydraulic pump. The brake control modulator will close the input valve of the line connected to
the locked-up wheel to stop any increase in fluid pressure to the brake caliper. If this fails to prevent the wheel
locking, the pressure in the caliper will be decreased by opening the return valve until the wheel starts accelerating
again. The fluid pressure from the return valve is directed into the low pressure accumulator, housed in the modulator
body.
From the low pressure accumulator, fluid is pumped through the damping chamber to the brake master cylinder. The
pressure to the brake caliper will then be increased in small steps to maintain maximum adhesion between the tire and
the road surface. This is achieved by closing the return valve, and opening the inlet valve for short periods to increase
the pressure.
Although the system senses all four wheels independently, the rear wheels are regulated as a pair. If a sensor on a
rear wheel detects a wheel decelerating rapidly, the fluid pressure to both rear wheels is reduced. The fluid pressure
is then dictated by the wheel having the least adhesion to the road surface.
The system will adopt a fail-safe mode if a fault is detected, and a warning light on the instrument panel will notify the
driver. The brake system will still operate conventionally, with the same level of performance as a vehicle not equipped
with ABS.
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.
3. In order to confirm the customer concern, it may be necessary to follow a drive cycle which will enable the
system to perform it's diagnostic routine (see below),
NOTE:
See DTC index for details of codes and possible sources/actions.
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DTC Cycle to detect fault Cycle to clear fault System response to fault detection
C1095 Drive vehicle to activate ABS Drive vehicle at more than 40 km/h (25 ABS shut-down, ABS light ON, TCS
mph) for more than 2 minutes shut-down, TCS light ON
C1137 Ignition ON for more than 8 minutes Turn the ignition switch to the ON ABS shut-down, ABS light ON, TCS
position shut-down, TCS light ON
C1145/C1155/C1165/C1175 Drive vehicle at more than 20 km/h (12.5 Drive vehicle at more than 20 km/h (12.5 ABS shut-down, ABS light ON, TCS
mph) for more than 2 minutes mph) shut-down, TCS light ON
C1233/C1234/C1235/C1236 Drive vehicle at more than 40 km/h (25 Drive vehicle at more than 20 km/h (12.5 ABS shut-down, ABS light ON, TCS
mph) for more than 2 minutes mph) shut-down, TCS light ON
C1267 Drive vehicle at more than 40 km/h (25 Turn the ignition switch to the ON ABS shut-down, ABS light ON, TCS
mph) position shut-down, TCS light ON
B1342 Drive vehicle at more than 20 km/h (12.5 Turn the ignition switch to the ON Traction control switches off
mph) position
B1676 Turn the ignition switch to the ON Turn the ignition switch to the ON System functions between 9 and 19 volts
position position
Visual Inspection
Mechanical Electrical
Check the tire sizes, condition, and inflation Warning light operation
Brake fluid level Fuses (see table)
Wheel speed sensor fitment ABS/Traction control control unit
Wheel speed sensor air gap Wheel speed sensors
Wheel speed sensor toothed wheels (missing teeth/contamination) Connectors/pins
Harnesses
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Fuse Identification Table
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 cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve the fault codes before
proceeding to the Diagnostic Trouble Code (DTC) Index Chart.
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C1155 Left-hand front wheel speed Wheel speed sensor circuit; open circuit, short For left-hand front WSS circuit tests,
sensor (WSS) circuit failure circuit Goto <<D>>
.
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
C1165 Right-hand rear wheel speed Wheel speed sensor circuit; open circuit, short For right-hand rear WSS circuit tests,
sensor (WSS) circuit failure circuit Goto <<E>>
.
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
C1175 Left-hand rear wheel speed Wheel speed sensor circuit; open circuit, short For left-hand rear WSS circuit tests,
sensor (WSS) circuit failure circuit Goto <<F>>
.
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
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C1233 Left-hand front wheel speed Wheel speed sensor gap incorrect For left-hand front WSS circuit tests,
sensor signal failure Goto <<D>>
Foreign matter on sensor face
. For sensor and wheel information, REFER to wheel
Missing tooth on sensor wheel speed sensor and wheel speed sensor ring in this
section.
Wheel speed sensor circuit; open circuit, short
circuit
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
C1234 Right-hand front wheel speed Wheel speed sensor gap incorrect For right-hand front WSS circuit tests,
sensor signal failure Goto <<C>>
Foreign matter on sensor face
. For sensor and wheel information, REFER to wheel
Missing tooth on sensor wheel speed sensor and wheel speed sensor ring in this
Wheel speed sensor circuit; open circuit, short section.
circuit
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
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C1235 Right-hand rear wheel speed Wheel speed sensor gap incorrect For right-hand rear WSS circuit tests,
sensor signal failure Goto <<E>>
Foreign matter on sensor face
. For sensor and wheel information, REFER to wheel
Missing tooth on sensor wheel speed sensor and wheel speed sensor ring in this
section.
Wheel speed sensor circuit; open circuit, short
circuit
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
C1236 Left-hand rear wheel speed Wheel speed sensor gap incorrect For left-hand rear WSS circuit tests,
sensor signal failure Goto <<F>>
Foreign matter on sensor face
. For sensor and wheel information, REFER to wheel
Missing tooth on sensor wheel speed sensor and wheel speed sensor ring in this
Wheel speed sensor circuit; open circuit, short section.
circuit
Wheel speed sensor to control module circuit; high
resistance, open circuit, short circuit to ground
Wheel speed sensor failure
Control module failure
C1267 Modulator valve fault Modulator valve failure For module supply circuit tests, REFER to section
<<418-00>>.
Supply circuit fault (fuse, etc)
Control module failure
B1342 CAN circuit malfunction CAN open circuit fault For CAN circuit tests, REFER to section
<<418-00>>.
CAN short circuit fault
Control module failure
B1676 Supply voltage out of range Battery to control module B+ supply circuit; open Check the battery condition and charging system, REFER
circuit, high resistance to sections <<414-00>> and <<414-01>>.
Battery failure, loose connections
Charging system failure
Control module failure
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Pinpoint Tests
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
A1 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
A2 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO BATTERY
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A3 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
A4 : CHECK THE BATTERY POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO BATTERY
1. Measure the resistance between LF37, pins 08 and 24 (B) and GROUND.
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1.
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Contact dealer technical support for advice on possible control module failure.
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
B1 : CHECK THE IGNITION SWITCHED POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE
B2 : CHECK THE IGNITION SWITCHED POWER SUPPLIES TO THE ABS/TRACTION CONTROL CONTROL MODULE FOR SHORT TO
BATTERY
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1. Measure the resistance between LF37, pins 08 and 24 (B) and GROUND.
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Contact dealer technical support for advice on possible control module failure.
C : C1145, C1234; RIGHT-HAND FRONT WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
NOTE:
Sensor resistances should be measured using a +/- of 60 ohms.
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Is the voltage greater than 0 volts, but less than 5 volts? (The voltage will fluctuate, and be proportional to wheel speed).
-> Yes
Goto <<C4>>
-> No
Goto <<C3>>
NOTE:
In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of
these conditions be found, repair as necessary.
NOTE:
The air gap should be measured using a +/- of 0.75 mm.
1. Measure the gap between the WSS face and the toothed wheel.
Is the air gap 0.90 mm?
-> Yes
Goto <<C5>>
-> No
Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
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1. Measure the resistance between LF37, pin 04 (G) and FR01, pin 01 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Carry out mechanical checks on the WSS. if no fault is found, install a new Right front wheel speed sensor. CLEAR the DTC. TEST the system for normal
operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
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D : C1155, C1233; LEFT-HAND FRONT WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
NOTE:
Sensor resistances should be measured using a +/- of 60 ohms.
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In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of
these conditions be found, repair as necessary.
NOTE:
The air gap should be measured using a +/- of 0.75 mm.
1. Measure the gap between the WSS face and the toothed wheel.
Is the air gap 0.90 mm?
-> Yes
Goto <<D4>>
-> No
Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
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-> No
Goto <<D6>>
1. Measure the resistance between LF37, pin 18 (R) and FL01, pin 01 (R).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Carry out mechanical checks on the WSS. if no fault is found, install a new Left front wheel speed sensor. CLEAR the DTC. TEST the system for normal
operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
E : C1165, C1235; RIGHT-HAND REAR WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
NOTE:
Sensor resistances should be measured using a +/- of 60 ohms.
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NOTE:
In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of
these conditions be found, repair as necessary.
NOTE:
The air gap should be measured using a +/- of 0.75 mm.
1. Measure the gap between the WSS face and the toothed wheel.
Is the air gap 0.90 mm?
-> Yes
Goto <<E4>>
-> No
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Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
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-> No
Goto <<E7>>
1. Measure the resistance between LF37, pin 06 (Y) and RR01, pin 01 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Carry out mechanical checks on the WSS. if no fault is found, install a new Right front wheel speed sensor. CLEAR the DTC. TEST the system for normal
operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
F : C1175, C1236; LEFT-HAND REAR WHEEL SPEED SENSOR (WSS) ELECTRICAL FAILURE
NOTE:
Check connectors and pins for damage/corrosion. (See visual inspection).
NOTE:
Sensor resistances should be measured using a +/- of 60 ohms.
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NOTE:
In the course of this test, it will be possible to check for contamination of the sensor face and/or toothed wheel, and to check the wheel for damage. Should any of
these conditions be found, repair as necessary.
NOTE:
The air gap should be measured using a +/- of 0.75 mm.
1. Measure the gap between the WSS face and the toothed wheel.
Is the air gap 0.90 mm?
-> Yes
Goto <<F4>>
-> No
Reset the air gap. CLEAR the DTC. TEST the system for normal operation.
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1. Measure the resistance between LF37, pin 22 (U) and RL01, pin 01 (U).
Is the resistance greater than 5 ohms?
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1999 XK RANGE - Anti-Lock Control - 206-09
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Carry out mechanical checks on the WSS. if no fault is found, install a new Right rear wheel speed sensor. CLEAR the DTC. TEST the system for normal
operation. If the DTC is repeated, contact dealer technical support for advice on possible control module failure.
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
1. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
3. Open engine compartment and fit paint work protection covers to fenders.
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4. NOTE:
The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting
brake tubes.
5. Depress and hold down brake pedal to specified position using special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
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10. Position an absorbent cloth underneath the HCU to absorb brake fluid spillage.
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11. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
12. Remove control module from HCU, take care not to damage brake tubes.
Remove bolts.
Remove control module.
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Installation
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7. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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Installation
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
1. Disconnect battery ground cable (IMPORTANT, see operation <<86.15.19>> for further information).
3. Open engine compartment and fit paint work protection covers to fenders.
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4. NOTE:
The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting
the brake tubes.
5. Depress and hold down brake pedal to the specified position using special tool
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
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8. Position an absorbent cloth underneath the brake control modulator to collect brake fluid spillage.
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9. CAUTION:
Remove brake fluid spillage immediately from paint work, with clean water.
NOTE:
To minimize brake fluid loss, release the brake tubes in the order shown.
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Installation
1. NOTE:
The replacement brake control modulator is pre-filled with brake fluid.
2. NOTE:
To minimize brake fluid loss, install the brake tubes in the order shown.
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setting.
5. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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Installation
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Removal 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. See section <<100-00>> for
information.
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7. Using special tool, secure vertical link and hub assembly in a vice.
Secure special tool in a vice.
Position hub in tool.
Install and tighten wheel nuts.
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Installation
1. If necessary, install a grease deflector ring to the rotor nut. Refer to <<70.60.26>>.
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3. CAUTION:
Do not slacken the rotor nut to engage the spring clip.
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6. Install vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>.
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Removal 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. See section <<100-00>> for
information.
NOTE:
The grease deflector ring was fitted to production vehicles at VIN number 018108 and on. Vehicles before this
number must be fitted with a deflector ring when the rotor nut is removed for repair purposes.
7. Remove ABS hub rotor nut from vertical link and hub assembly. Refer to operation <<70.60.25>>.
9. Clean components.
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Installation
2. Install ABS hub rotor nut to vertical link and hub assembly. Refer to operation <<70.60.25>>.
4. Install vertical link and hub assembly to vehicle. Refer to operation <<60.25.38.90>>.
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Item Specification
Power steering pump relief pressure 106-114 bar
Item Specification
Power steering fluid Dextron 3
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If possible, allow the vehicle to stand for thirty minutes before restarting the engine to vent any further air.
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Fluid Hoses
1. Parts List
Item Description
1 Return Hose
2 High Pressure Hose
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1. The steering gear should always be centralized prior to steering column or suspension geometry adjustment.
Centralization of the steering gear is achieved by aligning the marker on the centralizing cap with a locator
on the pinion housing.
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2. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
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Steering System
Details of the Steering System can be found in sections <<211-02>>, <<211-03>>, <<211-04>> and <<211-05>>.
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Steering System
Mechanical Checks
Incorrect tire pressure, loose wheel nuts, incorrect wheel alignment
Loose tie-rods
Loose damper and spring assemblies or ball joint
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.
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
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
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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.
Item Description
1 Steering transducer ground
2 Ignition feed
3 Steering transducer feed
4 Ground
5 Speed sensor signal
6 Serial interface
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.
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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 information, <<211-04>>
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.
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Power Steering Pressure Test
Test Equipment
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.
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.
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Steering Fault Diagnosis by Symptom Charts
Leakage
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Functional
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' Steering transducer not CHECK the SCM and INSTALL a new SCM as
open, steering control necessary.
module (SCM) fault.
Carry out the electrical checks and tests. For
additional information, REFER to the Electrical
Checks and Tests in this section.
' Steering transducer not CHECK the speedo circuit. For additional
open, speedo signal error. information, REFER to the wiring diagrams.
' CHECK the power INSTALL a new power steering fluid low
steering fluid low pressure pressure pipe.
pipe for restricted flow.
Steering heavy operation Air in power steering CHECK for an air leak into the power steering
during rapid manoeuvring system. system and repair as necessary.
BLEED the power steering system. For additional
information,
' Fluid loss at the power CHECK the power steering pump for signs of
steering pump shaft seal. steering fluid loss.
INSTALL a new power steering pump as
necessary. For additional information, <<211-02>>
' Power steering fluid CHECK the power steering pump for signs of
delivery pressure or flow steering fluid loss.
too low.
CHECK the power steering pressure. For
additional information, REFER to the Power
Steering Pressure Test in this section.
INSTALL a new power steering pump as
necessary. For additional information, <<211-02>>
Steering heavy operation in Lower steering column CHECK the steering column is free from
one direction interference. interference from the engine harness, sound
proofing or the floor covering.
' Incorrect steering CHECK the front wheel alignment. For additional
geometry. information, <<204-00>>
' Faulty rotary valve/seal. CHECK the power steering pressure. For
additional information, REFER to the Power
Steering Pressure Test in this section.
INSTALL a new steering gear as necessary. For
additional information, <<211-02>>
' Tire fouling on the wheel CHECK for clearance between the tire and the
arch liner. wheel arch liner.
Remove and refit the wheel arch liner or
INSTALL a new wheel arch liner as necessary.
Steering heavy operation in Low power steering fluid. CHECK steering system for signs of steering fluid
both directions loss.
BLEED the power steering system. For additional
information, <<211-00>>
' Air in power steering CHECK the power steering pump for signs of
system. steering fluid loss.
INSTALL a new power steering pump as
necessary. For additional information, <<211-02>>
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' Fluid loss at the power CHECK the power steering pump for signs of
steering pump shaft seal. steering fluid loss.
INSTALL a new power steering pump as
necessary. For additional information, <<211-02>>
' Power steering fluid CHECK the power steering pump for signs of
delivery pressure or flow steering fluid loss.
too low.
CHECK the power steering pressure. For
additional information, REFER to the Power
Steering Pressure Test in this section.
INSTALL a new power steering pump as
necessary. For additional information, <<211-02>>
Steering operation varies Lower steering column CHECK the steering column is free from
from heavy to light when interference. interference from the engine harness, sound
driving at constant speed proofing or the floor covering.
' Incorrect speedometer CHECK the speedo circuit. For additional
signal. information, refer to the wiring diagrams.
' Steering transducer CHECK the steering transducer circuit. For
cable/connection faulty or additional information, refer to the wiring diagrams.
grounded.
Carry out the electrical checks and tests. For
additional information, REFER to the Electrical
Checks and Tests in this section.
Steering wheel varies from Lower steering column CHECK the steering column is free from
light to heavy two times per interference. interference from the engine harness, sound
revolution proofing or the floor covering.
' Steering column universal INSTALL a new steering column. For additional
joints binding. information, <<211-04>>
' Seized or damaged CHECK for wear or failure of suspension bushes
steering components. and ball joints. For additional information,
<<204-00>>
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Noise
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Vibration
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Boom
Rhythmic sound like a drum roll or distant thunder. May cause pressure on the ear drum.
Buzz
Chatter
Chuckle
Rapid noise that sounds like a stick against the spokes of a spinning bicycle wheel.
Chirp
Click
Click/Thump
Grind
Groan/Moan
Continuous, low-pitched humming sound.
Groan/Howl
Hiss
Hum
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Knock
Ping
Rattle
Roar
Deep, long, prolonged sound like an animal, or winds and ocean waves.
Rumble
Scrape
Grating noise like one hard plastic rubbing part rubbing against another.
Squeak
Squeal
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
Whistle
Belt Squeal
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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.
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.
Rack Knock is a rattle sound and steering wheel vibration caused by separation of the steering gear and pinion while
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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 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.
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.
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.
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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.
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 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. 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.
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 information, <<211-04>>
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Unit Specification
PAS Fluid Dexron 3
Capacities
Unit Liters
PAS System 1.0
PAS Reservoir 0.4
Torques
Component Nm
Steering Rack Mounting Bracket to Crossbeam 40-50
PAS Pump to Mounting Bracket 22-26
PAS Pump to Cylinder Block 38-48
Pulley to PAS Pump 18-24
Hose-High Pressure to PAS Pump 22-28
Steering Rack Pipe Latch Plate Bolt 9-11
Outer Tie Rod End Locknut 71-85
Reservoir to Brake Modulator Bracket 4-5
Reservoir Retention Bracket 4-5
Fluid Cooler to Bumper Beam 2.5-3.5
Transfer Pipe to Steering Rack 7-8
Transfer Pipe to Hydraulic Control Valve 7-8
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Power Steering
Component Relationship
Item Description
1 Rack and Pinion Assembly
2 PAS Pump
3 Fluid Reservoir with Integral Filter
4 Wire Bound Tube Type Fluid Cooler
5 Hoses and Pipework
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Mounting Brackets
Item Description
1 Resilient Wrap Around Handed Bushes
2 Mounting Brackets
3 Bracket Securing Bolts
Transfer pipework.
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Transducer.
Clips and fittings for the above components.
Centralizing cap.
Outer Ball Joint.
Rack Gaiters.
Major Components
Item Description
1 Rack
2 Pinion
3 Fluid Reservoir
4 PAS Pump
5 Fluid Return Line
6 Fluid Pressure Line
7 Pressure and Flow Limiting Valve
8 Rack Housing
9 Rack Gaiter
10 Inner Ball Joint
11 Tie Rod
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Operation
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Item Description
1 Rack
2 Drive Pinion
3 Operating Cylinder
4 Oil Reservoir
5 PAS Pump
6 Return Line
7 Pressure and Flow Limiting Valve
8 Pressure Line
9 Lower Steering Spindle
10 Torsion Bar
11 Upper Radial Groove
12 Lower Radial Groove
13 Rotary Distributor
14 Control Sleeve
15 Inlet Port
16 Inlet Port
17 Axial Groove
18 Axial Groove
19 Return Slot
20 Return Groove
21 Return Slot
22 Web
23 Control Slot
The rack / piston assembly of the operating cylinder move to the right.
Pressurized fluid is supplied to the left piston chamber to provide power assistance.
The three control ports of the rotary distributor are moved in a clockwise direction so that the inlet ports (16)
are opened further.
As this occurs, the inlet ports (15) close to prevent the fluid reaching axial grooves (17) in the control sleeve.
With the valve in the operating position pressurized fluid flows through the inlet ports (16) to the lower radial
groove (12) in the control sleeve.
From the control sleeve, pressurized fluid flows to the left piston chamber to provide hydraulic assistance for
the piston movement.
The closed control slot (23) prevents fluid flowing back to the reservoir.
The oil is forced out of the right piston chamber through the upper radial groove (11) in the sleeve to the
return slots (19) in the rotary distributor.
Webs (22) on the rotary distributor prevent the fluid flowing directly to the return grooves (20), which are
always open in the direction of the control sleeve.
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The rack and piston of the operating cylinder move to the left.
Pressurized fluid is supplied to the right piston chamber to provide power assistance.
Item Description
1 Torsion Bar
2 Metal Bellows Spring
3 End Piece
4 Caged Ball Bearings
When the steering wheel motion commences, the spring force of the torsion bar must be overcome.
Two centring pieces each of which has a prism shaped recess at its front end.
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At the start of the torsional motion, the metal bellows spring produces a substantial additional torsional resistance.
As soon as the prisms of the two centring pieces start being displaced to one another from a torsion bar angle of
approx 0.2 degrees, the torsional rigidity will decrease and become comparable to a conventional torsion bar.
Item Description
1 Steering Rack
2 Tooth Contact Angles at Center of Rack
3 Tooth Contact Angles at Ends of Rack
The variable ratio rack permits quick and precise reactions at speed and optimum vehicle control during manoeuvring.
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Servotronic Unit
System Components
Item Description
1 Speedometer
2 Electronic Control Unit
3 Electro-Hydraulic Converter
4 Steering Valve Housing
5 PAS Steering Pump
6 Battery
The Servotronic unit is speed dependent and is triggered by the electronic speedometer. It is entirely independent of
the engine speed:
A microprocessor evaluates the speed signal and decides the amount of hydraulic power assistance
required. This in turn determines the amount of driver effort required.
The power value is transmitted as impulses to the rotary spool steering valve, via an electro-hydraulic
converter.
The degree of assistance is proportional to the road speed. This means that minimum driver effort is required
at parking speed.
As the road speed increases, the steering characteristic feels more direct (less hydraulic assistance),
enabling precise and responsive reactions to steering wheel movement.
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Item Description
1 PAS Pump
2 Pump Mounting Bracket
3 High Pressure Port
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Fluid Reservoir
Item Description
1 Fluid Reservoir
2 Supply Line
3 Return Line
4 Filler Cap
NOTE:
1. The integral filter is not serviceable.
NOTE:
2. A new reservoir must be fitted if the steering rack, PAS Pump or fluid cooler are renewed.
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Item Description
1 Supply/Return Pipes and Latch-plate Assembly
2 Latch-plate Securing Screw
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Quick-fit Connector
Connector Details
Item Description
1 Quick-fit Connector
2 Return Tube
A quick-fit connector with double 'O' ring seals is incorporated in the return hose and is clipped to the
right hand chassis side member.
The hoses and pipework are used to connect the system components together to form a functional
system.
All hoses and pipework should be renewed as complete assemblies.
The quick-fit connector 'O' rings are not serviceable.
All hoses and pipework are designed to reduce system noise.
A special tool is necessary to disconnect the quick-fit connector.
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Fluid Cooler
Item Description
1 Fluid Cooler
2 Integral Hoses
3 Cooler Mountings
4 Body Cross Beam
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Power Steering
The layout of the power steering circuits, both hydraulic and electrical, are detailed and illustrated in the Description
and Operation section. Refer to the overall system diagram in the sub-section Servotronic Unit.
There are two major components of the Servotronic rack which provide the unique, variable effort control, based on
vehicle speed. The first is the Servotronic Valve which provides the variable steering effort and the second is the
Positive Centre Feel Torsion Bar. The Servotronic Valve is controlled electronically by a Power Steering Control
Module.
The Servotronic valve provides hydraulic reaction to oppose normal movement of the power piston. The benefit of this
is to give increased stiffness and feel to the system at higher vehicle speeds.
To achieve the hydraulic reaction, a co-axial piston assembly has been incorporated into the valve housing, which is
linked to the inner valve rotor and to the outer valve sleeve, via a series of ball bearings.
The Servotronic valve consists of a variable size orifice (effectively) which varies in size depending on the position of a
needle valve. The position of the needle valve is controlled by a solenoid, the armature of which will remain at any
fixed point within its overall limit of travel, dependent on the amount of current supplied to the solenoid windings.
As the speed of the vehicle increases, the current supplied to the valve is reduced in stages and the needle moves off
its seat which allows pressurised oil to pass into the reaction circuit. The driver subsequently, has to apply more
torque to the steering wheel to overcome the added reaction pressure.
Test Equipment
Item Description
1 Pressure Gauge Hose
2 Pump Return Hose
3 Pump Return Hose Connector
4 Test Equipment to HP Hose Adaptor
5 Pump HP Outlet to Hose Adaptor
6 Pump Adaptor to Control Valve Hose
7 Control Valve
8 Pressure Gauge
9 'O' Ring
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During turning.
When the steering is held on full lock.
With the steering at rest.
WARNING:
TO AVOID EXCESSIVE HEATING OF THE PAS PUMP, DO NOT CLOSE THE VALVE FOR LONGER THAN
NECESSARY.
WARNING:
DO NOT DRIVE THE VEHICLE WITH THE TEST EQUIPMENT INSTALLED.
With the control valve (7) CLOSED the pump maximum output pressure can be checked.
As described above, the control of the valve is by varying the current which is applied to it. The current signal is
provided by the Control Module which inputs a vehicle speed signal from the Instrument Cluster.
The microprocessor and associated algorithm within the module, provides maximum output current (854mA) when the
vehicle is stationary - the valve will be held closed, providing very easy steering. The current progressively decreases
towards zero (15mA) as the frequency of the speed signal from the Instrument Cluster increases - the valve will be
opening in stages. Consequently, an increasing amount of hydraulic pressure is applied to the reaction piston, which
increases the feel to the driver.
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Before changing a component, check fuse No. 12 (10A) in the driver's side fuse box on the fascia. However, if this
fuse is faulty a number of other components will also fail to function.
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Item Description
1 Servotronic Valve
2 Power Steering Control Module
3 Diagnostic Line
4 Speed Signal from Instrument Cluster
5 Ground
6 Ignition Supply +12V
7 Base of Power Steering Control Module
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2. CAUTION:
To prevent the ingress of foreign particles into the steering rack, make sure the blanking plugs stay
in position,
4. Fit jaw protectors to a vice and position steering rack in the vice with the pinion housing uppermost.
Carefully tighten the vice - do not use excessive clamping force.
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CAUTION:
The pinion shaft must not be rotated from this setting, until a new dirt protection shield has been
fitted.
Move pinion shaft to align centralising index - located on dirt protection shield, with alignment hole - located
on pinion valve housing.
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9. NOTE:
Note orientation of transducer for assembly reference.
Remove transducer.
1. Remove upper and lower screws.
2. Remove transducer.
Remove and discard O-ring seals.
Retrieve and discard filter.
Place transducer in a clean plastic bag until required for assembly.
10. NOTE:
Note orientation of pinion valve housing for assembly reference.
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12. Clean and inspect all relevant components and mating faces.
Installation
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7. Operate the steering rack lock-to-lock to check for freedom of movement, without tight spots.
The centralising index peg will shear (this is intentional).
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Removal
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6. Raise vehicle.
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Installation
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6. Remove reservoir.
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Installation
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5. Fit reservoir.
1. Fit mounting bracket to body studs.
2. Fit and tighten nuts.
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Power Steering Fluid Reservoir to Power Steering Pump Supply Hose 57.15.20
Removal
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Installation
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4. Loosen, but do not remove bolts which secure drive pulley to power steering pump.
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Remove bolts.
Remove pulley.
7. Release harness retaining clip from engine oil dipstick-tube bracket, reposition harness.
8. Disconnect power steering pump inlet hose and drain the fluid.
Place a drain pan under vehicle.
1. Release clip.
2. Disconnect hose and drain fluid.
3. Fit blanking plugs to pump and hose.
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Installation
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11. Fit a new power steering oil reservoir (combined reservoir and oil filter assembly) and bleed air from
system. Refer to operation <<57.15.08>>.
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Installation
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4. Refill with new fluid and bleed air from the system. Refer to General Procedures.
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Taper Separator
211-098 (JD 100)
Removal
5. From below the vehicle, check that steering rack is centralised by aligning the centralising notch on the dirt
protection cover with the location hole in the pinion housing casting.
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11. Release retaining plate from pinion shaft cover, to access hoses.
1. Remove bolt.
Move retaining plate along hose.
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12. Position drain pan under pinion-shaft housing and disconnect hoses.
Allow fluid to drain.
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15. Fit blanking plugs to feed hose, return hose and pinion housing ports.
16. NOTE:
The steering rack mounting bushes are handed; they are marked accordingly and should be replaced as a
pair.
17. Remove steering rack mounting bracket bushes. Refer to operation <<57.10.30>>.
18. NOTE:
When removing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes.
19. Using a tap (M10 x 1.5 mm), clean the steering rack to crossbeam bolt hole threads.
Installation
1. NOTE:
When installing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes.
4. A new steering rack and pinion housing assembly is supplied with a dirt protection cover/centralizing cap fitted.
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5. Remove blanking plugs from feed and return hoses and pinion housing ports of the new steering rack.
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9. Clean any fluid spillage from steering rack and surrounding area.
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12. NOTE:
Make sure steering wheel and wheels are in the straight ahead position before fitting steering column.
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14. Fit a new fluid reservoir, refill with new power steering fluid and bleed air from the system; refer to
Operation <<57.15.08>>.
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1. NOTE:
The steering rack mounting bracket bushes are handed; they are marked accordingly and should be
replaced as a pair.
3. NOTE:
For assembly reference note orientation of mounting bracket before removing.
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4. NOTE:
For assembly reference note orientation of mounting bush before removing.
5. With reference to orientation of previous bush, fit new LH mounting bush to steering rack.
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6. With reference to orientation of mounting bracket as noted in removal, fit LH mounting bracket to steering
rack.
Fit bracket.
Fit, but do not tighten bolts.
7. NOTE:
For assembly reference note orientation of mounting bracket before removing.
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8. NOTE:
For assembly reference note orientation of mounting bush before removing..
9. With reference to orientation of old bush, fit new RH mounting bush to steering rack.
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10. With reference to orientation of mounting bracket as noted in removal; fit RH mounting bracket to steering
rack.
Fit bracket.
Fit, but do not tighten bolts.
Installation
2. Lower vehicle.
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Removal
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Installation
3. Fill with new fluid and bleed air from the system. Refer to General Procedures.
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Torques
Component Nm
Outer Tie Rod End Securing Nut 71-85
Outer Tie Rod End Jam Nut 71-85
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Steering Linkage
Major Components
Parts List
Item Description
1 Rack Assembly
2 Gaiter
3 Inner Ball Joint
4 Outer Tie Rod End
5 Jam Nut
The steering linkage consists of tie rods, inner ball joints and outer tie rod ends and are used to convey the steering
movements of the steering rack to the vertical link. The inner ball joints are part of the power steering rack assembly.
Concertina type gaiters are installed between the rack housing and tie rods to retain lubricant and prevent the ingress
of foreign matter. They also permit lateral steering movement of the rack and arced movements of the ball joints
during suspension operation.
The tie rods are threaded at their ends to accept the ball joints and outer tie rod ends and to provide toe adjustment.
Jam nuts are used to secure the tie rod ends to the tie rods.
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Torques
Component Nm
Steering column to upper bracket retaining nuts 22 - 28
Upper bracket to body retaining screws 22 - 28
Steering column lower bracket retaining nuts 22 - 28
Steering column lower shaft retaining bolts 22 - 28
Upper and lower cowl retaining screws 1.5
Steering wheel retaining bolt 40
Column switchgear to column 4-5
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Steering Column
Steering Wheel
Item Description
1 ICE switchpack
2 Cruise control switchpack
3 Horn pad
4 Air bag module location
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ICE Switchpack
Item Description
1 Volume increase control
2 ICE select button
3 Volume decrease button
4 Radio skip cycle button
The in-car entertainment switchpack is installed to the left of the steering wheel center and performs the following
functions:
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Item Description
1 Speed set or increase button
2 Speed resume button
3 Speed set or decrease button
4 Speed cancel button
The cruise control switchpack is installed to the right of the steering wheel center and performs the following functions:
Item Description
1 Horn operating pad
2 Air bag module location
The horn operating pad is mounted in the central area of the steering wheel.
The driver air bag is mounted below the horn operating pad area, adjacent to the steering wheel hub.
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Upper Steering Column
Parts List
Item Description
1 Upper cowl
2 Lower cowl
3 Column adjustment switch
4 Dimmer switch
5 Tilt motor
6 Reach motor
The upper steering column is adjustable for both tilt and reach.
Manual Adjustment
The cable operated reach adjustment has approximately sixteen latched positions.
The desired position is fixed by a rack and wedge.
Tilt variations are stepped at approximately 3° intervals.
Four latched positions are available.
The uppermost position is unlatched.
From the uppermost position the column may be pulled down to engage the first detent without using the tilt
lever.
Serviceable Parts.
The only serviceable part is the Bowden wire and lever assembly.
Electric Adjustment.
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If the ignition key is removed and the adjustment switch is in the 'AUTO' position, the column will tilt away for
entry and exit.
A column adjustment switch is installed on the left side of the lower cowl.
Serviceable Parts
Item Description
1 Universal joint to steering rack
2 Dust seal
3 Boot
4 Universal joint to upper column
5 Column outer slider
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rings. The rolling element locates in a rubber boot which seals to the toeboard.
Has a lower universal joint connecting the lower column to the steering rack.
Has an upper universal joint connecting the lower column to the upper column.
Has a NVH damper incorporated into the upper universal joint assembly.
May be installed in any orientation on the universal joint splines.
Requires no setting or adjustment.
Has no serviceable components.
It is essential to disconnect the lower column from the steering rack before removing the engine or front suspension
crossbeam. Should the telescopic slider mechanism become separated, for any reason, it must not be reassembled.
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1. Power the driver's seat to the lowest and most rearward position.
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6. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
8. Unscrew and remove the upper steering column to universal joint nuts.
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13. Disconnect the key lock solenoid and key barrel transponder harness multiplugs.
1. Disconnect the key lock solenoid harness multiplug.
2. Disconnect the key barrel transponder harness multiplug.
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14. Unscrew and remove the column lower mounting bracket securing bolts.
15. Unscrew and remove the column to upper mounting bracket securing nuts.
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19. Insert the ignition key in the steering lock barrel and turn it to the auxiliary position.
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20. Remove the lock barrel assembly from the steering column.
1. Depress the lock barrel retaining peg.
2. Withdraw the lock barrel assembly.
21. Remove the key lock solenoid from the steering column housing.
1. Use a suitable pin punch to drive out the pin securing the key lock solenoid to the housing.
2. Withdraw the solenoid.
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Installation
3. Turn the ignition key to the OFF position and remove it from the lock barrel.
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6. Place the steering column in the vehicle and through the column mounting bracket.
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7. Engage the lower steering column universal joint with the upper column.
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9. Install and tighten the column lower securing nuts and bolts.
1. Install and tighten the column lower securing nuts.
2. Tighten the previously installed column upper securing nuts.
10. Apply a suitable thread locking compound and install the universal joint securing bolt and tighten to
specification.
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12. Connect the key lock solenoid and transponder harness multiplugs.
1. Connect the key lock solenoid harness multiplug.
2. Connect the key lock barrel transponder harness multiplug.
18. Install the steering column upper cowl; refer to Section <<501-05>>.
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19. Install the steering column lower cowl; refer to Section <<501-05>>.
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Installation
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2. Remove and discard the steering column lower shaft retaining bolt.
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5. Remove the floor covering retaining clip and reposition the floor covering.
6. Remove and discard the steering column lower shaft retaining bolt.
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Installation
NOTATION GIF
ENTITY SYSTEM "..\GRAPHIC\E42128.GIF"
1. CAUTION:
Make sure the boot is fully seated at the top and bottom.
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2. CAUTION:
Make sure the steering column lower shaft rolling element is fully seated into the boot.
CAUTION:
Make sure the boot is fully seated at the top and bottom.
3. CAUTION:
Make sure the steering column lower shaft is fully installed to the steering column shaft splines.
CAUTION:
Make sure the steering column lower shaft rolling element is fully seated into the boot.
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4. WARNING:
INSTALL A NEW STEERING COLUMN LOWER SHAFT RETAINING BOLT. FAILURE TO FOLLOW
THIS INSTRUCTION, MAY RESULT IN PERSONAL INJURY.
CAUTION:
Make sure the steering column lower shaft is fully installed on the steering column shaft splines.
5. Reposition the floor covering and install the floor covering retaining clip.
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8. WARNING:
INSTALL A NEW STEERING COLUMN LOWER SHAFT RETAINING BOLT. FAILURE TO FOLLOW
THIS INSTRUCTION, MAY RESULT IN PERSONAL INJURY.
Install the steering column lower shaft retaining bolt.
Tighten to 22 - 28 Nm.
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1. Remove the driver air bag module. For additional information, refer to<<501-20A>><<501-20B>> .
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Installation
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1. NOTE:
Install a new steering wheel retaining bolt.
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2. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG HAS A
BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
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WARNING:
DO NOT ROTATE THE POTENTIOMETER SPINDLE AFTER REMOVAL FROM THE MOTOR UNIT.
3. Remove the potentiometer from the tilt motor.
Installation
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Torques
Component Nm
Switchgear Securing Screws 4-5
Steering Column Upper Cowl 1,5 Nominal
Steering Column Lower Cowl 1,5 Nominal
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Ignition Switch
The key-operated ignition switch is located on the right hand side of the steering column and has four positions.
Position 'O'.
OFF. The only position in which the key can be inserted or removed. With the key removed, the steering lock engages.
Position 'I'.
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AUXILIARY. Certain circuits, i.e. radio and windows, can be operated without switching on the ignition.
Position 'II'.
IGNITION. All circuits, except the starter motor, are activated. The key remains in this position when driving.
Position 'III'.
START. The starter operates for as long as the key is held in this position, against the spring pressure. If the engine
fails to start, the key must be returned to position 'I' before another start is attempted.
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Lighting Switch
Item Description
1 Direction Indicators
2 All lamps Off
3 Sidelamps
4 Headlamps
5 Headlamp Main Beam
6 Main Beam Flash
7 Message Center Function Button
Direction Indicators.
The direction indicators operate when the ignition switch is in position 'II'.
To indicate for a right or left turn, move the column switch stalk up or down respectively, until the switch
latches in position.
An audible ticking and a flashing green warning lamp on the instrument cluster indicates that the direction
indicators are operating.
S Upon completion of the turn, the switch automatically returns to the center position and the indicators
cancel.
If an indicator bulb fails, the warning lamp and ticking operate at twice the normal rate.
Off Position.
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Sidelamps Position.
The front sidelamps, tail, license plate and any other lamps required by local legislation are switched 'ON'.
The sidelamps tell-tale lamp will be 'ON'.
Headlamps Position.
The headlamps are switched 'ON' (with the ignition switch in position 'II') in addition to the lamps switched on
in the sidelamps position.
NOTE:
If the ignition is switched to position 'O' with the rotary collar in the Headlamps 'ON' position:
The sidelamps, tail and license plate lamps will stay on, but the headlamps will switch 'OFF'.
When the ignition is switched to position 'II', they will come 'ON' automatically.
NOTE:
The main beam only operates with the dipped headlamps switched 'ON'.
Push the column switch stalk away from the steering wheel.
The message center function button is located in the end of the switch stalk.
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Item Description
1 Wipers Off
2 Intermittent Wipe
3 Normal Speed Wiper Operation
4 High Speed Wiper Operation
5 Flick Wipe Facility
6 Programmed Wash/Wipe Button
The right hand column switch controls the following functions with the ignition in position 'II':
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Position 'III'. High Speed Wiper Operation.
Flick Wipe.
Pull the switch stalk towards the steering wheel for a single slow speed wipe.
With the switch held in this position, the wiper will operate continuously at slow speed until released.
Programmed Wash/Wipe.
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2. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
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5. Release the ignition switch multiplug from the mounting bracket and disconnect it.
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Installation
2. Reconnect the ignition switch multiplug and locate it in the mounting bracket.
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1. Power the driver's seat to the lowest and most rearward position.
Installation
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6. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
10. Remove the steering column switchgear mounting bracket; refer to this section.
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Installation
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2. Install the steering column switchgear mounting bracket; refer to this section.
10. Install the steering column lower cowl; refer to Section <<501-05>>.
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5. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
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Installation
1. Install and align the cancellation module and switch assemblies to the steering column mounting bracket.
1. Install and align the flasher switch assembly to the module mounting bracket.
2. Install and align the washer switch assembly to the module mounting bracket.
3. Install and align the switchgear assembly to the steering column.
4. Install and tighten the switch assemblies/cancellation module securing screws.
2. Connect the module harness multiplugs and install in the mounting bracket.
1. Connect the module harness multiplugs.
2. Install the multiplugs in the mounting bracket.
3. Connect the switch assembly multiplugs.
4. Install the multiplugs in the mounting bracket.
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5. WARNING:
WAIT AT LEAST ONE MINUTE BEFORE STARTING WORK, BECAUSE THE AIR BAG IS EQUIPPED
WITH A BACK-UP POWER SOURCE AND MAY BE INADVERTENTLY DEPLOYED.
Disconnect the battery ground cable.
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13. Remove the switch assemblies from the cancellation module and mounting bracket.
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Installation
1. Install and align the cancellation module to the column mounting bracket.
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2. Install the flasher switch and washer switch assemblies to the module mounting bracket.
1. Install and align the flasher switch assembly.
2. Install and align the washer switch assembly.
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6. Install the steering wheel to the column in the correct orientation; refer to Section <<211-04>>
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Engine
Engine Torque
Engine Nm (DIN)/Rpm
Maximum Delivered - 4.0L 393 at 4250
Maximum Delivered - 4.0L SC 525 at 3600
Engine Power
Unit Specification
Engine Oil - USA/Canada API SJ/EC and ILSAC GF2
Engine Oil - UK and ROW API SJ/EC and
ACEA A1-98 or A3-98
Anti-Freeze ESD-M97B49-A
Sealant - Engine Block-to-Bedplate and Sump-to-Bedplate (RTV Silicone) Loctite 5699 Ultra Grey
Sealant - Engine Core Plugs and Block Stub Pipe (Anaerobic Sealant) Loctite 648
Capacities
Unit Liters
Engine Oil - With Oil Cooler 7,3
Engine Oil - Without Oil Cooler 6,5
Coolant - Complete System 10
Coolant - Complete System - Supercharged 12
Coolant - Engine Only 3,7
Firing Order
Viewed from the driver's seat, Bank 1 (previously described as A-bank) is on the right hand side:
1-1, 2-1, 1-4, 1-2, 2-2, 1-3, 2-3, 2-4.
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Engine
Normally Aspirated
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Supercharged
An eight cylinder 90 degree 'V' configuration liquid cooled aluminium cylinder block incorporating 'Nikasil'
plated cylinder bores.
Pistons of open-ended skirt design, with two compression and one oil control ring.
Two aluminium cylinder heads, each incorporating two camshafts.
Four valves per cylinder.
Aluminium valve lifters and top mounted shims.
Variable valve timing (VVT) of the intake camshafts (normally aspirated only).
Camshaft covers manufactured from Vinylester.
Aluminium timing cover which accommodates the crankshaft front oil seal.
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Single row primary and secondary chains drive the camshafts of each cylinder bank.
An aluminium bed plate, incorporating iron main bearing supports, which accommodate the oil pump
pick-up, diverter valve (if fitted) and oil filter.
Main bearings which are grooved in the upper positions and plain in the lower positions. They are
manufactured from aluminium / tin material.
A crankshaft with undercuts and rolled fillets for extra strength.
Fracture-split connecting rods in sintered-forged steel.
Brackets bolted to the front of the cylinder block are used to mount all accessories.
A single, seven ribbed vee belt drives the front end accessories on all versions of the engine.
A second, seven ribbed vee belt drives the supercharger.
Automatic belt tensioners - one for the front end accessory drive and one for the supercharger where
fitted. Each tensioner incorporates a belt wear indicator.
An advanced engine management system incorporating electronic throttle control.
The unit meets the requirements of the CARB OBDII USA legislation.
Ancillary Systems
The ancillary systems, driven by the engine, each have a detailed Description and Operation along with Diagnostic
Procedures, and Removal and Installation instructions; refer to the following sections of this manual:
Engine management and exhaust emissions are controlled by the ECM, which has the following main functions:
Fuel injection.
Idle speed.
Ignition.
Evaporative loss system.
Engine cooling fans.
Climate control compressor clutch demand.
The microprocessor within the ECM receives signals from various sensors and other modules and uses a
pre-determined program to compute engine management functions.
Adaptive functions are incorporated in the ECM to cater for continuous adjustments to its computations to suit
prevailing conditions. Because the system also controls emissions to suit all modes, neither CO levels nor idle
speed require service attention or adjustment, except if an error or component failure should occur.
On Board Diagnostics are controlled by the ECM with the continuous monitoring of incoming signals and the
subsequent verification against what the module expects to 'see'. Should a signal be incorrect or missing, the ECM
will substitute a fixed value to provide the 'limp home mode' and alert the driver of the problem. Fixed values may
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be adopted for:
Should either the ECM or TCM fail, ensure that the control housing cooling fan is operating correctly. Failure of
the cooling fan MUST be rectified before renewing a control module and details of a fan failure should
accompany a returned control module.
The ignition supply is the main power source for the ECM; this supply will be disconnected by an inertia switch if
the vehicle is subject to a violent deceleration, as in a collision. The ECM has separate ignition and battery supply
inputs. The battery input maintains the ECM memory as long as the vehicle battery is connected.
Electronic Throttle
The electronic throttle assembly, in response to signals from both the driver and the ECM, adjusts idle speed, sets
the throttle valve to the position requested by the throttle pedal, cruise and traction control, power limitation and
catalyst warm-up.
The air flow meter assembly outputs an analogue voltage to the ECM. This sensor measures air flow into the
engine intake system and is calibrated to measure kg / hour.
The intake air temperature sensor is located in the air flow meter assembly and outputs an analogue voltage to
the ECM. The ECM will substitute a default value equal to 50°C should this sensor fail.
Fuel Injectors
The eight fuel injectors are located in individual apertures in the intake manifold. The fuel rail is separate and
supplies fuel to the top of each injector. Air injection is provided to the base of each injector to further improve fuel
delivery and atomisation. Air is provided by an air gallery which is integral with the intake manifold. The fuel
injectors are electromagnetic solenoid valves controlled by the ECM. The electrical pulse time for the injector
combined with the fuel pressure determines the volume of fuel injected to the manifold.
Fuel Delivery
The fuel pump provides fuel to the fuel rail where the circulating pressure is controlled by a pressure regulator
valve; excess fuel is returned to the fuel tank.
The pressure regulator valve is controlled by manifold depression so that fuel delivery pressure is maintained at
approximately 3 bar above manifold pressure.
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The ECM controls this component for normal engine running. The security system may disable this relay via
communication with the ECM.
The quantity of fuel in the tank is measured by the fuel level sensor . This signal is used by the ECM as an input to
certain diagnostics.
Evaporative Valve
Excess vapour formed in the fuel tank is absorbed into the evaporative emission purge control canister. While the
engine is running, the fuel absorbed in the canister is gradually purged back into the engine. The rate of purging is
governed by the operating conditions of the engine and vapour concentration level. Operating conditions which
affect the purge rate are:
When the purging process is operational the ECM modifies the basic fuelling calculation to maintain the correct air
/ fuel ratio.
Purging is inhibited during fuel cut-off and stability / traction control intervention.
The sensor outputs a voltage to the ECM which decreases as temperature increases.
Cooling Fans
In response to engine coolant temperature and climate control system demand, the ECM will energize the cooling
fans.
The ECM will allow the compressor clutch to be engaged if the engine temperature and load demand are normal.
Should the driver require maximum engine power or the coolant temperature be high, the request will be denied.
Cranking Signal
The ECM reacts to a signal from the Body Processor Module (BPM) when the starter motor relay is energized.
This signal is used to trigger starting, fuel and ignition strategies.
Engine speed and crank position are monitored by a sensor which is mounted on the cylinder block (flywheel
housing) in front of the crankshaft drive plate. It indicates rotational speed to the ECM in the form of 35 pulses per
crank revolution. Engine speed is used for synchronization of fuel and ignition systems, as well as other functions.
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Camshaft Position
A camshaft position sensor is mounted at the rear of each cylinder head on the intake side and each provides four
signals every 720 degrees of crankshaft rotation. The combination of signals from both sensors (normally only
Bank 1 sensor is used in conjunction with the crankshaft sensor for normal fuelling and ignition functions) can
indicate to the ECM when a particular piston is approaching TDC on the compression stroke.
On supercharged engines, one sensor is mounted at the rear of Bank 1 cylinder head on the intake side and
provides one signal every 720 degrees of crankshaft rotation. The signal, in conjunction with the signals from the
crankshaft position sensor, indicates to the ECM that the piston of cylinder 1A is approaching TDC on the
compression stroke.
The valve timing (camshaft phasing) is infinitely variable within the maximum design limits of advance and retard.
An actuating shuttle valve directs engine oil pressure to either side of the control piston within the VVT unit to
advance or retard the intake camshaft, as calculated and controlled by the ECM. Movement of the actuating
shuttle valve is by a linear solenoid.
Closed loop sensing and control of each intake camshaft is provided by the ECM in response to signals from each
camshaft position sensor.
Ignition
Each on-plug coil unit also comprises an amplifier module. The ECM controls each amplifier module which in turn
switches the coil primary to generate the HT voltage within the secondary winding.
Knock Sensor
This sensor uses a piezo-electric sensing element to detect knock which may occur under acceleration at critical
conditions. Should detonation be present the ECM will retard the ignition timing of individual cylinders.
The EGR valve (where fitted) reduces NOx emissions by recirculating a portion of the exhaust gases back into the
intake manifold.
The heated oxygen sensors, one per bank, are situated upstream of the catalysts. Integral to the sensors are
heaters (under ECM control) which allow the sensors to reach their operating temperature as soon as possible
after engine start. A comparison between the level of oxygen in the exhaust gas to that in the atmosphere
produces an output signal. This signal is used by the engine closed loop fuel strategy to make fuelling corrections
and so control overall emission levels.
Oxygen Sensors
These sensors, one per bank, are situated downstream of the heated oxygen sensors. The comparison of
upstream and downstream signals allows determination of catalyst conversion efficiency.
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Cylinder and Crankshaft Grading
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.
Read the grade letters from LEFT to RIGHT = FRONT to REAR of engine eg. for this example engine, the
crankpin at the front of the engine is grade A and at the rear is also grade A.
Bank 2 - Cylinder 1, Bank 2 - Cylinder 2, Bank 2 - Cylinder 3, Bank 2 - Cylinder 4, Bank 1 - Cylinder 4,
(Note, in earlier publications Bank 1 was described as A-Bank and Bank 2 as B-Bank)
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Read the grade letters from LEFT to RIGHT = FRONT to REAR of engine eg. for this example engine, the crank
journal bore at the front of the engine is grade W, and at the rear is grade N.
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Crankshaft Main Bearing Shell Selection Chart
The axes on the chart refer to: X1 Crankshaft Bore in Cylinder Block.
The number in each diagonal band represents a PAIR of colour coded main bearing shells which must be used
with a specific journal, depending on the combination of journal diameter and crankshaft bore diameter. The
colour codes for each band are as follows:
1 - Blue / Green and Blue / Green, 2 - Blue / Green and Blue, 3 - Blue and Blue,
4 - Blue and Green, 5 - Green and Green, 6 - Green and Yellow, 7 - Yellow and Yellow.
Consider crankshaft journal 5 (from the example grade markings on the cylinder block) - the cylinder block bore is
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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 colour codes have been selected for a journal, either colour 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.
Piston Identification
Item Description
1 4.0L Normally Aspirated
2 4.0L Supercharged
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Piston / Connecting Rod Orientation
Item Description
1 FRONT of engine
2 Thick Flange of Connecting Rod. Must face FRONT of engine on BANK 1
3 Grade on Piston Crown. To front of engine on both banks
4 Thick Flange of Connecting Rod. Must face REAR of engine on BANK 2
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Engine
Engine Torque
Engine Nm (DIN)/Rpm
Maximum Delivered - 4.0L 393 at 4250
Maximum Delivered - 4.0L SC 526 at 3500
Engine Power
Unit Specification
Engine Oil - USA/Canada API SH or SJ / ILSAC GF-2
Engine Oil - Mexico API SJ
Engine Oil - UK and ROW API SH or SJ / ACEA A2
Engine Oil - Supercharged API SH or SJ / ACEA A3
Anti-Freeze ESD-M97B49-A
Sealant-Engine Block-to-Bedplate and Sump-to-Bedplate (RTV Silicone) Loctite 5699 Ultra Grey
Sealant-Engine Core Plugs and Block Stub Pipe (Anaerobic Sealant) Loctite 648
Capacities
Unit Liters
Engine Oil-With Oil Cooler 7,3
Engine Oil-Without Oil Cooler 6,5
Coolant-Complete System 10
Coolant-Engine Only 3,7
Valve Clearances
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Torque Specifications
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Tappet adjustment
303-540
1. Open the engine compartment and fit paintwork protection sheets. Open to the service position.
2. Carefully remove both engine covers, taking care not to damage the plastic fixings or the rubber inserts.
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4. Remove the cam cover from the 'A' bank and the 'B' bank. Refer to Operations <<12.29.43>> and
<<12.29.44>>.
5. Check, and note the valve clearances, as described earlier in this section.
6. Use a rag to wipe up as much oil as possible from the tappet wells.
8. The following instructions describe the PROCEDURE FOR ADJUSTING THE VALVE CLEARANCES.
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9. Fit the base plate of the tappet adjusting tool 303 - 540 to one of the heads; use the bolts which are
supplied with the tool.
It should be fitted along the head, between the two camshafts, and bolted to the tapped holes which
normally secure the cam cover.
10. Rotate the crankshaft so that there are four valves which are 'off the cam' (cam lobes uppermost), so
that their clearance may be measured.
11. CAUTION:
Do not rotate the crankshaft while the attachment is fitted to the base plate.
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12. Position the fingers on to the outer edges of the tappet. It is essential that the recessed step on each
finger, locates on the edge of the tappet as indicated. The use of a mirror will help, as viewing access is
restricted.
13. Tighten the knurled bolts to compress the valve springs, until a firm resistance is felt.
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14. WARNING:
THE FOLLOWING OPERATIONS REQUIRE THE USE OF COMPRESSED AIR - ALWAYS WEAR
SUITABLE EYE PROTECTION.
Remove, clean and measure the shims.
1. Surround the immediate working area with clean rag to contain any loose objects and shims
displaced by the compressed air.
2. Use 303 - 590 Air Gun (with a fan nozzle) aimed at the edge of the shim to lift it from the tappet.
Remove the shim from each tappet, noting the position of each.
16. Assess the increase or decrease required in shim thickness to produce the correct valve clearance.
17. Select two shims of the correct size, lubricate each and fit each to the respective tappet (as calculated in
the previous step). Shims must be fitted with the size marking facing the tappet NOT the cam.
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18. Loosen the knurled screws on 303 - 540 attachment to allow the valve springs to return to their normal
position.
19. Check the valve clearance of the two valves. If the clearance is correct, remove the attachment from the
base plate. transfer the attachment to the other two valves which are in position to be adjusted.
21. Refit the cam covers and associated components. Refer to Operations <<12.29.43>> and <<12.29.44>>.
24. Move the engine compartment cover from the service position and connect the gas struts.
25. Remove the paint protection sheets and close the cover.
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1. Open the engine compartment and fit paintwork protection sheets. Open to the service position.
2. Carefully remove both engine covers, taking care not to damage the plastic fixings or the rubber inserts.
4. Remove the cam cover from the 'A' bank and the 'B' bank. Refer to Operations <<12.29.43>> and
<<12.29.44>>.
5. Rotate the crankshaft so that there are four valves which are 'off the cam' (cam lobes uppermost), so that
their clearance may be measured.
6. Measure the gap on each of the four valves. Note which valve has been measured, along with its relevant
clearance.
7. Rotate the crankshaft a small amount so that the next four valves are 'off the cam'. Measure and note the
clearances.
Repeat this step a further six times, until all valve clearances have been measured and noted.
8. Refit the cam covers and associated components. Refer to Operations <<12.29.43>> and <<12.29.44>>.
10. Move the engine compartment cover from the service position and connect the gas struts.
11. Remove the paint protection sheets and close the cover.
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Engine
Cylinder Block
The cylinder block is of an enclosed 'Vee' design with 'Nikasil' plated cylinder bores to reduce piston friction, improve
warm up and oil retention. A low volume coolant jacket improves warm up time and reduces piston noise levels.
Viewed from the driving position, the right-hand cylinder bank is designated A-bank and the left-hand cylinder bank as
B-bank.
The cylinder bores of each bank are numbered 1 to 4, from the front of the vehicle.
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Cylinder Block Drain Plug/Heater Unit
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 -30°C) 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 flying lead of each
sensor is secured to a bracket on (or near to, depending on the model) the thermostat housing.
These piezo-electric sensors provide inputs to the ECM to indicate the detection and location of detonation during
combustion.
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Crankshaft
The cast iron crankshaft has undercut and rolled fillets for improved strength and six counter-balance weights ensure
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 damper and pulley assembly is bolted to the crankshaft nose.
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.
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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 flat upper surfaces (dished on supercharged engines) to reduce heat
absorption. The piston crown has four cut-outs to clear the valve heads for any available combination of cam profile
and valve phasing. Three piston rings, two compression and one oil control, are fitted to each piston. Each piston is
fitted on a wrist pin which operates in a lead / bronze bush fitted in the connecting rod.
Timing Gear
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Item Description
Single row primary and secondary chains drive the camshafts of each cylinder bank. The primary chains transmit the
drive from two sprockets 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. Guide rails are used on the drive side of the primary chains.
A key locates the two drive sprockets on the crankshaft and these are retained in position by the crankshaft torsional
vibration damper.
Parts List
Item Description
1 Variable Valve Timing Unit, where fitted
2 Secondary Chain
3 Secondary Chain Tensioner
The variable valve timing units and the exhaust camshaft sprockets are a non-interference, non-keyed fit on their
respective camshafts. They are clamped in place on the camshafts by the securing bolt and clamping plate/washer.
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Timing Cover
Parts List
Item Description
1 Crankshaft Front Oil Seal
2 Silicon Rubber Gaskets
The aluminium-alloy timing cover accommodates the crankshaft front oil seal. Silicon rubber in-groove gaskets seal the
joint between the timing cover and the front face of the engine.
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Cylinder Heads and Valve Gear
Item Description
1 Cylinder Head Bolt
2 Lifting Eye
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.
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Valve head diameter is 31 mm for exhaust and 35 mm for intake, and all valve stems are 5 mm diameter. Valve seats
and guides are sintered metal inserts.
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. For spark plug details refer
to Section <<303-07>>.
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, marked on the outer face of each cap.
A machined flat near the front of each camshaft enables the camshafts to be locked, using a special tool, during the
valve timing procedure.
Camshaft Sensor
The camshaft sensor is a variable reluctance sensor that provides an input to the ECM of intake camshaft position.
On normally aspirated engines, a camshaft position sensor is mounted at the rear of each cylinder head on the inlet
side and is triggered by a four toothed sensing ring, to provides four signals every 720 degrees of crankshaft rotation.
The combination of signals from both sensors can indicate to the ECM when a particular piston is approaching TDC on
the compression stroke, should it need to e.g. if a fault occured with the crankshaft position sensor. However, during
normal operation, only the A-bank sensor is used in conjunction with the crankshaft sensor for normal fuelling and
ignition functions.
On supercharged engines, one camshaft sensor is fitted to the rear of the B-bank cylinder head and is triggered by a
single toothed sensing ring fitted to the rear of the intake camshaft.
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Camshaft Covers
The camshaft covers are made from vinyl-ester plastic; the A-bank cover incorporates an outlet for the full load engine
breather.
The B-bank cover incorporates the engine oil filler cap and an outlet for the part 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.
Lifting Eyes
There are four lifting eyes for the engine. One lifting eye is cast into the front of each cylinder head assembly and the
rear lifting eyes, also one per cylinder head, are bolt-on special tools.
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Bedplate
Item Description
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.
Slight changes to main bearing clearance due to expansion are minimised 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.
The engine speed sensor is located at the rear of the bedplate and is a variable reluctance sensor that provides an
input to the ECM representing engine crankshaft speed and position.
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The intake manifold is manufactured in plastic with plastic integrated fuel rails and metal thread inserts; the very
smooth internal surfaces give excellent air flow.
Individual ducts lead off a central chamber to the inlet valves of each cylinder.
Silicon rubber gaskets, located in channels in the intake manifold, seal the joints between the ducts and the cylinder
heads.
Supercharged engines do not have a conventional manifold, but use an Intercooler Adaptor Assembly on each cylinder
head to pass cooled air from the intake air charge coolers (one for each bank) to the engine intake. The fuel injectors
and fuel rail are also located on each Intercooler Adaptor Assembly.
Induction Elbow
The induction elbow provides the interface between the electronic throttle and the intake manifold.
Connections on the induction elbow provide vacuum take-offs for various services.
A boss on the rear of the elbow accommodates the EGR valve - where fitted. On engines without EGR, the boss is
closed by a blanking plate.
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Exhaust Manifold
The thin walled cast iron manifolds are unique to each cylinder bank. On engines with Exhaust Gas Recirculation
(EGR) (see Section <<303-08>>) the A-bank manifold has a transfer pipe connection. Spacers on the securing bolts
allow expansion and retraction upon temperature changes whilst maintaining clamping loads. Heat shields are
integrated in the exhaust manifold gaskets.
Engine Mountings
The engine is mounted at three points. At the front, on each side of the engine, there is a mounting bracket with a
Hydramount mounted to the crossbeam. At the rear, a single rubber / metal composite mount is fixed to the cast
crossmember.
The rear engine mounting rubber provides support for the rear of the engine and the transmission unit. This is a rubber
mount and metal bracket assembly secured with a single fixing onto the crossmember. This, in turn, is located on an
extension bracket at the rear of the transmission unit.
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Engine Lubrication
Item Description
1 Valve Lifter Supply
2 Main Bearing Supply
3 Connecting Rod Bearing Supply
4 Bedplate/Cylinder Block Interface
5 Oil Pick-Up
6 Pressure Relief Valve
7 Oil Pressure Switch
8 Oil Temperature Switch
9 Oil Filter
10 Structural Sump/Bedplate Interface
11 Bedplate/Cylinder Block Interface
12 Oil Pump
13 Primary Chain Tensioner Supply
14 Cylinder Block/Cylinder Head Interface
15 Variable Valve Timing Supply
16 Camshaft Bearing Supply
17 Secondary Chain Tensioner Supply
18 Oil Diverter (Where fitted)
19 Oil Supply and Return
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.
With the exception of the pump and the oil level gauge (dip stick), 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
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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
provides 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.
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).
Installed at the right front of the structural sump adjacent to the pressure switch. Indicates to the Engine Control
Module the temperature of the engine oil, for use in the variable valve timing computations.
Oil Pump
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An uprated (higher capacity) oil pump is fitted to cope with the increased demands of the linear VVT system. The
pump is located 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 drain plug, bolted to the structural sump.
Oil is drawn from the oil reservoir in the oil pan, pressurized by the oil pump, cooled (on vehicles with an oil cooler),
filtered and distributed through internal oil passages. Oil returns to the pan under gravity.
Oil Filter
A renewable canister type oil filter is fitted on the adapter which is located on the right-hand side of the structural
sump towards the front of the engine. An internal bypass facility permits full flow bypass if the filter is blocked.
The oil level gauge is located towards the front of the engine on the left side of the oil pan, supported in a tube fitted in
the bedplate. The holes in the end of the oil gauge indicate minimum and maximum oil levels; approximately 1 liter
difference.
The oil filler cap is located on the top of the B-bank camshaft 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.
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Engine Oil Cooler (Where Fitted)
The engine oil cooler is located in front of the radiator, mounted off-center with two steady brackets bolted onto the
front upper crossmember in front of the cooling module.
When an oil cooler is fitted, an oil diverter valve is also fitted onto the oil filter with supply and return piping to and from
the oil cooler.
This valve is fitted between the oil pump outlet and the oil filter inlet.
The oil diverter valve operates thermostatically and at higher temperatures diverts the oil through the oil cooler. The
valve begins to open between 103°C and 107°C and is fully open, diverting 100% of the oil, at 119°C.
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Crankcase Ventilation
Item Description
1 Oil Entry Point
2 Wire Gauze
3 Breather Outlet
The engine is ventilated through a part-load and a full-load breather; one on each camshaft cover. These flexible
plastic hoses incorporate O-ring seals and quick release connectors.
The part-load breather ventilates the left-hand camshaft 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 sensor (MAFS) and the throttle body.
The MAFS 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 camshaft cover oil separator consists of wire gauze packed into an open ended enclosure in the top of the
cover, below the breather outlet.
Engine Covers
Engine covers are fitted over the fuel injectors on each cylinder bank and are isolated from the engine by rubber
grommets to prevent noise.
A shaped plug / cover, known as the 'Valley' plug, is fitted to the top of the engine block at the centre of the 'Vee'
formed by the angle between the 'A' and 'B' banks of the cylinder block.
Ring dowels
To assist in the location / installation of each cylinder head to its respective location on the block.
Two are used to locate the main sump body to the cylinder block.
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Two are used at the rear of the engine block to locate the mating face of the transmission housing.
Two are fitted into the casting at the front, one on each side, to locate and align the timing cover and two more each
side of the front face to locate the VVT bush carriers (where fitted).
Two are fitted each side near the front to locate the accessory mounting bracket and the generator mounting bracket.
Block Plugs
Two core plugs are fitted in the rear face of the engine block.
Three flanged, threaded plugs with micro-encapsulated sealant and a sealing washer are fitted, one into the front face
of the block behind the water pump, one to the rear face adjacent to the two core plugs and one to the rear of the left
hand side.
Stub Pipe
A stub pipe in the centre of the raised part of the block casting for the thermostat housing, accommodates one end of
the heater return hose.
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Engine Sealing
a) In-groove seals.
For a) and b) the seals are to be renewed if the mating components are disturbed during service i.e. they are not
re-usable.
For c) no general servicing is required - sealant/joint designed for service life of engine (must be renewed if the mating
components are disturbed).
Anaerobic (Loctite 648): used on core plugs and block stub pipe.
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RTV silicone sealant (Loctite 5699 Ultra Grey): used on block-to-bedplate and sump-to-bedplate joints. Designed
service life is 150,000 miles.
Ignition System
The ignition system consists of eight ignition coils, one per spark plug, each incorporating an amplifier module which is
controlled by one of two outputs from the ECM. Each output of the ECM controls four of the spark plug mounted
ignition coils, two on each bank.
The 14mm spark plugs, one per cylinder, locate in recesses along the center-line of each cylinder head. The on-plug
ignition coils are secured to the camshaft covers and each on-plug coil has its own plastic cover.
Item Description
1 Variable Valve Timing (VVT) Unit
2 Solenoid / Shuttle Valve
3 Bush Carrier
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For each intake camshaft there is a variable valve timing unit, a bush carrier assembly and a solenoid / shuttle valve.
It is an infinitely variable system (within the prescribed operating range) operating on the intake camshafts only. There
is the equivalent of 48° of crankshaft movement between the retarded and advanced positions. Engine oil pressure
operates the system under the control of the ECM.
The variable valve timing system improves both low speed and high speed engine performance, engine idle quality and
exhaust emissions. Engine idle is improved due to the ECM being able to retard the valve timing by an additional 10°
compared to the previous VVT system; this also reduces the internal EGR at idle, where it is not required. However,
the internal EGR system is improved at normal engine running speeds to reduce NOx emission and eliminate the need
for any external EGR system components.
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Parts List
Item Description
1 Ring Piston
2 Inner Sleeve
3 Body and Sprocket Assembly
4 Helical Gears - Piston to Body
5 Helical Gears - Piston to Inner Sleeve
The valve timing unit turns the intake camshaft relative to the primary chain to advance or retard the timing.
The unit consists of a body and sprocket assembly separated from an inner sleeve by a ring piston and two helical
ring gears; the inner sleeve is bolted to the camshaft.
The two helical ring gears are part of the cylindrical extention of the piston, one gear on the outer bore (meshing with
the helical gear which is on the inner bore of the body and sprocket assembly) and one on the inner bore (meshing
with the inner sleeve).
As engine oil pressure moves the piston in the advance direction (to the right on the illustration) the helical ring gear on
the outer bore of the piston causes the whole piston assembly to turn to the right as well as moving to the right. In the
same way, the movement of the piston to the right, combined with the rotation caused by the outer helical gear
assembly, causes the inner sleeve and hence the camshaft to rotate to the right in the advanced direction. The
procedure is identical, but in the opposite direction for retarding the timing.
A light bias spring in the retard direction is provided along with anti-backlash springs.
Bush Carrier
This contains the oil passages that link the engine oil supply from the cylinder block gallery to the variable valve timing
(VVT) unit. A lug on the bush carrier locates in the central bore of the VVT unit.
Two hollow dowels at the bush carrier and cylinder block ensure that the lug is accurately located within the valve
timing unit. O-rings seal the joint between the lug and the valve timing unit.
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Variable Valve Timing (VVT) Solenoid / Shuttle Valve
The VVT solenoid / shuttle valve assembly is bolted to the bush carrier and protrudes through the camshaft cover.
Electrical connection to the solenoid is from the engine harness.
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Parts List
Item Description
1 Solenoid / Shutle Valve Assembly
2 Bush Carrier
3 Variable Valve Timing Unit
4 Intake Camshaft
The valve timing solenoid controls the position of the shuttle valve relative to the two ports in the bush carrier.
The shuttle valve, depending on its position set by the solenoid at any instant, directs engine oil pressure to either the
retard side or the advance side of the piston assembly.
The position of the solenoid / shuttle valve is controlled by a return spring and a 300 Hz pulse-width-modulated signal
provided by the ECM.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. Remove the twin fan and motor assembly. Refer to Operation 26.25.12.
6. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>.
7. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
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12. Remove the oil pan body assembly. Refer to Operation <<12.60.48>>.
13. Install the old bolt which secured the crankshaft damper, to allow the crankshaft to be rotated. Use a new
bolt on final installaion.
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14. The following group of instructions (until stated otherwise) describe the procedure to renew the bearing
shells in one connecting rod. Repeat the instructions as necessary.
15. Rotate the crankshaft until the required connecting rod bolts are accessible.
1. Remove the bolts which secure the bearing cap.
2. Note the position of the identification marks and remove the cap.
Remove the bearing shell from the cap and note the grade (colour coded).
16. Carefully move the connecting rod and piston assembly towards the cylinder head to disconnect it from the
crankshaft. Rotate the crankshaft slightly if necessary.
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17. Remove the bearing shell from the connecting rod and note the grade (colour coded). The crankpin grades
are also stamped on the cylinder block.
18. Refer to the Specification Section for details of the crankpin and bearing shell grades.
20. Install and align the new bearing shell to the connecting rod.
21. Apply new engine oil to the connecting rod bearing and to the crankpin.
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22. Carefully move the connecting rod and piston assembly towards the the crankshaft and connect it to the
crankpin. Rotate the crankshaft slightly if necessary.
23. If necessary, refer to the Specification Section for details of piston and connecting rod orientation.
24. Install and align the new bearing shell to the connecting rod cap.
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26. Install the cap and NEW bolts to the connecting rod.
1. Note the position of the identification marks and install the cap so that the identification marks are
adjacent to those on the connecting rod.
2. Install the new bolts which secure the bearing cap.
29. Repeat the previous operations for each connecting rod bearing as necessary.
Installation
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2. Position and align the oil pan gasket to the oil pan body assembly.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.
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4. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated.
Tighten the drain plug to 30-40 Nm.
Install a new oil filter.
7. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
8. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>.
9. Install the twin fan and motor assembly. Refer to Operation 26.25.12.
10. NOTE:
When the engine is started from cold and run for a short period only, before being switched off, a quantity
of oil will be 'hung up' within the engine because it is not up to operating temperature.
Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
12. Check the oil level and start the engine. Check for leaks and that the engine runs correctly.
14. Remove the paintwork protection sheets and close the engine compartment cover.
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Adaptor
303-191-02
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Removal
3. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
4. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
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5. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
NOTE:
Should extra locking of the crankshaft be required, use a lever against one torque converter boss. Remove
the plastic mesh cover from the torque converter housing for access.
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7. NOTE:
The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing
the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from
the split locking ring.
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12. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant.
Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only.
Installation
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3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
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6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
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8. Install the drive belt to the front accessory drive. Refer to Section <<303-05>>.
9. Install the twin fan and motor assembly. Refer to Section 303-03.
10. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft.
11. Reset the engine compartment cover to the normal position and connect the gas struts.
12. Remove the paintwork protection sheets and close the engine compartment.
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Adaptor
303-191-02
Adaptor
303-191-03
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Removal
4. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
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5. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
NOTE:
Should extra locking of the crankshaft be required, use a lever against one torque converter boss. Remove
the plastic mesh cover from the torque converter housing for access.
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8. NOTE:
The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing
the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from
the split locking ring.
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13. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant.
Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only.
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Installation
3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
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6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
8. Install the drive belt to the front accessory drive. Refer to Operation <<12.10.40>>..
10. Install the twin fan and motor assembly. Refer to Section 303-03.
11. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft.
12. Reset the engine compartment cover to the normal position and connect the gas struts.
13. Remove the paintwork protection sheets and close the engine compartment.
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1. Remove the left-hand primary timing chain. <<Primary Timing Chain LH>>
2. Note the orientation of the sprockets relative to each other (half a tooth out of line).
3. Remove the sprocket from the crankshaft. To remove the Bank 2 sprocket, the Bank 1 sprocket must be
removed first.
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Installation
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Adaptor
303-191-02
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Removal
3. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
4. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
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5. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
NOTE:
Should extra locking of the crankshaft be required, use a lever against one torque converter boss. Remove
the plastic mesh cover from the torque converter housing for access.
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7. NOTE:
The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing
the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from
the split locking ring.
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12. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant.
Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only.
Installation
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3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
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6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
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8. Install the drive belt to the front accessory drive. Refer to Section <<303-05>>.
9. Install the twin fan and motor assembly. Refer to Section 303-03.
10. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft.
11. Reset the engine compartment cover to the normal position and connect the gas struts.
12. Remove the paintwork protection sheets and close the engine compartment.
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Adaptor
303-191-02
Adaptor
303-191-03
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Removal
4. Remove the drive belt from the front accessory drive. Refer to Operation <<12.10.40>>.
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5. Remove the twin fan and motor assembly for access. Refer to Operation 26.25.12
6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
NOTE:
Should extra locking of the crankshaft be required, use a lever against one torque converter boss. Remove
the plastic mesh cover from the torque converter housing for access.
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8. NOTE:
The damper only needs to be withdrawn along the crankshaft nose by approximately 2mm before removing
the puller. The damper will then either be loose or only require a sharp tap with a mallet to release it from
the split locking ring.
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13. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant.
Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only.
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Installation
3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
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6. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operations, to lock the crankshaft.
8. Install the drive belt to the front accessory drive. Refer to Operation <<12.10.40>>..
10. Install the twin fan and motor assembly. Refer to Section 303-03.
11. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft.
12. Reset the engine compartment cover to the normal position and connect the gas struts.
13. Remove the paintwork protection sheets and close the engine compartment.
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Removal
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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6. Fit and align the seal removal tool 303 - 538 to the crankshaft.
1. Unscrew the two nuts towards the head of each bolt to allow the bolts to fit fully into the crankshaft.
2. Unscrew the cente bolt until it is below the face of the main tool and position the tool to the rear of the
crankshaft.
3. Lightly tighten the two bolts so that they fully locate in the crankshaft.
7. Hold the tool against the crankshaft and lightly and evenly tighten the two nuts to the face of the tool; to
secure the tool and to hold it parallel to the face of the crankshaft.
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8. Secure the oil seal to the tool using the three self-tapping screws spaced evenly around the face of the tool.
Use the punch (provided) and a hammer to pierce the seal face and provide a pilot hole for one of the
self-tapping screws provided.
Fit a self-tapping screw and tighten by 11/2 turns only. DO NOT TIGHTEN BY MORE THAN TWO TURNS
OR THE SCREW MAY BREAK.
Repeat the above steps for the other two screws.
9. Hold the two bolts stationary and loosen fully the two nuts.
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10. Tighten the centre bolt. This will draw out the seal and tool assembly which will be supported by the two
bolts.
11. Remove the two bolts to release the tool and seal assembly from the crankshaft.
Remove the three self-tapping screws.
Remove and discard the seal.
Unscrew the centre bolt until it is below the face of the tool.
Installation
1. Ensure that the transit sleeve is correctly in place and fit the new seal over the crankshaft. Do not use any
lubricant on the seal, the transit sleeve or the crankshaft.
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4. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are
approximately parallel to the rear of the engine.
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9. Remove the paint protection sheets and close the engine compartment cover.
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Removal
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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6. Fit and align the seal removal tool 303 - 538 to the crankshaft.
1. Unscrew the two nuts towards the head of each bolt to allow the bolts to fit fully into the crankshaft.
2. Unscrew the cente bolt until it is below the face of the main tool and position the tool to the rear of the
crankshaft.
3. Lightly tighten the two screws so that they fully locate in the crankshaft.
7. Hold the tool against the crankshaft and lightly and evenly tighten the two nuts to the face of the tool; to
secure the tool and to hold it parallel to the face of the crankshaft.
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8. Secure the oil seal to the tool using the three self-tapping screws spaced evenly around the face of the tool.
Use the punch (provided) and a hammer to pierce the seal face and provide a pilot hole for one of the
self-tapping screws provided.
Fit a self-tapping screw and tighten by 11/2 turns only. DO NOT TIGHTEN BY MORE THAN TWO TURNS
OR THE SCREW MAY BREAK.
Repeat the above steps for the other two screws.
9. Hold the two bolts stationary and loosen fully the two nuts.
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10. Tighten the centre bolt. This will draw out the seal and tool assembly which will be supported by the two
bolts.
11. Remove the two bolts to release the tool and seal assembly from the crankshaft.
Remove the three self-tapping screws.
Remove and discard the seal.
Unscrew the centre bolt until it is below the face of the tool.
Installation
1. Ensure that the transit sleeve is correctly in place and fit the new seal over the crankshaft. Do not use any
lubricant on the seal, the transit sleeve or the crankshaft.
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4. Tighten the nuts, finger tight, to hold the tool assembly against the seal. Check that the seal and the tool are
approximately parallel to the rear of the engine.
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9. Remove the paint protection sheets and close the engine compartment cover.
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All vehicles
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Vehicles with supercharger
All vehicles
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Vehicles with supercharger
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
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All vehicles
Installation
All vehicles
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Vehicles with supercharger
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All vehicles
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Vehicles with supercharger
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All vehicles
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All vehicles
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Vehicles with supercharger
All vehicles
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1999 XK RANGE - Engine - 303-01
Vehicles with supercharger
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
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All vehicles
Installation
All vehicles
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1999 XK RANGE - Engine - 303-01
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Vehicles with supercharger
12 2012-07-23
1999 XK RANGE - Engine - 303-01
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1999 XK RANGE - Engine - 303-01
All vehicles
14 2012-07-23
1999 XK RANGE - Engine - 303-01
Vehicles with supercharger
15 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
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3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
6. Remove the camshaft locking tool 303 - 530 (fitted for previous operation).
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1999 XK RANGE - Engine - 303-01
Installation
2 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Fit the camshaft locking tool 303 - 530 (fitted for following operation) align the camshaft as necessary..
5. With the camshaft (303 - 530) and crankshaft (303 - 531) setting tools removed, after the previous operation,
adjust the valve clearances on the exhaust camshaft. refer to Operation <<12.29.48>>.
6. Move the engine compartment cover from the service position and connect the gas struts.
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1999 XK RANGE - Engine - 303-01
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
6. Remove the camshaft locking tool 303 - 530 (fitted for previous operation).
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1999 XK RANGE - Engine - 303-01
Installation
2 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Fit the camshaft locking tool 303 - 530 (fitted for following operation) align the camshaft as necessary.
5. With the camshaft (303 - 530) and crankshaft (303 - 531) setting tools removed, after the previous operation,
adjust the valve clearances on the exhaust camshaft. refer to Operation <<12.29.48>>.
6. Move the engine compartment cover from the service position and connect the gas struts.
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1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
Removal
1 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Rotate the crankshaft until the triangular arrow indent on the drive plate is visible through the access hole;
confirm that the timing flat on each camshaft is uppermost.
9. Install the crankshaft setting peg 303-531 to the crankshaft position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
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1999 XK RANGE - Engine - 303-01
11. Install the camshaft locking tool 303-530 to Bank 2 camshafts, aligning the shafts slightly as necessary.
12. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
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1999 XK RANGE - Engine - 303-01
13. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
14. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
Remove the sprocket and leave the chain resting on the cylinder head.
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1999 XK RANGE - Engine - 303-01
Installation
1. Push the tensioner piston into the body to provide clearance for installing. Tensioner fitted to cylinder head.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
4. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
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1999 XK RANGE - Engine - 303-01
11. Move the engine compartment cover from the service position and connect the gas struts.
12. Remove the paint protection sheets and close the engine compartment cover.
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1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
Removal
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
1 2012-07-23
1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
7. Rotate the crankshaft until the triangular arrow indent on the drive plate is visible through the access hole;
confirm that the timing flat on each camshaft is uppermost.
8. Install the crankshaft setting peg 303-531 to the crankshaft position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
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1999 XK RANGE - Engine - 303-01
10. Install the camshaft locking tool 303-530 to Bank 2 camshafts, aligning the shafts slightly as necessary.
11. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
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1999 XK RANGE - Engine - 303-01
12. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
13. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
Remove the sprocket and leave the chain resting on the cylinder head.
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1999 XK RANGE - Engine - 303-01
Installation
1. Push the tensioner piston into the body to provide clearance for installing. Tensioner fitted to cylinder head.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
4. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
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1999 XK RANGE - Engine - 303-01
11. Remove the paint protection sheets and close the engine compartment cover.
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1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
Removal
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1999 XK RANGE - Engine - 303-01
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Rotate the crankshaft until the triangular arrow indent on the drive plate is visible through the access hole;
confirm that the timing flat on each camshaft is uppermost.
9. Install the crankshaft setting peg 303-531 to the crankshaft position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
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1999 XK RANGE - Engine - 303-01
11. Install the camshaft locking tool 303-530 to Bank 1 camshafts, aligning the shafts slightly as necessary.
12. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
13. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
14. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
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1999 XK RANGE - Engine - 303-01
15. Remove the secondary chain tensioner. The tensioner piston cannot be pushed into the body with the
assembly in position.
1. Remove the two bolts which secure the tensioner.
Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly.
2. Remove the tensioner rearward from between the chain.
16. Remove the sprocket and leave the chain resting on the cylinder head.
Installation
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1999 XK RANGE - Engine - 303-01
2. Push the tensioner piston into the body to provide clearance for installing.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
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1999 XK RANGE - Engine - 303-01
13. Move the engine compartment cover from the service position and connect the gas struts.
14. Remove the paint protection sheets and close the engine compartment cover.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
Removal
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
1 2012-07-23
1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
7. Rotate the crankshaft until the triangular arrow indent on the drive plate is visible through the access hole;
confirm that the timing flat on each camshaft is uppermost.
8. Install the crankshaft setting peg 303-531 to the crankshaft position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
3 2012-07-23
1999 XK RANGE - Engine - 303-01
10. Install the camshaft locking tool 303-530 to Bank 1 camshafts, aligning the shafts slightly as necessary.
11. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
12. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
13. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
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1999 XK RANGE - Engine - 303-01
14. Remove the secondary chain tensioner. The tensioner piston cannot be pushed into the body with the
assembly in position.
1. Remove the two bolts which secure the tensioner.
Lift the tensioner, sprocket (release it fully from the camshaft) and chain assembly.
2. Remove the tensioner rearward from between the chain.
15. Remove the sprocket and leave the chain resting on the cylinder head.
Installation
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1999 XK RANGE - Engine - 303-01
2. Push the tensioner piston into the body to provide clearance for installing.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
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1999 XK RANGE - Engine - 303-01
13. Remove the paint protection sheets and close the engine compartment cover.
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1999 XK RANGE - Engine - 303-01
3. Remove the downpipe catalytic converter, left hand side. Refer to Section <<309-00>>.
4. Working from above the vehicle, remove the bolts which secure the front section of the exhaust manifold to
the cylinder head.
5. If working on a left hand drive vehicle; working from below the vehicle, reposition the steering rack for access.
1. Remove the two bolts which secure the steering rack at the driver's side.
2. Loosen, but do not remove, the two bolts which secure the steering rack at the passenger side.
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1999 XK RANGE - Engine - 303-01
7. Clean the manifold faces (if refitting) and the mating faces on the cylinder head.
8. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
Installation
1. Installation is the reverse of removal. Use new gaskets and new securing bolts for the manifold.
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1999 XK RANGE - Engine - 303-01
4. Remove the downpipe catalytic converter, right hand side. Refer to Section <<309-00>>.
5. From above the vehicle, disconnect the EGR pipe from the exhaust manifold.
1. Remove the two nuts which secure the EGR flange to the right hand exhaust manifold.
2. Reposition the EGR pipe from the manifold.
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1999 XK RANGE - Engine - 303-01
6. Remove the bolts which secure the front section of the exhaust manifold to the cylinder head.
7. If working on a right hand drive vehicle; reposition the steering rack for access.
1. Remove the two bolts which secure the steering rack at the passenger side.
2. Loosen, but do not remove, the two bolts which secure the steering rack at the driver's side.
Reposition the steering rack for access.
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1999 XK RANGE - Engine - 303-01
10. If fitting a new manifold, remove the two studs from the EGR flange of the manifold. and transfer them to
the new manifold.
11. Clean the manifold faces (if refitting) and the mating faces on the cylinder head.
12. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.
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1999 XK RANGE - Engine - 303-01
Installation
3. Working from above the vehicle, fit and tighten the remaining manifold securing bolts.
4. Working from below the vehicle, fully tighten the rear bolts on each manifold.
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1999 XK RANGE - Engine - 303-01
6. From above the vehicle, connect the EGR pipe to the exhaust manifold.
1. Fit a new EGR gasket to the manifold.
2. Reposition the EGR pipe to the manifold.
3. Fit the two nuts which secure the EGR flange to the exhaust manifold.
7. Fit the downpipe catalytic converter, right hand side. Refer to Section <<309-00>>.
10. Remove paintwork protection sheets and close the engine compartment.
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1999 XK RANGE - Engine - 303-01
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
4. Remove the Engine Covers, Air Intake Tube, Catalytic Converters and the Front Muffler. Drain the
transmission fluid and remove the transmission for access.
Refer to Operation <<44.20.01>> Transmission Remove, which includes each of the above operations.
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1999 XK RANGE - Engine - 303-01
6. Clean the crankshaft mating face and any other components which are to be refitted.
Installation
1. WARNING:
MAKE SURE NEW DRIVE PLATE RETAINING BOLTS ARE INSTALLED. FAILURE TO FOLLOW THIS
PROCEDURE MAY RESULT IN DAMAGE TO THE VEHICLE.
Fit the drive plate.
Fit and align the drive plate to the crankshaft.
Fit, but not tighten, the bolts which secure the drive plate to the crankshaft.
Prevent the drive plate from rotating by use of a small wedge in the ring gear.
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1999 XK RANGE - Engine - 303-01
2. Tighten the securing bolts in two stages and in the order shown.
STAGE ONE tighten to 14-16 Nm.
3. Tighten the securing bolts in two stages and in the order shown.
STAGE TWO tighten to 95-125 Nm.
4. Refit the Transmission, Catalytic Converters and the Front Muffler, Air Intake Tube and Engine Covers. Refill
the transmission with new fluid.
Refer to Operation <<44.20.01>> Transmission Install, which includes each of the above operations.
5. Remove the paint protection sheets and close the engine compartment cover.
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1999 XK RANGE - Engine - 303-01
2. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
4. Remove the Engine Covers, Air Intake Tube, Catalytic Converters and the Front Muffler. Drain the
transmission fluid and remove the transmission for access.
Refer to Operation 44.20. 01 Transmission Remove, in Section <<307-01B>>, which includes each of the
above operations.
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1999 XK RANGE - Engine - 303-01
6. Clean the crankshaft mating face and any other components which are to be refitted.
Installation
1. The drive plate and securing bolts are different for 99MY compared to previous engines. The differences are
as follows:
Longer bolts.
Spaceing plate welded to the drive plate on the crankshaft mating face.
Smaller locating hole for stepped dowel.
Plastic plug identifier (disposable) on new service part.
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1999 XK RANGE - Engine - 303-01
3. Tighten the securing bolts in two stages and in the order shown.
STAGE ONE tighten to 14-16 Nm.
4. Tighten the securing bolts in two stages and in the order shown.
STAGE TWO tighten to 95-125 Nm.
5. Refit the Transmission, Catalytic Converters and the Front Muffler, Air Intake Tube and Engine Covers. Refill
the transmission with new fluid.
Refer to Operation 44.20. 01, Transmission Install, in Section <<307-01B>>, which includes each of the
above operations.
6. Remove the paint protection sheets and close the engine compartment cover.
7. Connect the battery and fit the battery cover.
Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
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1999 XK RANGE - Engine - 303-01
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1999 XK RANGE - Engine - 303-01
5. Clean and inspect the sealing faces on the oil pan body assembly.
Clean and inspect the new oil pan mating face.
Installation
1. Fit the oil pan gasket to the oil pan body assembly.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.
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1999 XK RANGE - Engine - 303-01
3. Tighten the oil pan bolts to the correct torque figure 11 - 13 Nm, in the sequence indicated.
A new oil pan is supplied with the drain plug fitted. Check that the plug is tightened to the correct torque
figure of 30 - 40 Nm.
4. NOTE:
When the engine is started from cold and run for a short period only, before being switched off, a quantity
of oil will be 'hung up' within the engine because it is not up to operating temperature.
Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
Lower the ramp. Refill the engine with the correct specification engine oil.
5. Remove the paint protection sheets and close the engine compartment.
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1999 XK RANGE - Engine - 303-01
1 2012-07-23
1999 XK RANGE - Engine - 303-01
5. Clean and inspect the sealing faces on the oil pan. and mating faces.
Installation
1. Fit the oil pan gasket to the cylinder block adaptor body.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.
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1999 XK RANGE - Engine - 303-01
3. Tighten the bolts to the correct torque figure 11 - 13 Nm, in the sequence indicated.
Tighten the drain plug to 30 - 40 Nm.
Fit a new oil filter.
4. NOTE:
When the engine is started from cold and run for a short period only, before being switched off, a quantity
of oil will be 'hung up' within the engine because it is not up to operating temperature.
Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
Lower the ramp. Refill the engine with the correct specification engine oil.
5. Remove the paint protection sheets and close the engine compartment.
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1999 XK RANGE - Engine - 303-01
Installation
1. NOTE:
Fit new sealing washer to oil pressure switch.
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1999 XK RANGE - Engine - 303-01
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Remove the engine compartment cover (bonnet) for improved access to the front of the engine. Refer to
Operation <<76.16.01>>.
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1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
2. Refit both sprockets to the crankshaft, both primary timing chains, the timing cover and all associated
components. Refer to Operation <<12.65.76>>.
4. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
3 2012-07-23
1999 XK RANGE - Engine - 303-01
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Remove the engine compartment cover (bonnet) for improved access to the front of the engine. Refer to
Operation <<76.16.01>> (SC).
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1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
2. Refit both sprockets to the crankshaft, both primary timing chains, the timing cover and all associated
components. Refer to Operation <<12.65.76>> (SC).
3. Refit the engine compartment cover (bonnet). Refer to Operation <<76.16.01>> (SC).
4. Reset the side glass memory. Refer to the Battery Reconnection Procedure <<86.15.15>>.
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1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
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1999 XK RANGE - Engine - 303-01
Removal
All vehicles
1. Remove the right-hand primary timing chain. <<Primary Timing Chain RH>>
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1999 XK RANGE - Engine - 303-01
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals.
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
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1999 XK RANGE - Engine - 303-01
5. Install the camshaft locking tool 303-530 to the left-hand camshafts, aligning the camshafts as necessary.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
Vehicles without supercharger
7. Loosen the variable camshaft timing oil control unit retaining bolt.
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
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1999 XK RANGE - Engine - 303-01
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1999 XK RANGE - Engine - 303-01
12. Push the tensioner piston (secondary chain) into the body to to release the tension on the left-hand
secondary timing chain.
Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
13. Reposition the timing chain assembly forward along the camshaft bosses to enable the primary timing chain
to clear the cylinder head casting.
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1999 XK RANGE - Engine - 303-01
15. Note the orientation of the sprockets relative to each other (half a tooth out of line).
Installation
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
1. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket.
Reposition the sprockets for the most advantageous position for use of the tool.
Remove the tool.
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1999 XK RANGE - Engine - 303-01
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1999 XK RANGE - Engine - 303-01
5. Push the tensioner piston into the body to provide clearance for fitting.
1. Install a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
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1999 XK RANGE - Engine - 303-01
9. Rotate the variable camshaft timing oil control unit fully counter-clockwise to the fully retarded position.
1. Install the variable camshaft timing oil control unit setting tool 303-654.
2. Rotate the variable camshaft timing oil control unit fully anti-clockwise to the fully retarded position.
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1999 XK RANGE - Engine - 303-01
10. Tighten the variable camshaft timing oil control unit retaining bolt.
1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the
wedges are still in place, carry out the variable camshaft timing oil control unit retaining bolt tightening
sequence.
Tighten to 40 Nm + 90°.
Remove the chain tensioning tool and the wedge(s).
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1999 XK RANGE - Engine - 303-01
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
13. Install new seals to the variable camshaft timing oil control unit housing.
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1999 XK RANGE - Engine - 303-01
14. WARNING:
CHECK THAT THE RING DOWELS ARE ENGAGED SQUARELY. FULLY LOCATE THE ASSEMBLY AS
MUCH AS POSSIBLE BY HAND PRESSURE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT
IN DAMAGE TO THE VEHICLE.
NOTE:
Lubricate the seals and the bush.
Install the variable camshaft timing oil control unit housing to the cylinder block.
1. Install the variable camshaft timing oil control unit housing.
2. Install the two retaining bolts and one nut. Tighten to 19-23 Nm.
16. Install the right-hand primary timing chain. <<Primary Timing Chain RH>>
16 2012-07-23
1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
1 2012-07-23
1999 XK RANGE - Engine - 303-01
Crankshaft setting
303-531
2 2012-07-23
1999 XK RANGE - Engine - 303-01
Removal
All vehicles
3 2012-07-23
1999 XK RANGE - Engine - 303-01
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals.
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
5. Temporarily install the crankshaft pulley and retaining bolt, hand-tight only.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
8. CAUTION:
Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Position the crankshaft so the timing slot on the drive plate is visible through the CKP sensor location.
5 2012-07-23
1999 XK RANGE - Engine - 303-01
11. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operation to lock the crankshaft.
Using the special tools, remove the crankshaft pulley retaining bolt.
6 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Install the camshaft locking tool 303 - 530 to the right-hand camshafts, aligning the camshafts as necessary.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
15. Loosen the variable camshaft timing oil control unit retaining bolt.
8 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
10 2012-07-23
1999 XK RANGE - Engine - 303-01
21. Note the orientation of the sprockets relative to each other (half a tooth out of line).
Installation
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
11 2012-07-23
1999 XK RANGE - Engine - 303-01
1. Install the chain tensioning tool 303 - 532 to the exhaust camshaft sprocket.
Reposition the sprockets for the most advantageous position for use of the tool.
Remove the tool.
12 2012-07-23
1999 XK RANGE - Engine - 303-01
4. Push the tensioner piston into the body to provide clearance for fitting.
1. Install a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
13 2012-07-23
1999 XK RANGE - Engine - 303-01
14 2012-07-23
1999 XK RANGE - Engine - 303-01
7. Install primary chain tensioner wedge 303-533 (or two if required) between the primary chain tensioner and
tensioner blade, to take up the slack in the chain.
15 2012-07-23
1999 XK RANGE - Engine - 303-01
9. Rotate the variable camshaft timing oil control unit fully counter-clockwise to the fully retarded position.
1. Install the variable camshaft timing oil control unit setting tool 303-654.
2. Rotate the variable camshaft timing oil control unit fully anti-clockwise to the fully retarded position.
10. Tighten the variable camshaft timing oil control unit retaining bolt.
1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the
wedges are still in place, carry out the variable camshaft timing oil control unit retaining bolt tightening
sequence.
Tighten to 40 Nm + 90°.
Remove the chain tensioning tool and the wedge(s).
16 2012-07-23
1999 XK RANGE - Engine - 303-01
Vehicles with supercharger
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
17 2012-07-23
1999 XK RANGE - Engine - 303-01
18 2012-07-23
1999 XK RANGE - Engine - 303-01
Vehicles without supercharger
17. Fit new seals to the variable camshaft timing oil control unit housing.
18. WARNING:
CHECK THAT THE RING DOWELS ARE ENGAGED SQUARELY. FULLY LOCATE THE ASSEMBLY AS
MUCH AS POSSIBLE BY HAND PRESSURE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT
IN DAMAGE TO THE VEHICLE.
NOTE:
Lubricate the seals and the bush.
Install the variable camshaft timing oil control unit housing to the cylinder block.
1. Install the variable camshaft timing oil control unit housing.
2. Install the two retaining bolts and one nut. Tighten to 19-23 Nm.
19 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
20 2012-07-23
1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
1 2012-07-23
1999 XK RANGE - Engine - 303-01
Crankshaft setting
303-531
2 2012-07-23
1999 XK RANGE - Engine - 303-01
Removal
All vehicles
3 2012-07-23
1999 XK RANGE - Engine - 303-01
4. Remove and discard the variable camshaft timing oil control unit housing O-ring seals.
1. Remove the sealing rings from the variable camshaft timing oil control unit housing.
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
5. Temporarily install the crankshaft pulley and retaining bolt, hand-tight only.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
8. CAUTION:
Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Position the crankshaft so the timing slot on the drive plate is visible through the CKP sensor location.
5 2012-07-23
1999 XK RANGE - Engine - 303-01
11. CAUTION:
Under no circumstances should the crankshaft setting peg 303-531 be used in the following
operation to lock the crankshaft.
Using the special tools, remove the crankshaft pulley retaining bolt.
6 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Install the camshaft locking tool 303-530 to the left-hand camshafts, aligning the camshafts as necessary.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
15. Loosen the variable camshaft timing oil control unit retaining bolt.
8 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
10 2012-07-23
1999 XK RANGE - Engine - 303-01
20. Push the tensioner piston (secondary chain) into the body to to release the tension on the left-hand
secondary timing chain.
Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
21. Reposition the timing chain assembly forward along the camshaft bosses to enable the primary timing chain
to clear the cylinder head casting.
11 2012-07-23
1999 XK RANGE - Engine - 303-01
22. Detach the left-hand primary timing chain, and allow it rest against the crankshaft sprocket.
Installation
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
12 2012-07-23
1999 XK RANGE - Engine - 303-01
1. Fit the assembly to the camshafts with the chain correctly positioned over the tensioner; variable
camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) to the
inlet and the sprocket to the exhaust.
2. Fit, but do not tighten, each bolt which secures the variable camshaft timing oil control unit (or intake
camshaft sprocket - vehicles fitted with supercharger) and the exhaust sprocket to the camshafts.
Allow the variable camshaft timing oil control unit sufficient space to fit the primary chain, in a later
operation.
2. Install the chain tensioning tool 303-532 to the exhaust camshaft sprocket, Bank 2.
Reposition the sprocket and the variable camshaft timing oil control unit (or intake camshaft sprocket -
vehicles fitted with supercharger) for the most advantageous position for use of the tool.
Remove the tool.
13 2012-07-23
1999 XK RANGE - Engine - 303-01
14 2012-07-23
1999 XK RANGE - Engine - 303-01
6. Push the tensioner piston into the body to provide clearance for fitting.
1. Install a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
15 2012-07-23
1999 XK RANGE - Engine - 303-01
16 2012-07-23
1999 XK RANGE - Engine - 303-01
10. Rotate the variable camshaft timing oil control unit fully counter-clockwise to the fully retarded position.
1. Install the variable camshaft timing oil control unit setting tool 303-654.
2. Rotate the variable camshaft timing oil control unit fully anti-clockwise to the fully retarded position.
17 2012-07-23
1999 XK RANGE - Engine - 303-01
11. Tighten the variable camshaft timing oil control unit retaining bolt.
1. Whilst still applying the opposing force to the sprocket and chain (using 303 - 532), check that the
wedges are still in place, carry out the variable camshaft timing oil control unit retaining bolt tightening
sequence.
Tighten to 40 Nm + 90°.
Remove the chain tensioning tool and the wedge(s).
18 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
14. Install new seals to the variable camshaft timing oil control unit housing.
19 2012-07-23
1999 XK RANGE - Engine - 303-01
15. WARNING:
CHECK THAT THE RING DOWELS ARE ENGAGED SQUARELY. FULLY LOCATE THE ASSEMBLY AS
MUCH AS POSSIBLE BY HAND PRESSURE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT
IN DAMAGE TO THE VEHICLE.
NOTE:
Lubricate the seals and the bush.
Install the variable camshaft timing oil control unit housing to the cylinder block.
1. Install the variable camshaft timing oil control unit housing.
2. Install the two retaining bolts and one nut. Tighten to 19-23 Nm.
20 2012-07-23
1999 XK RANGE - Engine - 303-01
All vehicles
21 2012-07-23
1999 XK RANGE - Engine - 303-01
2. Push the tensioner piston (secondary chain) into the body to to release the tension on the right-hand
secondary timing chain.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
1 2012-07-23
1999 XK RANGE - Engine - 303-01
2. Remove the variable camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with
supercharger), exhaust sprocket and secondary chain as an assembly (release the chain from the
tensioner which is still secured to the cylinder head).
Remove the secondary chain from the variable camshaft timing oil control unit (or intake camshaft sprocket
- vehicles fitted with supercharger) and the sprocket.
Installation
1. Fit the assembly to the camshafts with the chain correctly positioned over the tensioner; variable
camshaft timing oil control unit (or intake camshaft sprocket - vehicles fitted with supercharger) to the
inlet and the sprocket to the exhaust.
2. Fit, but do not tighten, each bolt which secures the variable camshaft timing oil control unit (or intake
camshaft sprocket - vehicles fitted with supercharger) and the exhaust sprocket to the camshafts.
Allow the variable camshaft timing oil control unit sufficient space to fit the primary chain, in a later
operation.
2 2012-07-23
1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
RemovalNOTE:
Vehicles without supercharger shown, vehicles with supercharger similar
1 2012-07-23
1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
5. CAUTION:
Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Position the crankshaft so the timing slot on the drive plate is visible through the CKP sensor location.
3 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Install the camshaft locking tool 303-530 to Bank 2 camshafts, aligning the shafts slightly as necessary.
9. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
10. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
11. Push the tensioner piston (secondary chain) into the body to to release the tension on the left-hand
secondary timing chain.
Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
5 2012-07-23
1999 XK RANGE - Engine - 303-01
12. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
14. Remove the sprocket if required, or leave it in the chain resting on the cylinder head.
6 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
2. Push the tensioner piston into the body to provide clearance for installing.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
8 2012-07-23
1999 XK RANGE - Engine - 303-01
6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Move the engine compartment cover from the service position and connect the gas struts.
14. Remove the paint protection sheets and close the engine compartment cover.
10 2012-07-23
1999 XK RANGE - Engine - 303-01
Camshaft setting
303-530
Crankshaft setting
303-531
RemovalNOTE:
Vehicles without supercharger shown, vehicles with supercharger similar
1 2012-07-23
1999 XK RANGE - Engine - 303-01
2 2012-07-23
1999 XK RANGE - Engine - 303-01
5. CAUTION:
Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Position the crankshaft so the timing slot on the drive plate is visible through the CKP sensor location.
3 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Install the camshaft locking tool 303-530 to Bank 1 camshafts, aligning the shafts slightly as necessary.
9. CAUTION:
Use a length of steel strip that will not fall into the timing cover.
Protect the upper face of the timing cover from scratches, when removing the bolt which secures the sprocket.
1. Place a flat piece of steel strip along the timing cover horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
10. A ball-ended hexagon drive bit is required to remove the sprocket securing bolt. A suitable tool is available
from Snap On as (FABLM10E) Long Series 10mm AF.
11. Remove the bolt which secures the sprocket to the exhaust camshaft.
Move the sprocket forward from the camshaft boss.
5 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Remove the sprocket if required, or leave it in the chain resting on the cylinder head.
Installation
6 2012-07-23
1999 XK RANGE - Engine - 303-01
2. Push the tensioner piston into the body to provide clearance for installing.
1. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the
non-return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
6. Remove the tape and steel strip from the timing cover upper face. Wipe any residue of tape from the joint
face.
8 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Move the engine compartment cover from the service position and connect the gas struts.
14. Remove the paint protection sheets and close the engine compartment cover.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
Removal
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>.
6. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
1 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Remove the two bolts which secure the generator cooling duct to the oil pan body and remove the duct.
9. Remove the front cross member for access. Refer to Operation 76.10.05. Includes cruciform strut assembly
on convertible.
2 2012-07-23
1999 XK RANGE - Engine - 303-01
12. NOTE:
Place a suitable container underneath filter to prevent oil spillage.
13. Remove the oil pressure switch. <<Oil Pressure Switch - >>
3 2012-07-23
1999 XK RANGE - Engine - 303-01
15. Remove the bolt which secures the transmission cooler pipes and remove the clamping bracket.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
17. Remove the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
5 2012-07-23
1999 XK RANGE - Engine - 303-01
6 2012-07-23
1999 XK RANGE - Engine - 303-01
19. Remove the bolts, ten outer and six inner, which secure the oil pan body.
Remove the oil pan body.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
20. Remove the eight screws and release the windage tray.
22. Clean all components and relevant mating faces; cylinder block, oil pan, oil pan body, windage tray, oil
pick-up pipe, diverter valve and timing cover.
8 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
1. Reposition the windage tray and install the eight screws, tighten to 5-7 Nm.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the bed plate flange OR
around the oil pan body flange; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV
sealant.
10 2012-07-23
1999 XK RANGE - Engine - 303-01
4. Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the oil pick-up pipe and the
diverter valve flanges; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV
sealant.
11 2012-07-23
1999 XK RANGE - Engine - 303-01
12 2012-07-23
1999 XK RANGE - Engine - 303-01
7. Install the oil pan gasket to the oil pan body assembly.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.
13 2012-07-23
1999 XK RANGE - Engine - 303-01
9. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated.
Tighten the drain plug to 30-40 Nm.
10. Install the oil pressure switch. <<Oil Pressure Switch - >>
14 2012-07-23
1999 XK RANGE - Engine - 303-01
11. NOTE:
Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal.
15 2012-07-23
1999 XK RANGE - Engine - 303-01
13. Install the four bolts (two each side) which secure the exhaust downpipes to the oil pan body and
transmisssion casing.
16 2012-07-23
1999 XK RANGE - Engine - 303-01
15. Position the transmission cooler pipes and the clamping bracket. Install the bolt to secure the clamp and
tighten to 7-9 Nm.
16. Install the front crossmember. Refer to Operation 76.10.05. Includes cruciform strut assembly on
convertible.
17. Position the generator cooling duct to the oil pan body and install the two bolts.
19. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
20. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>.
21. NOTE:
17 2012-07-23
1999 XK RANGE - Engine - 303-01
When the engine is started from cold and run for a short period only, before being switched off, a quantity
of oil will be 'hung up' within the engine because it is not up to operating temperature.
Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
23. Check the oil level and start the engine. Check for leaks and that the engine runs correctly.
24. Reposition the engine compartment cover and connect the gas struts.
25. Remove the paintwork protection sheets and close the engine compartment cover.
18 2012-07-23
1999 XK RANGE - Engine - 303-01
Removal
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. Remove the twin fan and motor assembly. Refer to Operation 26.25.12.
1 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Remove the supercharger drive belt idler pulley. Refer to Operation <<18.50.09>>.
10. Remove the supercharger drive belt tensioner. Refer to Operation <<18.50.24>>.
11. Remove the timing cover and all associated components, as detailed in Operation <<12.65.01>>.
12. Remove both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
2 2012-07-23
1999 XK RANGE - Engine - 303-01
14. Remove the two bolts which secure the generator cooling duct to the oil pan body and remove the duct.
15. Remove the front cross member for access. Refer to Operation 76.10.05. Includes cruciform strut assembly
on convertible.
3 2012-07-23
1999 XK RANGE - Engine - 303-01
4 2012-07-23
1999 XK RANGE - Engine - 303-01
19. NOTE:
Place a suitable container underneath filter to prevent oil spillage.
20. Remove the oil pressure switch. <<Oil Pressure Switch - >>
5 2012-07-23
1999 XK RANGE - Engine - 303-01
22. Remove the bolt which secures the transmission cooler pipes and remove the clamping bracket.
6 2012-07-23
1999 XK RANGE - Engine - 303-01
24. Remove the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
8 2012-07-23
1999 XK RANGE - Engine - 303-01
27. Remove the bolts, ten outer and six inner, which secure the oil pan body.
Remove the oil pan body.
9 2012-07-23
1999 XK RANGE - Engine - 303-01
28. Remove the eight screws and release the windage tray.
30. Clean all components and relevant mating faces; cylinder block, oil pan, oil pan body, windage tray, oil
pick-up pipe, diverter valve and timing cover.
10 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
1. Reposition the windage tray and install the eight screws, tighten to 5-7 Nm.
11 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the bed plate flange OR
around the oil pan body flange; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV
sealant.
12 2012-07-23
1999 XK RANGE - Engine - 303-01
4. Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the oil pick-up pipe and the
diverter valve flanges; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV
sealant.
13 2012-07-23
1999 XK RANGE - Engine - 303-01
14 2012-07-23
1999 XK RANGE - Engine - 303-01
15 2012-07-23
1999 XK RANGE - Engine - 303-01
8. Install the oil pan gasket to the oil pan body assembly.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.
16 2012-07-23
1999 XK RANGE - Engine - 303-01
10. Tighten the bolts to the correct torque figure 11-13 Nm, in the sequence indicated.
Tighten the drain plug to 30-40 Nm.
11. Install the oil pressure switch. <<Oil Pressure Switch - >>
12. NOTE:
Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal.
17 2012-07-23
1999 XK RANGE - Engine - 303-01
14. Install the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.
18 2012-07-23
1999 XK RANGE - Engine - 303-01
16. Position the transmission cooler pipes and the clamping bracket. Install the bolt to secure the clamp and
tighten to 7-9 Nm.
19 2012-07-23
1999 XK RANGE - Engine - 303-01
17. Connect the oil cooler pipes to the oil pan body assembly (vehicles with engine oil cooler).
1. Remove the blanking plugs and install new O-ring seals.
2. Connect the oil cooler pipes.
3. Install the clamp and bolt which secures the oil cooler pipes. Tighten to 18-24 Nm.
18. Install the front crossmember. Refer to Operation 76.10.05. Includes cruciform strut assembly on
convertible.
19. Position the generator cooling duct to the oil pan body and install the two bolts.
21. Install both front wheel and tyre assemblies. Refer to Operation <<74.20.05>>.
22. Install the timing cover and all associated components, as detailed in Operation <<12.65.01>>. Do not efill
the cooling system at this stage.
20 2012-07-23
1999 XK RANGE - Engine - 303-01
23. Install the supercharger drive belt tensioner. Refer to Operation <<18.50.24>>.
25. Install the supercharger drive belt idler pulley. Refer to Operation <<18.50.09>>. (34-46 Nm).
28. Install the twin fan and motor assembly. Refer to Operation 26.25.12.
29. Refill the cooling system. Refer to Operation 26.10.01 in General Procedures section of the cooling system.
30. NOTE:
When the engine is started from cold and run for a short period only, before being switched off, a quantity
of oil will be 'hung up' within the engine because it is not up to operating temperature.
Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
32. Check the oil level and start the engine. Check for leaks and that the engine runs correctly.
34. Remove the paintwork protection sheets and close the engine compartment cover.
21 2012-07-23
1999 XK RANGE - Engine - 303-01
1 2012-07-23
1999 XK RANGE - Engine - 303-01
3. Disconnect the variable camshaft timing oil control solenoid electrical connector.
All vehicles
2 2012-07-23
1999 XK RANGE - Engine - 303-01
3 2012-07-23
1999 XK RANGE - Engine - 303-01
9. Release the clips which secure the engine harness to the cam cover.
4 2012-07-23
1999 XK RANGE - Engine - 303-01
Vehicles with supercharger
10. Detach the fuel injection supply manifold wiring harness retaining bracket.
All vehicles
5 2012-07-23
1999 XK RANGE - Engine - 303-01
12. NOTE:
On removal of the valve cover retaining bolts note their positions in the valve cover.
6 2012-07-23
1999 XK RANGE - Engine - 303-01
Installation
All vehicles
2. Install the valve cover retaining bolts to their positions previously noted.
1. Install the valve cover retaining bolts.
Install new valve cover retaining bolt O-ring seals.
7 2012-07-23
1999 XK RANGE - Engine - 303-01
3. 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 cam cover immediately after
applying the sealant.
The cover should be installed directly to the head without smearing the sealant.
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Vehicles with supercharger
6. Attach the fuel injection supply manifold wiring harness retaining bracket.
Tighten to 5 Nm.
All vehicles
7. Reposition the clips which secure the engine harness to the cam cover.
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Vehicles without supercharger
13. Connect the variable camshaft timing oil control solenoid electrical connector.
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All vehicles
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5. Remove the intake tube / air flow meter / air cleaner cover assembly.
1. Remove the intake tube / air flow meter / air cleaner cover assembly.
2. Remove and discard the rubber seal; air intake tube to throttle body.
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Vehicles without supercharger
7. Disconnect the variable camshaft timing oil control solenoid electrical connector.
All vehicles
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9. Release the clips which secure the engine harness to the cam cover.
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11. Detach the fuel injection supply manifold wiring harness retaining bracket.
All vehicles
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13. Separate the screws and seals from the cam cover.
1. One at a time, remove each securing screw from the cam cover.
2. Remove the rubber sealing ring from each securing screw.
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Installation
All vehicles
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3. Apply RTV sealant WSS-M4G320-A3 to two places on the joint between the timing cover and the cylinder
head.
The application of sealant must be 3mm diameter by 12mm long. Install the cam cover immediately after
applying the sealant.
The cover should be installed directly to the head without smearing the sealant.
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5. Tighten the securing screws to 9-11 Nm. Tighten in the sequence indicated.
Screws annotated in a square have studs to install other components onto, and must be installed in the
positions shown.
6. Attach the fuel injection supply manifold wiring harness retaining bracket.
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All vehicles
8. Reposition the clips which secure the engine harness to the cam cover.
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Vehicles without supercharger
10. Connect the variable camshaft timing oil control solenoid electrical connector.
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All vehicles
12. Install the intake tube / air flow meter / air cleaner cover assembly.
1. Install a new rubber seal; air intake tube to throttle body.
2. Install the intake tube / air flow meter / air cleaner cover assembly.
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16. Remove the paintwork protection sheets and close the engine compartment.
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Drain
2. Ensure that the cooling system is cool and very carefully, remove the pressure cap from the header tank.
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Refill
1. Refill the cooling system with a 50% solution of water and Jaguar Antifreeze / Corrosion Inhibitor ESD -
M97B49 - A.
Fill the cooling system at the header tank until the level stabilises at the top of the breather neck.
Allow at least 2 minutes for air to purge from the system.
Top up the header tank as required and fit the pressure cap.
2. Switch on the ignition, switch off the climate control system and start the engine.
3. Run the engine at between 1500 and 2000 rpm until the cooling fans operate.
4. Switch on the A/C system, set to maximum heat, and check that heat is coming from the heater at the
fascia vents or the footwell outlets.
6. When cool, remove the pressure cap and top up the system as necessary at the header tank.
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9. Remove the paintwork protection sheets and close the engine cover.
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Drain
2. Ensure that the cooling system is cool and very carefully, remove the pressure cap from the header tank.
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Refill
1. Refill the cooling system with a 50% solution of water and Jaguar Antifreeze / Corrosion Inhibitor ESD -
M97B49 - A.
1. Remove the threaded plug and Dowty washer from the charge air cooler fill point.
2. Fill the cooling system at the header tank until the level stabilises near the top of the charge air
cooler fill point. This will take some time, as air is being purged from the system.
Ensure that the header tank is full.
2. NOTE:
To ensure that air is not drawn into the system during the following operations:
Do not remove the cap from the header tank whilst the charge air cooling system is open to
atmosphere.
Do not switch on the ignition when the charge air cooling system is open to atmosphere
because the electrical cooling pump may draw air into the system.
Fit the pressure cap to the header tank.
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3. Pour coolant carefully into the charge air cooler fill point until the system is full.
Fit the plug and washer to the fill point.
5. Switch on the ignition and switch off the climate control system.
Leave the ignition switched on (do not start the engine) for at least 2 minutes to allow the charge air
cooler electric water pump to operate and to purge any air from the charge air cooler radiator to the
header tank. (This operation will be repeated later)
7. Leave the ignition switched on (do not start the engine) for at least 2 minutes to allow the charge air cooler
electric water pump to operate and to purge any air from the charge air cooler radiator to the header tank.
9. Run the engine at between 1500 and 2000 rpm until the cooling fans operate.
10. Switch on the climate control system, set to maximum heat, and check that heat is coming from the
heater at the fascia vents or the footwell outlets.
12. When cool, remove the pressure cap and top up the system as necessary at the header tank.
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14. Check that the pressure cap is fitted. Remove the plug from the charge air cooler fill point. Pour coolant
carefully into the charge air cooler fill point until the system is full.
Fit the plug to the fill point, using a new Dowty sealing washer.
15. Remove the paintwork protection sheets and close the engine cover.
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Removal 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
3. Place a cloth under the expansion tank to absorb any spillage caused by disconnecting the hoses.
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Installation
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2. Ensure that the cooling system is cool and very carefully, remove the pressure cap.
3. Place a cloth under the expansion tank to absorb any spillage caused by disconnecting the hoses.
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8. Empty any surplus coolant from the expansion tank into a drain tray.
9. Remove the cloth from the engine and clean any spillage from the engine bay.
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Installation
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2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage
when removing the outlet pipe.
3. Disconnect the top hose and breather pipe from the coolant outlet pipe.
1. Release and reposition the hose clip, and disconnect the top hose.
2. Release and disconnect the breather pipe quick fit connector.
3. Disconnect the multi-plug from the temperature sensor and unscrew the sensor from the outlet pipe.
4. Release and reposition the hose clip along the bypass hose.
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6. Release and reposition the clip which secures the heater hose to the outlet pipe and disconnect the hose.
Remove the outlet pipe.
8. Remove and discard the sealing rings from the outlet pipe grooves.
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Installation
2. Tighten the coolant outlet pipe bolts to 8 - 12 Nm. If replacing the coolant temperature sensor, tighten to
15 - 19 Nm.
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1. Remove the Twin Fan and Motor Assembly (26.25.12) described in this section. Do not remove the
harness and pipe securing clips from the assembly.
2. Remove the fan and motor unit from the twin fan and motor assembly.
1. Remove the three nuts which secure the fan and motor unit.
2. Remove the fan and motor unit.
Installation
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All vehicles
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the
doors remain open until after the battery has been disconnected.
4. Drain the cooling system. <<Cooling System Draining, Filling and Bleeding - Vehicles With:
Supercharger>>
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All vehicles
6. Remove the two nuts which secure the fan and motor assembly to the radiator.
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10. Carefully release and reposition the climate control pipe from the securing clip on the fan and motor
assembly.
12. Carefully remove the fan and motor assembly from the vehicle.
13. Remove the harness and pipe securing clips from the assembly.
Installation
1. Installation is the reverse of the removal procedure. Ensure that the fan and motor assembly locate into
the lower mountings.
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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.
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Installation
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Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the
doors remain open until after the battery has been disconnected.
5. Depressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings
and precautions stated in that section.
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7. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
1. Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.
8. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
1. Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.
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10. From above the vehicle, disconnect the transmission oil cooler upper pipe.
1. Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe.
2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the
union on the radiator.
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15. Disconnect the pipe from the climate control receiver / drier.
1. Remove the bolt which secures the pipe to the receiver / drier and disconnect the pipe.
2. Remove and discard the O-ring.
3. Install blanking plugs to the pipe and the receiver drier.
16. Disconnect the pipe from the climate control condenser joint (condenser to compressor).
1. Remove the nut which secures the pipe to the condenser and disconnect the pipe.
2. Remove and discard the O-ring.
3. Install blanking plugs to the pipe and the condenser.
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Installation
1. Install new foam sealing strips to the radiator top, bottom and left side.
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4. With assistance, reposition the radiator to the vehicle. Check that the lower mounting rubbers are located
correctly.
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11. From below the vehicle, connect the transmission lower cooler pipe to the radiator.
1. Remove the blanking plugs and install a new O-ring seal to the cooler pipe.
2. Reposition the pipe and the union nut to the radiator.
3. Connect and tighten the union nut.
4. Reposition and install the climate control pipe to the clips on the fan cowl.
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14. Check the level and replenish the transmission fluid as necessary.
15. From above the vehicle, install the air cleaner assembly; refer to Opeeration 19.10.05.
16. Refill the cooling system. Refer to the Refill Procedure 26.10.01.
17. Repressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings
and precautions stated in that section.
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the
doors remain open until after the battery has been disconnected.
5. Depressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings
and precautions stated in that section.
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7. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
1. Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.
8. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
1. Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.
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10. From above the vehicle, disconnect the transmission oil cooler upper pipe.
1. Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe.
2. Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the
union on the radiator.
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15. Disconnect the pipe from the climate control receiver / drier.
1. Remove the bolt which secures the pipe to the receiver / drier and disconnect the pipe.
2. Remove and discard the O-ring.
3. Install blanking plugs to the pipe and the receiver drier.
16. Disconnect the pipe from the climate control condenser joint (condenser to compressor).
1. Remove the nut which secures the pipe to the condenser and disconnect the pipe.
2. Remove and discard the O-ring.
3. Install blanking plugs to the pipe and the condenser.
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Installation
1. Install new foam sealing strips to the radiator top, bottom and left side.
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4. With assistance, reposition the radiator to the vehicle. Check that the lower mounting rubbers are located
correctly.
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11. From below the vehicle, connect the transmission lower cooler pipe to the radiator.
1. Remove the blanking plugs and install a new O-ring seal to the cooler pipe.
2. Reposition the pipe and the union nut to the radiator.
3. Connect and tighten the union nut.
4. Reposition and install the climate control pipe to the clips on the fan cowl.
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14. Check the level and replenish the transmission fluid as necessary.
15. From above the vehicle, install the air cleaner assembly; refer to Operation 19.10.05.
16. Refill the cooling system. Refer to the Refill procedure (SC) 26.10.01.
17. Repressurise the climate control system. Refer to Operation <<82.30.30>>. Observe all safety warnings
and precautions stated in that section.
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2. Drain the radiator. Refer to General Procedures. Retain the coolant drain tray in position to catch any
spillage when removing the thermostat cover.
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5. Disconnect the radiator bottom hose from the thermostat cover and air charge cooler.
1. Release and reposition the hose clip, and disconnect the bottom hose from the thermostat cover.
2. Release and reposition the hose clips, and disconnect the two sections of moulded hose from the air
charge cooler.
Remove the hose assembly.
Installation
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2. Drain the radiator. Refer to General Procedures. Retain the coolant drain tray in position to catch any
spillage when removing the hose.
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Installation
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2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage
when removing the thermostat cover.
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1. Remove the three bolts which secure the thermostat cover to the housing.
2. Remove the thermostat cover from the housing.
Installation
2. Fit the thermostat so that the vent ball valve locates in the recess in the cover.
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2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage
when removing the outlet pipe.
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Installation
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2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage
when removing the outlet pipe.
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Installation
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2. Drain the radiator. Refer to this Section. Retain the coolant drain tray in position to catch any spillage
when removing the outlet pipe.
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Installation
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3. Slacken the three screws which secure the water pump pulley.
4. CAUTION:
When releasing the belt tension, never apply any torque in a clockwise direction to the pulley
centre bolt (left hand thread) as it could subsequently loosen.
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Remove the drive belt from the generator and accessory drive.
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt
tensioner idler pulley, to turn the adjuster assembly to the left against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner slowly and remove the spanner.
Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
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Installation
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4. Slacken the three screws which secure the water pump pulley.
5. CAUTION:
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When releasing the belt tension, never apply any torque in a clockwise direction to the pulley
centre bolt (left hand thread) as it could subsequently loosen.
Remove the drive belt from the generator and accessory drive.
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt
tensioner idler pulley, to turn the adjuster assembly to the left against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner slowly and remove the spanner.
Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
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Installation
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2. Slacken the three screws which secure the water pump pulley.
3. Remove the drive belt from the generator and accessory drive.
1. Use a spanner e.g. Churchill JD - 230 or Snap On XDHM 1415, on the centre bolt of the belt
tensioner idler pulley, to turn the adjuster assembly to the left against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner slowly and remove the spanner.
Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
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Installation
1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolts to 10 - 14 Nm.
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3. Slacken the three screws which secure the water pump pulley.
4. CAUTION:
When releasing the belt tension, never apply any torque in a clockwise direction to the pulley
centre bolt (left hand thread) as it could subsequently loosen.
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Remove the drive belt from the generator and accessory drive.
1. Use a spanner e.g. Churchill JD - 230 or Snap On XDHM 1415, on the centre bolt of the belt
tensioner idler pulley, to turn the adjuster assembly to the left against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner slowly and remove the spanner.
Disconnect the belt from the other pulleys, as necessary, to move it clear of the pump pulley.
Installation
1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolts to 10 - 14 Nm.
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Water Pump
Removal
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the
doors remain open until after the battery has been disconnected.
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7. Remove the two bolts which secure the mounting bracket to the vehicle body.
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9. Disconnect the pipes from the pump and remove the pump.
1. Release and reposition the hose clip along the inlet hose and disconnect the hose.
2. Release and reposition the hose clip along the outlet hose and disconnect the pump from the hose.
3. Fit blanking plugs to the pipes and to the pump.
Remove the pump and mounting bracket assembly from the vehicle.
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Installation
3. Switch on the ignition and allow the pump to operate for one minute to circulate coolant.
Switch off the ignition.
Top up the coolant. If necessary, refer to Operation 26.10.01 (SC) Coolant Refill Procedure.
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Torque Specifications
Component Nm
Fuel injector clamp plate retaining bolts - vehicles with supercharger 4-6
Intake manifold fuel feed pipe to fuel rail bolts 8-12
Harness to camshaft cover nuts 4-5
Fuel pressure regulator / return pipe to fuel rail bolts - vehicles with supercharger 8-12
Fuel injection supply manifold to charge air cooler adaptor bolts - vehicles with 18-24
supercharger
Fuel injection supply manifold retaining bolts - vehicles without supercharger 12
Fuel rail to fuel cross-over pipe bolt - vehicles with supercharger 8-12
Fuel feed pipe to fuel rail bolts - vehicles with supercharger 8-12
Throttle body retaining bolts 18-24
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Vehicles Without Supercharger
Location of fuel charge components - vehicles without supercharger
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Parts List
Item Description
Fuel Distribution
Fuel is supplied to the engine via eight fuel injectors. The injectors are located in fuel injection supply manifold.
Fuel pumped from the tank enters a feed pipe at the rear of bank 2. Fuel flow is along bank 2, across the top front
of the engine (cross-over pipe) and through bank 1, the unused fuel returning to the tank via a pressure regulator.
The fuel injectors are each controlled electrically from the engine control module (ECM).
A test valve is fitted to the fuel injection supply manifold. This valve allows the fuel system to be depressurized
during servicing and troubleshooting.
Fuel Injector
The eight fuel injectors are located in individual apertures in the intake manifold. The fuel rail is separate and
supplies fuel to the top of each injector. Air injection is provided to the base of each injector to further improve fuel
delivery and atomisation. Air is provided by an air gallery which is integral with the intake manifold. The fuel
injectors are electromagnetic solenoid valves controlled by the ECM. The electrical pulse time for the injector
combined with the fuel pressure determines the volume of fuel injected to the manifold.
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The pressure regulator is a diaphragm-operated valve that regulates fuel-rail pressure at 3,0 bar above the intake
manifold pressure. A pipe connects the throttle induction elbow to the pressure regulator to provide the vacuum
control signal. On supercharged engines, the pressure regulator vacuum feed is taken from the top of the
supercharger outlet duct.
The regulator is fitted between the rear end of the fuel injection supply manifold and the fuel return line to the tank.
Throttle Body
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Item Description
1 Throttle Motor
2 Throttle Position (TP) Sensor
3 Coolant Inlet
4 Coolant Outlet
5 Air Assist Control Valve
6 Accelerator pedal position (APP) sensor
Throttle Body
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Fuel Injector
The eight injectors installed in the fuel rails of supercharged engines are of a higher flow rating than those
installed in normally aspirated engines and are secured in position by spring clips. The fuel is supplied to the side
each injector. Seals are installed between the injector mounts of the fuel rails and the related recesses in the
charge air cooler adaptors.
provide the interface between the charge air coolers and the cylinder heads
locate the fuel rails and injectors
For removal and installation refer to section <<303-01>>.
Fuel Rails
The plastic fuel rails locate in the charge air cooler adaptors:
Bank 2 fuel rail has the fuel feed pipe attached at the rear of the engine and the fuel cross-over pipe at
the front
Bank 1 fuel rail connects to the other side of the cross-over pipe at the front of the engine and the fuel
return pipe / pressure regulator at the rear
The fuel cross-over pipe connects the fuel rails together but is not interchangeable between the normally
aspirated engine and the supercharged version.
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2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
6. 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.)
7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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:
If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a
reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A
cycle is an ignition OFF/ON, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of
conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
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8. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Symptom Chart
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Difficult to start cold Rochester valve For rochester valve tests, <<303-14>> For battery information, <<414-01>> Check bulletins for throttle cleaning procedure.
Check fuel pressure, <<310-00>> For ECT sensor circuit tests, <<303-14>> For evaporative emissions tests, <<303-13>>
Battery
Check bulletins and service actions.
Throttle contaminated
Fuel pump
Engine coolant temperature (ECT) sensor
Purge valve
Cylinder compression loss (short-term.
Refer to bulletin; 303-52)
Blocked part-load breather (service action
S474)
Refer to service action S491
Difficult to start hot Rochester valve For Rochester valve test, <<303-14>> Check fuel pressure, <<310-00>> For evaporative emissions tests, <<303-13>>
Check bulletins for throttle cleaning procedure. Check fuel pressure. For ECT sensor tests, <<303-14>> Check bulletins
Purge valve
and service actions.
Throttle contaminated
Fuel pump
Engine coolant temperature (ECT) sensor
Blocked part-load breather (service action
S474)
Injector leak
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Engine hesitates/poor Fuel pump Check fuel pressure, <<310-00>> For EGR information, <<303-08>> For intake system information, <<303-12>> For stop
acceleration lamp switch information, refer to the wiring diagrams. For throttle position sensor and throttle motor relay tests, <<303-14>>
Exhaust gas recirculation (EGR)
For ignition system, <<303-07>> Contact dealer technical support for advice on possible ECM failure.
Air leakage
Stop lamp switch
Throttle sensors
Throttle motor
Spark plugs fouled
Check for water ingress into spark plug
wells (SC only)
Ignition coil failure(s)
HT short to ground (tracking) check
rubber boots for cracks/damage
ECM failure
Engine backfires Fuel pump Check fuel pressure, <<310-00>> For intake system information, <<303-12>> For MAF and HO2 sensor circuit tests,
<<303-14>> For ignition system, <<303-07>>
Air leakage
MAF sensor
HO2 sensors
Spark plugs
Check for water ingress into spark plug
wells (SC only)
HT short to ground (tracking) check
rubber boots for cracks/damage
Ignition coil failure(s)
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Engine surges Air leakage For intake system information, <<303-12>> Check fuel pressure, <<310-00>> For stop lamp switch information, refer to the
wiring diagrams. For MAF sensor, throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system,
Fuel pump
<<303-07>> Contact dealer technical support for advice on possible ECM failure.
Stop lamp switch
MAF sensor
Harness
Throttle sensors
Throttle motor
Spark plugs
Check for water ingress into spark plug
wells (SC only)
HT short to ground (tracking) check
rubber boots for cracks/damage
ECM failure
Engine Fuel pump Check fuel pressure. <<310-00>> For HO2 sensor circuit tests, check for DTC indicating which sensor and follow indicated
detonates/knocks pinpoint test. For intake system information, <<303-12>> Check service action S474. For MAF sensor circuit tests,
HO2 sensors
<<303-14>>
Air leakage
Blocked part-load breather (service action
S474)
Mass air flow (MAF) sensor
No throttle response Throttle sensors For throttle position sensor and throttle motor relay circuit tests, <<303-14>>
Throttle motor
Poor throttle response Throttle sensors For throttle position sensor and throttle motor relay circuit tests, <<303-14>> For intake system, <<303-12>> For MAF
sensor tests, <<303-14>>
Throttle motor
Air leakage
Mass air flow (MAF) sensor
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions.
NOTE:
For definitions of Default Modes, see the foot of this table.
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Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1230
Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1671
Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1112, P1113
Amber Restricted Performance Gearbox default to 4th gear P1601 (SC only)
Amber Restricted Performance Gearbox default to 4th gear P1605 (NA only)
Amber Restricted Performance Gearbox default to 4th gear P0702
Amber Restricted Performance Gearbox default to 4th gear P1795
Amber Restricted Performance Gearbox default to 4th gear P1796
Amber Restricted Performance Gearbox default to 4th gear P1797
Amber Restricted Performance Gearbox default to 4th gear P1605
Amber None Gearbox default to 4th gear P0705 (SC only)
Amber None Gearbox default to 4th gear P0706
Amber None Gearbox default to 4th gear P1720
No electronic throttle operation. (Mechanical operation for last quarter of pedal travel)
Maximum 25° throttle opening, depending on adjustment of throttle mechanical linkage.
Engine speed restricted to 3000 RPM maximum, by fuel cut-off.
High idle speed. (1200 RPM approx.)
Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut)
Cruise Control Inhibited
REVERSE THROTTLE PROGRESSION ENABLED
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P0175 Left-hand cylinders combustion too rich Engine misfire Check for 'engine misfire detected' DTCs. Check the air filter element, <<303-12>>
Check the fuel lines, <<310-01>> Check the fuel injectors, <<Fuel Injector - Vehicles
Blocked air filter
With: Supercharger>> For fuel pressure regulator check,
Fuel system return blockage Goto <<D>>
. Check for DTCs indicating a sensor fault, <<303-14>>
Leaking fuel injector(s)
Fuel pressure regulator failure (high fuel
pressure)
ECM receiving incorrect signal from one or
more of the following sensors - ECT, MAF, IAT,
TP
P0201 Fuel injector circuit malfunction, Cyl 1 Injector disconnected For fuel injector circuit tests,
Goto <<A>>
Injector wiring open or short circuit
.
Injector failure
' ' P0202 Fuel injector circuit malfunction, Cyl 3
' ' P0203 Fuel injector circuit malfunction, Cyl 5
' ' P0204 Fuel injector circuit malfunction, Cyl 7
' ' P0205 Fuel injector circuit malfunction, Cyl 2
' ' P0206 Fuel injector circuit malfunction, Cyl 4
' ' P0207 Fuel injector circuit malfunction, Cyl 6
' ' P0208 Fuel injector circuit malfunction, Cyl 8
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P0300 Random misfire detected ECM to ignition module primary circuit faults For ignition circuit tests, <<303-07>> For engine information, <<303-00>> For fuel
(cylinder misfire detected DTCs also logged) injector circuit tests,
Goto <<A>>
Ignition module to ignition coil primary circuit
. Check fuel pressure, <<310-00>> Check fuel injectors, Check service actions.
fault(s) (cylinder misfire DTC also logged)
Ignition module ground circuit; open circuit,
high resistance
Ignition coil failure(s)
Ignition module failure(s)
Check for water ingress into spark plug wells
(SC only)
HT short to ground (tracking) check rubber
boots for cracks/damage
Spark plug failure/fouled/incorrect gap
Cylinder compression low
Fuel injector circuit fault(s) [injector DTCs also
logged]
Fuel delivery pressure (low/high)
Fuel injectors restricted/leaking
Fuel contamination
PAS pulley bolts loose (see Service Action
S462)
Worn camshaft/broken valve springs
P0301 Misfire detected, Cyl 1 Refer to possible sources for P0300 Refer to actions for P0300
' ' P0302 Misfire detected, Cyl 3
' ' P0303 Misfire detected, Cyl 5
' ' P0304 Misfire detected, Cyl 7
' ' P0305 Misfire detected, Cyl 2
' ' P0306 Misfire detected, Cyl 4
' ' P0307 Misfire detected, Cyl 6
' ' P0308 Misfire detected, Cyl 8
P0460 Fuel level sense signal performance Fuel level sensor to instrument cluster circuits For fuel level sensor circuit tests,
intermittent short or open circuit Goto <<B>>
.
Fuel level sensor failure
Instrument cluster fault (incorrect fuel level
data)
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Concern with throttle motor control circuit Throttle motor disconnected For throttle motor circuit tests, <<303-14>>
P1229
Throttle motor to ECM drive circuits; short
circuit or open circuit
Throttle motor failure
P1224 Concern with throttle control position Throttle adaptations not performed after Carry out throttle adaptation procedure, <<303-14>> ECM adaptation. For TP sensor,
battery disconnect throttle motor, and ECM circuit tests, <<303-14>> For throttle body information,
<<Throttle Body - >>
TP sensor disconnected
TP sensor to ECM sense circuits; open circuit,
high resistance
Throttle motor relay failure
Throttle motor relay to ECM circuit fault
Throttle motor relay power supply open circuit
ECM ground circuit fault (relay coil drive)
Throttle motor to ECM drive circuits; open
circuit, short circuit, high resistance
Throttle motor failure
Throttle body failure
P1250 Engine load malfunction Air intake leak Check air intake for leaks, <<303-12>> Check engine breather system for leaks, check
throttle valve spring. See <<pinpoint test f>>or P0121.
Engine breather leak
TP sensor circuit fault (DTC P0121)
Throttle valve spring failure
P1646 Fuel pump 2 (S/C) relay malfunction. NOTE. Fuel pump 2 relay failure For fuel pump 2 relay circuit tests,
This DTC applies only to the S/C system fuel Goto <<C>>
Fuel pump 2 relay to ECM circuit fault
pump 2 .
Fuel pump 2 relay coil power supply open
circuit
ECM ground circuit fault (relay coil drive)
Pinpoint Tests
A : DTC P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208; FUEL INJECTOR CIRCUIT MALFUNCTION
NOTE:
The DTC set will indicate which cylinder injector or circuit is faulty. Only in the event of multiple cylinder misfires will it be necessary to check more than one injector or circuit, in which case, multiple
DTCs will be set.
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1. Measure the resistance between the injector pin 1 and the injector body.
2. Measure the resistance between the injector pin 2 and the injector body.
Are both resistances greater than 10 Mohms?
-> Yes
Goto <<A3>>
-> No
INSTALL a new injector. <<Fuel Injector - Vehicles With: Supercharger>> CLEAR the DTC. TEST the system for normal operation.
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-> Yes
Goto <<B2>>
-> No
Goto <<B3>>
B2 : CHECK THE FUEL LEVEL SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the instrument cluster electrical connector, FC25.
2. Measure the resistance between FC25, pin 14 (RW) and BT15 (RW).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<B3>>
1. Disconnect the fuel level sensor electrical connectors, BT14 and BT15.
2. Empty the fuel tank.
3. Measure the resistance between the fuel level sensor connections.
Is the resistance 900 ohms?
-> Yes
Goto <<B4>>
-> No
INSTALL a new fuel level sensor. <<310-01>> CLEAR the DTC. TEST the system for normal operation.
B5 : CHECK THE FUEL LEVEL SENSOR SIGNAL WIRE FOR HIGH RESISTANCE
1. Disconnect the instrument cluster electrical connector, FC25.
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2. Measure the resistance between FC25, pin 13 (BW) and BT14 (BW).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
INSTALL a new instrument cluster. <<413-01>> CLEAR the DTC. TEST the system for normal operation.
NOTE:
This DTC applies only to the supercharged system fuel pump 2.
CAUTION:
Do not run the engine for more than 30 seconds with the vacuum hose disconnected.
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Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION.
WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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5. NOTE:
Place an absorbent cloth underneath fuel connection to absorb any spillages.
NOTE:
Cap the fuel line and fuel injection supply manifold to prevent contamination.
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6. NOTE:
Place an absorbent cloth underneath fuel connection to absorb any spillages.
NOTE:
Cap the fuel line and fuel injection supply manifold to prevent contamination.
7. NOTE:
Left-hand shown, right-hand similar.
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8. Detach the right-hand camshaft (CMP) sensor wiring harness from the intake elbow.
9. Detach the left-hand CMP sensor wiring harness from the intake elbow.
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Installation
1. CAUTION:
Make sure the fuel injectors are correctly located in the intake manifold. Failure to follow these
instructions may result in damage to the vehicle.
NOTE:
Install new fuel injector O-ring seals.
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3. Attach the left-hand CMP sensor wiring harness to the intake elbow.
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4. Attach the right-hand CMP sensor wiring harness to the intake elbow.
5. NOTE:
Left-hand shown, right-hand similar.
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6. NOTE:
Uncap the fuel line and fuel injection supply manifold.
NOTE:
Remove and dispose of absorbent cloth whilst complying to local health and safety standards.
7. NOTE:
Uncap the fuel line and fuel injection supply manifold.
NOTE:
Remove and dispose of absorbent cloth whilst complying to local health and safety standards.
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4. Remove seals between fuel rail and charge air cooler adaptor.
1. Discard seals.
2. Clean and inspect mating faces.
Installation
1. Install new seals between fuel rail and charge air cooler adapter ensuring that they are fully seated.
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Installation
1. Install new seals between fuel rail and charge air cooler adapter, ensuring they are fully seated.
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Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION.
WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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3. NOTE:
Left-hand shown, right-hand similar.
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Left-hand fuel injector
4. Detach the left-hand camshaft position (CMP) sensor wiring harness from the intake elbow.
5. Detach the left-hand fuel injectors and fuel supply manifold from the intake manifold.
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6. Detach the right-hand camshaft position (CMP) sensor wiring harness from the intake elbow.
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8. Detach the right-hand fuel injectors and fuel supply manifold from the intake manifold.
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Installation
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2. Tighten to 12 Nm.
3. Tighten to 12 Nm.
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1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
2. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Depressurize fuel system; refer to <<19.50.02>>.
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Installation
4. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
2. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Depressurize fuel system; refer to <<19.50.02>>.
12. Remove bank 1 or 2 charge air cooler as required; refer to <<18.50.18>> and / or <<18.50.19>>.
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14. CAUTION:
Take care to avoid dropping any objects or foreign matter into induction manifold with the fuel
injectors removed.
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Installation
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13. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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2. 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.
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6. Remove the intake tube / air flow meter / air cleaner cover assembly.
1. Remove the intake tube / air flow meter / air cleaner cover assembly.
2. Remove and discard the rubber seal; air intake tube to throttle body.
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11. Detach the right-hand camshaft position (CMP) sensor wiring harness.
12. NOTE:
Cap the coolant hose to minimize coolant loss.
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13. NOTE:
Cap the coolant hose to minimize coolant loss.
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17. Detach the left-hand CMP sensor wiring harness from the throttle body elbow.
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Installation
1. NOTE:
Install a new throttle body gasket.
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3. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
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6. NOTE:
Uncap the coolant hose.
7. NOTE:
Uncap the coolant hose.
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8. Attach the left-hand CMP sensor wiring harness to the throttle body elbow.
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13. Install the intake tube / air flow meter / air cleaner cover assembly.
1. Install a new rubber seal; air intake tube to throttle body.
2. Install the intake tube / air flow meter / air cleaner cover assembly.
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19. Carry out the battery reconnection procedure. For additional information refer to Section <<414-01>>.
20. NOTE:
Make sure all electrical loads are switched OFF.
NOTE:
Make sure the accelerator outer cable is disconnected.
21. Turn the ignition switch to the OFF position for a minimum of 10 seconds.
NOTE:
If the cooling fans are running, wait untill they stop and leave the ignition switch in the OFF position for an
additional 10 seconds.
24. Turn the ignition switch to the OFF position for a minimum of 10 seconds.
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1. CAUTION:
This process assumes the use of the original throttle cable. The cable setting procedure in this
instance is NOT appropriate for a new cable; see <<19.20.06>>.
Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
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5. NOTE:
Do not disturb adjusting nut
Release throttle cable locking nut and displace outer cable from the abutment bracket.
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Installation
2. Install throttle.
Install new gasket.
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3. Install connector.
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6. CAUTION:
Under no circumstances should quadrant be held clear of throttle stop by cable tension.
NOTE:
Make sure there is neither tension nor slack in the cable.
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8. Where appropriate check kickdown setting is within specification and reset if required as detailed from
step 6 (Installation).
PDU users see <<44.15.38>>
9. Connect scantool.
Read 'Current Powertrain Data'.
Display PID 120F (pedal demand).
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10. NOTE:
Ensure that contact with switch does not result in switch movement.
Push throttle pedal until light contact is made with kickdown switch.
13. Disconnect kickdown switch flying lead connector (to avoid cable twist as the switch is rotated).
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18. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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Accessory Drive
Item Description
1 Coolant Pump Drive
2 Air-Conditioning Compressor Drive
3 Power Steering Pump Drive
4 Automatic Belt Tensioner
5 Crankshaft Pulley
6 Idler Pulley
7 Generator Drive
Crankshaft Pulley
The combined crankshaft pulley and torsional vibration damper drives a single 7-ribbed vee belt. The belt drives
all of the engine-mounted accessories; the generator, the power assisted steering pump, the air-conditioning
compressor and the coolant water pump.
Idler Pulley
An idler pulley on the right-hand accessory mounting increases the wrap-angle around the generator pulley.
The coolant pump pulley is the uppermost of the accessory drive pulleys. The coolant pump is installed between
the two cylinder banks on the front face of the engine.
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The power assisted steering pump pulley is located on the left side of the group of drives for the engine
accessories above the air-conditioning compressor.
This is positioned at the lowest point of the front-end accessory-d rive on the left hand side.
Generator Drive
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Drive Belt
Item Description
1 Acceptable Drive Belt Cracking
2 Unacceptable Drive Belt Damage
The drive 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.
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Item Description
1 Belt Wear Indicator
2 Renew Belt Indicator
3 New Belt Maximum Length
4 New Belt Minimum Length
The automatic belt tensioner consists of an idler pulley which is free to rotate on a bearing, located at the end of a
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The pivot arm can be turned counter-clockwise (viewed from the front of the engine) for belt removal and
installation.
A belt-wear indicator is incorporated on the rear horizontal face of the pivot arm.
Parts List
Item Description
1 Right Hand Mounting Bracket
2 Left Hand Mounting Bracket
All engine accessories are rigidly-mounted onto the cylinder block by means of accessory mounting brackets on
the left and right-hand sides of the engine.
The left-hand bracket supports the air-conditioning compressor and steering pump.
Dowels between the accessory mounting brackets and the engine ensure that the accessory pulleys are
accurately aligned with the accessory drive belt.
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2. Check the belt wear indicator marks to confirm that the drive belt is within limits.
3. CAUTION:
When releasing the belt tension, never apply any torque in a clockwise direction to the pulley
centre bolt (left hand thread) as it could subsequently loosen.
Installation
1. Installation is the reverse of the removal procedure. Ensure that the belt is correctly and squarely located
on each pulley.
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Installation
1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolt to 53 -69 Nm. Ensure
that the belt is correctly and squarely located on each pulley.
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Installation
1. Installation is the reverse of the removal procedure. Tighten the tensioner assembly securing bolt to 38
-48 Nm. Ensure that the belt is correctly and squarely located on each pulley.
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Installation
1. Installation is the reverse of the removal procedure. Tighten the pulley securing bolt, left hand thread, to
the correct torque figure. Ensure that the belt is correctly and squarely located on each pulley.
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2. Check supercharger drive belt length by observing belt wear indicator marks on side of tensioner.
1. Pointer at this mark, indicates minimum new belt length.
2. Pointer at this mark, indicates maximum new belt length.
3. Pointer at this mark, indicates belt must be renewed.
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Installation
1. NOTE:
Ensure that belt is correctly and squarely located on each pulley. Check belt wear indicator marks to
confirm that drive belt is within limits.
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Installation
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Installation
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Starting System
Manufacturer - NipponDenso.
Type - RA1.4.
Output - 1.4 kW
The starter is of the pre-engaged type; located at the rear left-side of the engine.
When the starter is operated from the key-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.
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Starter Relay
The starter motor control relay is the front one of the three, located on the right hand inner wing panel, beneath
the bulkhead compartment right hand cover.
The starter drive plate is attached to the rear of the crankshaft by eight bolts.
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Timing Disc
A timing disc, for the engine speed sensor, is spot-welded to the front face of the starter drive plate.
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Item Description
1 Battery
2 To Rear Fusebox
3 High Power Protection Module
4 To Front Fuseboxes
5 Starter Relay
6 Body Processor Module (BPM)
7 Engine Control Module (ECM)
8 Ignition Switch
9 CRANK Signal
10 Ignition ON Signal
11 Inertia Switch
12 Starter Motor and Solenoid
The illustration above is a simplified explanation of how the starting system operates in conjunction with the Body
Processor Module (BPM) and the Engine Control Module (ECM).
When the ignition key is set to the normal run position, the following sequence occurs:
The isolation relay in each fusebox is energised to supply battery power to the fuses and associated
circuits.
The BPM 'IGN ON' terminal is taken to 0V by the ignition switch.
The BPM checks that various parameters are correct e.g. - inertia switch is in the active condition -
transmission is in PARK - security system has been correctly disabled.
When the ignition key is set to the crank position, the following sequence occurs:
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Item Description
1 Battery
2 Ignition Switch
3 Solenoid Contacts
4 Solenoid Pull-In Winding
5 Solenoid Hold-In Winding
6 Solenoid
7 Starter Motor Main Body
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Refer to the Starting Circuit Diagram in the Electrical Guide for the actual layout and connection details.
The starter motor and solenoid in the previous figure are shown diagramatically to indicate simply, the electrical
circuit and various connections.
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WARNING:
MAKE SURE THE VEHICLE IS IN NEUTRALOR PARK FOR VEHICLES WITH AUTOMATIC
TRANSMISSION, NEUTRAL FOR VEHICLES WITH MANUAL TRANSMISSION, AND APPLY THE
PARKING BRAKE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. If the concern is not visually evident, refer to the 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. Failure to follow this instruction may result in damage to the vehicle.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
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Symptom Chart
Pinpoint Tests
A : CHECK THE POWER SUPPLY, GROUND AND TRIGGER TO THE STARTER CIRCUIT
NOTE:
During cranking with the engine disabled, observe the engine cranking speed. A cranking speed as low as 90
RPM is acceptable, but will be difficult to measure. A degree of discretion must be used as to when an engine
is cranking too slowly.
1. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal,
ST10.
Is the volt drop greater than 1 volt?
-> Yes
CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor.
Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a
new battery lead. <<414-01>> TEST the system for normal operation.
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-> No
Goto <<A2>>
1. Measure the resistance between the engine GROUND lead and the starter motor body.
Is the resistance greater than 5 ohms?
-> Yes
Clean the connection between the starter motor body and it's fittings, recheck the resistance. TEST the
system for normal operation.
-> No
Goto <<A4>>
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REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<B1>>
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B6 : CHECK THE IGNITION SWITCHED GROUND CIRCUIT TO THE BPM FOR HIGH RESISTANCE
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WARNING:
MAKE SURE THE VEHICLE IS IN NEUTRALOR PARK AND APPLY THE PARKING BRAKE. FAILURE TO
FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
1. Verify the customer concern.
3. If an obvious cause for an observed or reported concern is found, correct the cause, (if possible) before
proceeding to the next step.
4. 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.)
5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan
tool to retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart, or the
Symptom Chart if no DTCs are set.
6. 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.
Symptom Chart
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00.
NOTE:
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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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Pinpoint Tests
C : CHECK THE POWER SUPPLY, GROUND AND TRIGGER TO THE STARTER CIRCUIT
NOTE:
Do not begin this test without a fully charged and sound battery.
NOTE:
During cranking with the engine disabled, observe the engine cranking speed. A cranking speed as low as 90
RPM is acceptable, but will be difficult to measure. A degree of discretion must be used as to when an engine
is cranking too slowly.
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1. Measure the volt drop across the circuit between the battery positive terminal and the starter motor terminal,
ST10.
Is the volt drop greater than 1 volt?
-> Yes
CHECK the battery connections, cable connections at false bulkhead stud connector, and starter motor.
Make sure all connections are in good condition and secure. If all connections are sound, INSTALL a
new battery lead. <<414-01>>TEST the system for normal operation.
-> No
Goto <<C2>>
1. Measure the resistance between the engine GROUND lead and the starter motor body.
Is the resistance greater than 5 ohms?
-> Yes
Clean the connection between the starter motor body and it's fittings, recheck the resistance. TEST the
system for normal operation.
-> No
Goto <<C4>>
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-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<D4>>
D6 : CHECK THE IGNITION SWITCHED GROUND CIRCUIT TO THE BPM FOR HIGH RESISTANCE
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the
doors remain open until after the battery has been disconnected.
5. Working from below the vehicle, remove the power steering rack for access. Refer to Section
<<211-02>>.
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9. The upper bolt may be removed (after loosening) using a 3/8' square drive 13 mm socket, extensions and
U.J as shown.
Installation
1. Installation is the reverse of the removal procedure. Tighten the starter motor securing bolts to 38 -48 Nm.
2. Refit the steering rack as detailed in Section <<211-02>>. Refill the reservoir with the recommended fluid
and bleed the steering system.
3. Lower the ramp. Remove the protection sheets and close the engine compartment cover.
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General Specifications
Torque Specifications
Component Nm
Spark Plugs 25 - 29
Coil on Plug Bolts 4-6
Coil Cover Bolts 4-6
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Engine Ignition
Ignition System
The ignition system provides timing control in accordance with the engine management strategy and powertrain
sensor inputs; the system consists of:
provides triggering for the ignition coil-on-plug to control individual firing of the spark plugs
Ignition Coils
Ignition Coil-on-plug
Four separate ignition coil-on-plugs are mounted to each camshaft cover, directly above the spark plugs
and are controlled by the ECM.
Each ignition coil-on-plug comprises an encapsulated ignition control module and a direct push on
connection to the spark plug.
Spark Plug
The spark plug changes the high voltage pulse into a spark which ignites the fuel and air mixture. Refer to
specification in this section for spark plug details covering different markets and models.
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2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
6. 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.)
7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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:
If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a
reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A
cycle is an ignition OFF/ON, which will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of
conditions needed to make the on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
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8. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Symptom Chart
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Difficult to start hot Rochester valve (Mexico only) For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel
pressure. For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>>
Injector leak
Purge valve
Fuel pump
Engine coolant temperature
(ECT) sensor
Difficult to start after hot soak (vehicle Rochester valve (Mexico only) For Rochester valve test, <<303-14>> For injector leak test, REFER to technical service bulletin; 303-39. Check fuel
standing after engine has reached operating pressure, <<310-00>> For evaporative emissions components, <<303-13>> For ECT sensor tests, <<303-14>>
Injector leak
temperature)
Purge valve
Fuel pump
Engine coolant temperature
(ECT) sensor
Engine stalls soon after start Fuel pump relay Check for DTCS. For fuel pump and ECM relay tests, <<303-14>> Check fuel pressure. <<310-00>> For ECT sensor
tests, <<303-14>> For fuel line information, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system
ECM relay
information, <<303-12>>
Harness damage
Fuel pump
Engine coolant temperature
(ECT) sensor
Fuel lines
Fuel pressure regulator
Air leakage
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Engine hesitates/poor acceleration Fuel pump Check fuel pressure, <<310-00>> For intake system information, <<303-12>> For fuel pressure regulator,
<<303-04>> For fuel lines information, <<310-01>> For throttle position sensor and throttle motor relay tests,
Air leakage
<<303-14>> For ignition system tests, REFER to pinpoint tests in this section. For EGR information, <<303-08>>
Fuel pressure regulator
Fuel lines
Harness damage
Throttle sensors
Throttle motor
Spark plugs fouled
Ignition coil failure(s)
Check for water ingress into
spark plug wells (SC only)
HT short to ground (tracking)
check rubber boots for
cracks/damage
Exhaust gas recirculation
(EGR) (SC only)
Engine backfires Fuel pump Check fuel pressure, <<310-00>> For fuel pump and lines, <<310-01>> For intake system, <<303-12>> For MAF
sensor tests, <<303-14>> For ignition system tests, REFER to pinpoint tests in this section.
Fuel lines
Air leakage
Mass air flow (MAF) sensor
Spark plugs
Check for water ingress into
spark plug wells (SC only)
HT short to ground (tracking)
check rubber boots for
cracks/damage
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Engine surges Air leakage For intake system, <<303-12>> Check fuel pressure, <<310-00>> For fuel pump and lines, <<310-01>> For MAF
sensor, throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, REFER to pinpoint
Fuel pump
tests in this section.
Fuel lines
Mass air flow (MAF) sensor
Harness damage
Throttle sensors
Throttle motor
Spark plugs
Check for water ingress into
spark plug wells (SConly)
HT short to ground (tracking)
check rubber boots for
cracks/damage
Engine detonates/knocks Fuel lines For fuel lines, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system, <<303-12>> For MAF sensor
and oxygen sensor tests, <<303-14>> Check fuel pressure, <<310-00>>
Fuel pressure regulator
Air leakage
Mass air flow (MAF) sensor
Oxygen sensors
Fuel pump
No throttle response Throttle sensors For throttle position sensor tests, throttle motor relay tests, <<303-14>>
Throttle motor
Poor throttle response Throttle sensors For throttle position sensor and throttle motor relay tests, <<303-14>> For intake system, <<303-12>> For MAF
sensor tests, <<303-14>>
Throttle motor
Air leakage
Mass air flow (MAF) sensor
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions.
NOTE:
For definitions of Default Modes, see the foot of this table.
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Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1230
Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1671
Amber Restricted Performance Engine Speed Limit (runs normally, limited to 3000 RPM) P1112, P1113
Amber Restricted Performance Gearbox default to 4th gear P1601 (SC only)
Amber Restricted Performance Gearbox default to 4th gear P1605 (NA only)
Amber Restricted Performance Gearbox default to 4th gear P0702
Amber Restricted Performance Gearbox default to 4th gear P1795
Amber Restricted Performance Gearbox default to 4th gear P1796
Amber Restricted Performance Gearbox default to 4th gear P1797
Amber Restricted Performance Gearbox default to 4th gear P1605
Amber None Gearbox default to 4th gear P0705 (SC only)
Amber None Gearbox default to 4th gear P0706
Amber None Gearbox default to 4th gear P1720
No electronic throttle operation. (Mechanical operation for last quarter of pedal travel)
Maximum 25° throttle opening, depending on adjustment of throttle mechanical linkage.
Engine speed restricted to 3000 RPM maximum, by fuel cut-off.
High idle speed. (1200 RPM approx.)
Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut)
Cruise Control Inhibited
REVERSE THROTTLE PROGRESSION ENABLED
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1999 XK RANGE - Engine Ignition - 303-07
8 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
P0351 Ignition coil primary/secondary circuit malfunction, cyl 1 ECM to ignition module primary circuit For ignition circuit tests,
open circuit, short circuit to ground, high Goto <<A>>
resistance .
Ignition module to ignition coil primary
circuit open circuit, short circuit to
ground, high resistance
Ignition module ground circuit open
circuit, high resistance
Ignition coil failure
Ignition module failure
' ' P0352 Ignition coil primary/secondary circuit malfunction, cyl 3
' ' P0353 Ignition coil primary/secondary circuit malfunction, cyl 5
' ' P0354 Ignition coil primary/secondary circuit malfunction, cyl 7
' ' P0355 Ignition coil primary/secondary circuit malfunction, cyl 2
' ' P0356 Ignition coil primary/secondary circuit malfunction, cyl 4
' ' P0357 Ignition coil primary/secondary circuit malfunction, cyl 6
' ' P0358 Ignition coil primary/secondary circuit malfunction, cyl 8
P0603 ECM data corrupted ECM Contact dealer technical support for advice on possible ECM failure
P1000 System checks not complete since last memory clear OBD diagnostic monitors have not Carry out comprehensive component monitor drive cycle. Refer to the DTC section
completed of JTIS, accessed by the icon on the opening page.
P1111 System checks complete since last memory clear OBD diagnostic monitors have No action necessary
completed
P1313 Misfire rate catalyst damage, Right-hand cylinders. NOTE. Refer to possible causes for Refer to actions for P0300-P0308
This DTC will flag only when accompanied by a random or P0300-P0308
individual cylinder misfire DTC; P0300, P0301 to P0304
' ' P1314 Misfire rate catalyst damage, Left-hand cylinders. NOTE. This DTC will flag only
when accompanied by a random or individual cylinder misfire DTC; P0300 to
P0308
' ' P1316 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an
individual cylinder misfire DTC; P0300 to P0308
P1367 Ignition monitor (ignition module 1) Ignition module 1 disconnected For ignition circuit tests,
Goto <<A>>
Ignition module 1 to ECM circuits open
.
circuit, short circuit to ground or short
circuit to B+ voltage
Ignition module 1 ground circuit fault
Ignition coil relay failure
Ignition coil open/short circuit
Ignition module 1 failure
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1999 XK RANGE - Engine Ignition - 303-07
P1368 Ignition monitor (ignition module 2) Ignition module 2 disconnected For ignition circuit tests,
Goto <<A>>
Ignition module 2 to ECM circuits open
.
circuit, short circuit to ground or short
circuit to B+ voltage
Ignition module 2 ground circuit fault
Ignition coil relay failure
Ignition coil open/short circuit
Ignition module 2 failure
Pinpoint Tests
A : DTC P0300, P0351, P0352, P0353, P0354, P0355, P0356, P0357, P0358; RANDOM MISFIRE DETECTED, COIL PRIMARY/SECONDARY CIRCUIT MALFUNCTION
NOTE:
Unless multiple cylinder misfires are apparent, only one circuit will normally need to be tested. The DTC set will indicate which cylinder is misfiring.
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1999 XK RANGE - Engine Ignition - 303-07
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1999 XK RANGE - Engine Ignition - 303-07
A6 : CHECK THE CIRCUIT BETWEEN THE IGNITION MODULES AND THE ECM FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Disconnect the ECM electrical connector, EM13.
3. Measure the resistance between the following -
Cyl 1 EM27, pin 02 (LGU) and EM13, pin 26 (LGU).
Cyl 2 EM29, pin 02 (LGP) and EM13, pin 34 (LGP).
Cyl 3 EM29, pin 05 (LGW) and EM13, pin 25 (LGW).
Cyl 4 EM27, pin 03 (LGS) and EM13, pin 33 (LGS).
Cyl 5 EM29, pin 03 (LGO) and EM13, pin 24 (LGO).
Cyl 6 EM27, pin 06 (LGR) and EM13, pin 32 (LGR).
Cyl 7 EM27, pin 05 (LGK) and EM13, pin 23 (LGK).
Cyl 8 EM29, pin 06 (LGY) and EM13, pin 31 (LGY).
Is the resistance greater than 5 Ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for normal operation.
-> No
INSTALL a new ignition module for the affected cylinder(s). CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, contact dealer technical support for advice on
possible ECM failure.
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1999 XK RANGE - Engine Ignition - 303-07
2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
6. 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.)
7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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:
If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no fault was present. This could result in a reported warning light/message
with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which will occur during the owner's
normal use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run, and may need a specific action on the
part of the technician. See the DTC summaries for drive cycle routines)
8. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
NOTE:
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1999 XK RANGE - Engine Ignition - 303-07
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Symptom Chart
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1999 XK RANGE - Engine Ignition - 303-07
Engine stalls soon after start Fuel pump relay Check for DTCS. For fuel pump and ECM relay tests, <<303-14>> Check fuel pressure. For ECT sensor tests, <<303-14>> For fuel
line information, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system information, <<303-12>>
ECM relay
Harness damage
Fuel pump
Engine coolant temperature (ECT)
sensor
Fuel lines
Fuel pressure regulator
Air leakage
Engine hesitates/poor acceleration Fuel pump Check fuel pressure. For intake system information, <<303-12>> For fuel pressure regulator, For fuel lines information, <<310-01>>
For throttle position sensor and throttle motor relay tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section. For
Air leakage
EGR information, <<303-08>>
Fuel pressure regulator
Fuel lines
Harness damage
Throttle sensors
Throttle motor
Spark plugs fouled
Ignition coil failure(s)
Check for water ingress into spark
plug wells (SC only)
HT short to ground (tracking) check
rubber boots for cracks/damage
Exhaust gas recirculation (EGR)
(SC only)
Engine backfires Fuel pump Check fuel pressure. For fuel pump and lines, <<310-01>> For intake system, <<303-12>> For MAF sensor tests, <<303-14>> For
ignition system tests, refer to pinpoint tests in this section.
Fuel lines
Air leakage
Mass air flow (MAF) sensor
Spark plugs
Check for water ingress into spark
plug wells (SC only)
HT short to ground (tracking) check
rubber boots for cracks/damage
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1999 XK RANGE - Engine Ignition - 303-07
Engine surges Air leakage For intake system, <<303-12>> Check fuel pressure. For fuel pump and lines, <<310-01>> For MAF sensor, throttle position sensor
and throttle motor relay tests, <<303-14>> For ignition system tests, refer to pinpoint tests in this section.
Fuel pump
Fuel lines
Mass air flow (MAF) sensor
Harness damage
Throttle sensors
Throttle motor
Spark plugs
Check for water ingress into spark
plug wells (SConly)
HT short to ground (tracking) check
rubber boots for cracks/damage
Engine detonates/knocks Fuel lines For fuel lines, <<310-01>> For fuel pressure regulator, <<303-04>> For intake system, <<303-12>> For MAF sensor and oxygen
sensor tests, <<303-14>> Check fuel pressure.
Fuel pressure regulator
Air leakage
Mass air flow (MAF) sensor
Oxygen sensors
Fuel pump
No throttle response Throttle sensors For throttle position sensor tests, throttle motor relay tests, <<303-14>>
Throttle motor
Poor throttle response Throttle sensors For throttle position sensor and throttle motor relay tests, <<303-14>> For intake system, <<303-12>> For MAF sensor tests,
<<303-14>>
Throttle motor
Air leakage
Mass air flow (MAF) sensor
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions.
NOTE:
For definitions of Default Modes, see the foot of this table.
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1999 XK RANGE - Engine Ignition - 303-07
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1999 XK RANGE - Engine Ignition - 303-07
No electronic throttle operation. (Mechanical operation for last quarter of pedal travel)
Maximum 25° throttle opening, depending on adjustment of throttle mechanical linkage.
Engine speed restricted to 3000 RPM maximum, by fuel cut-off.
High idle speed. (1200 RPM approx.)
Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut)
Cruise Control Inhibited
REVERSE THROTTLE PROGRESSION ENABLED
6 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
7 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
P0351 Ignition coil primary/secondary circuit malfunction, cyl 1 ECM to ignition coil primary circuit open circuit, For ignition coil circuit tests,
short circuit to ground, high resistance Goto <<B>>
Ignition coil ground circuit open circuit, high
resistance
Ignition coil failure
' ' P0352 Ignition coil primary/secondary circuit malfunction, cyl 3
' ' P0353 Ignition coil primary/secondary circuit malfunction, cyl 5
' ' P0354 Ignition coil primary/secondary circuit malfunction, cyl 7
' ' P0355 Ignition coil primary/secondary circuit malfunction, cyl 2
' ' P0356 Ignition coil primary/secondary circuit malfunction, cyl 4
' ' P0357 Ignition coil primary/secondary circuit malfunction, cyl 6
' ' P0358 Ignition coil primary/secondary circuit malfunction, cyl 8
P0603 ECM data corrupted ECM Contact Dealer technical support for advice on possible ECM failure
P1000 System checks not complete since last memory clear OBD diagnostic monitors have not completed Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed
by the icon on the opening page.
P1111 System checks complete since last memory clear OBD diagnostic monitors have completed No action necessary
P1313 Misfire rate catalyst damage, Right-Hand bank. NOTE. This Refer to possible causes for P0300-P0308 Refer to actions for P0300-P0308
DTC will flag only when accompanied by a random or
individual cylinder misfire DTC; P0300, P0301 to P0304
' ' P1314 Misfire rate catalyst damage, Left-Hand bank. NOTE. This DTC will flag only when accompanied by a
random or individual cylinder misfire DTC; P0300 to P0308
' ' P1316 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder
misfire DTC; P0300 to P0308
P1367 Ignition monitor (Right-Hand bank) Ignition monitoring circuit between splice and For ignition coil circuit tests,
ECM open circuit, short circuit to ground, or Goto <<B>>
short circuit to B+ voltage
Ignition coil group ground circuit fault
Ignition coil relay failure
P1368 Ignition monitor (Left-Hand bank) Ignition monitoring circuit between splice and For ignition coil circuit tests,
ECM open circuit, short circuit to ground, or Goto <<B>>
short circuit to B+ voltage
Ignition coil group ground circuit fault
Ignition coil relay failure
Pinpoint Tests
B : DTC P0300, P0351, P0352, P0353, P0354, P0355, P0356, P0357, P0358, P1367, P1368; RANDOM MISFIRE DETECTED, COIL PRIMARY/SECONDARY CIRCUIT MALFUNCTION, IGNITION MONITOR
MALFUNCTION
NOTE:
Unless multiple cylinder misfires are apparent, only one circuit will normally need to be tested. The DTC set will indicate which cylinder is misfiring.
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1999 XK RANGE - Engine Ignition - 303-07
-> Yes
INSTALL a new coil. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<B2>>
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1999 XK RANGE - Engine Ignition - 303-07
B5 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR HIGH RESISTANCE
B6 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR SHORT TO B+ VOLTAGE
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1999 XK RANGE - Engine Ignition - 303-07
B7 : CHECK THE IGNITION COIL (CYLS 1, 4, 6, AND 7) MONITOR CIRCUITS FOR SHORT TO GROUND
B8 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR HIGH RESISTANCE
B9 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR SHORT TO B+ VOLTAGE
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1999 XK RANGE - Engine Ignition - 303-07
B10 : CHECK THE IGNITION COIL (CYLS 2, 3, 5, AND 8) MONITOR CIRCUITS FOR SHORT TO GROUND
12 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
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1999 XK RANGE - Engine Ignition - 303-07
4. Detach harness from retaining clips as necessary and disconnect relevant coil connector.
2 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
Installation
2.
3 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
2. Remove the air intake tube / meter / air cleaner cover for access; refer to 19.10.30.
4. Detach harness from retaining clips as necessary and disconnect relevant coil connector.
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1999 XK RANGE - Engine Ignition - 303-07
Installation
2 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
2.
3 2012-07-19
1999 XK RANGE - Engine Ignition - 303-07
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
2. Remove air intake tube / meter / air cleaner cover for access; refer to 19.10.30.
3. Remove ignition coils; refer to 18.20.41 (bank 1) and 18.20.42 (bank 2).
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1999 XK RANGE - Engine Ignition - 303-07
Installation
2.
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1999 XK RANGE - Engine Emission Control - 303-08
2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc.
5. 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.)
6. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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.
7. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00.
NOTE:
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3
1 2012-07-19
1999 XK RANGE - Engine Emission Control - 303-08
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.
Symptom Chart
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1999 XK RANGE - Engine Emission Control - 303-08
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
A : DTC P0400, P0405; EGR VALVE FLOW MALFUNCTION/DRIVE CIRCUITS OPEN CIRCUIT
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1999 XK RANGE - Engine Emission Control - 303-08
Goto <<A3>>
-> No
INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
A3 : CHECK THE EGR VALVE COIL WINDINGS TO POWER SUPPLY CIRCUIT FOR CONTINUITY
A5 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO HIGH VOLTAGE
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1999 XK RANGE - Engine Emission Control - 303-08
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1999 XK RANGE - Engine Emission Control - 303-08
2. Visually inspect for obvious signs of mechanical or electrical damage, correct fitment, etc.
5. 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.)
6. If the cause is not visually evident and the Jaguar Approved Diagnostic System is not available, use 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.
7. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00.
NOTE:
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3
1 2012-07-19
1999 XK RANGE - Engine Emission Control - 303-08
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.
Symptom Chart
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1999 XK RANGE - Engine Emission Control - 303-08
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
B : DTC P0400, P0405; EGR VALVE FLOW MALFUNCTION/DRIVE CIRCUITS OPEN CIRCUIT
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1999 XK RANGE - Engine Emission Control - 303-08
Goto <<B3>>
-> No
INSTALL a new EGR valve. CLEAR the DTC. TEST the system for normal operation.
B3 : CHECK THE EGR VALVE COIL WINDINGS TO POWER SUPPLY CIRCUIT FOR CONTINUITY
B5 : CHECK THE EGR VALVE TO ECM CIRCUITS FOR SHORT TO HIGH VOLTAGE
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1999 XK RANGE - Engine Emission Control - 303-08
5 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
11. Detach engine harness retaining clip from rear of charge air cooler.
1 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
13. CAUTION:
Take care to avoid dropping any objects or foreign matter into engine inlet duct with charge air
cooler removed.
Installation
2 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
12. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
3 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
11. Remove intake air temperature sensor 2 from charge air cooler; refer to <<18.30.52>>.
12. Detach engine harness retaining clip from rear of charge air cooler.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
14. CAUTION:
Take care to avoid dropping any objects or foreign matter into engine inlet duct with charge air
cooler removed.
Installation
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
3. Install intake air temperature sensor 2 to charge air cooler; refer to <<18.30.52>>.
13. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Supercharger 18.50.15
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
1 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
1. Install supercharger.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
3. Disconnect coolant hoses and vacuum pipe from supercharger outlet duct.
Place absorbent rags under the two coolant hoses which are connected to the outlet duct.
1. Remove vacuum pipe.
2. Disconnect hoses.
Plug hoses and outlet duct stub pipes to prevent spillage.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
4. CAUTION:
Take care to avoid any coolant from dripping into supercharger.
5. Blank supercharger outlet with body tape, or similar, to prevent ingress of foreign matter.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
3 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
3. CAUTION:
Take care to avoid ingress of dirt or foreign matter into the supercharger.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
7. Install intake tube / air flow meter / air cleaner cover assembly; refer to 19.10.30.
5 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
1 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
4. Remove exhaust gas recirculation (EGR) valve where installed; refer 17.45.01.
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1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
2 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
3 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
4 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
9. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
5 2012-07-19
1999 XK RANGE - Intake Air Distribution and Filtering - 303-12
Installation
1 2012-07-19
1999 XK RANGE - Evaporative Emissions - 303-13
Evaporative Emissions
To reduce the emission of fuel vapor, the fuel tank is vented to atmosphere through activated evaporative
emission canisters which collect the fuel vapor. The evaporative emission canister is periodically purged of fuel
vapor when the evaporative emission canister purge valve opens the vapor line between the evaporative emission
canister and the air intake induction elbow. This action allows manifold depression to draw air through the
evaporative emission canister atmospheric vent, taking up the deposited fuel vapor from the charcoal adsorber
inside the evaporative emission canister and burning the resulting fuel vapor in the engine.
There are two variants of the evaporative emissions system. All systems use the charcoal adsorber storage
evaporative emission canisters and purge valve and operate as described above. The specific features of each
system are described below. The evaporative systems are designated as :
The evaporative emission canister purge valve controls the flow rate of fuel vapor drawn into the engine during the
canister purge operation. The valve is opened by a vacuum feed from the induction elbow : the vacuum feed is
controlled by the integral valve solenoid and is applied when the solenoid is energized. The solenoid is pulsed on
(energized) and off by a fixed frequency (100Hz) variable pulse width control signal (pulse width modulation). By
varying the pulse on to off time, the ECM controls the duty cycle of the valve (time that the valve is open to time
closed) and thus the vapor flow rate to the engine.
With no ECM signal applied to the valve solenoid, the valve remains closed.
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1999 XK RANGE - Evaporative Emissions - 303-13
engine not running in the fuel cut off condition (eg overrun).
the adaptive fuel correction function has not registered a rich or lean failure
the evaporative emission leak test has not failed
no faults have been diagnosed in the relevant sensor and valve circuits - air flow meter (AFM), engine
coolant temperature sensor, evaporative canister purge valve and evaporative emission canister vent
solenoid.
If these conditions have been satisfied, purging is started. If any failures are registered, purging is inhibited.
The canister(s) is purged during each drive cycle at various rates in accordance with the prevailing engine
conditions. The engine management software stores a map of engine speed (RPM) against engine load (grams of
air inducted / rev). For any given engine speed and load, a vapor purge rate is assigned (purge rate increases with
engine speed and load).
The preset purge rates are based on the assumption of a vapor concentration of 100%. The actual amount of
vapor is measured by the closed loop fueling system : the input of evaporative fuel into the engine causes the
outputs from the upstream oxygen sensors to change, the amount of change providing a measure of the vapor
concentration. This feedback causes the original purge rate to be adjusted and also reduces the amount of fuel
input via the injectors to maintain the correct air to fuel ratio.
Engine speed/load mapping and the corresponding purge rates are different for vehicles fitted on-board refueling
vapor recovery and vehicles without on-board refueling vapor recovery.
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1999 XK RANGE - Evaporative Emissions - 303-13
Vehicles With On-board Refueling Vapor Recovery.
Item Description
1 Evaporative emission canister purge valve
2 Evaporative emission canister
3 Fuel vapor vent valve housing
4 Evaporative emission canister vent solenoid
5 Evaporative emission canister
on-board refueling vapor recovery to reduce the fuel vapor vented directly to atmosphere from the filler
nozzle when refueling .
a fuel tank pressure sensor and an evaporative emission canister vent solenoid are fitted to allow the
on-board diagnostic facility to test for leaks in the fuel and evaporative system.
The evaporative emission canister vent solenoid is a solenoid operated device controlled by the ECM. The valve is
normally open and is closed only during the leak test sequence.
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The fuel tank pressure sensor is fitted to the fuel vapor vent valve housing and provides a voltage to the ECM
which is proportional to tank vapor pressure.
The on-board refueling vapor recovery system enables fuel vapor generated during refueling to be collected by
the charcoal canisters. During normal running of the vehicle, the vapor is collected and purged in the same way
as for vehicles without on-board refueling vapor recovery.
During refueling, the tank is vented via the fuel level vent valve, large bore vapor pipes and the charcoal canisters.
The fuel level vent valve incorporates a float valve which is closed by the rising fuel level, creating a back pressure
and causing the fuel delivery to stop. In the closed position, the fuel level vent valve also sets the fuel level.
With the fuel level vent valve closed (tank full), any increase in pressure or overfilling is relieved by a separate
rollover protected grade vent valve. The outlet from this valve feeds into the main fuel level vent valve vapor outlet
pipe, bypassing the closed fuel level vent valve.
When the fuel level is below full, the fuel level vent valve opens to allow unrestricted venting via the canisters.
A pressure relief valve is incorporated into the fuel level vent valve assembly and has an outlet pipe to the filler
nozzle,. If a blockage or other restriction (eg, evaporative emission canister vent solenoid in the closed position)
occurs in the vapor vent system, the pressure relief valve opens to allow venting to atmosphere via the filler nozzle
guide and fuel filler cap.
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Fuel Vapor Vent Valve Housing - Vehicles With On-Board Refueling Vapor Recovery
Item Description
1 Grade vent valve
2 Fuel pump module electrical connector
3 Fuel tank pressure sensor
4 Fuel level vent valve
5 Fuel vapor vent valve housing locking ring
The fuel vapor vent valve housing is fitted to the top of the tank via a seal and locking ring arrangement identical to
that used for vehicles without on-board refueling vapor recovery. The fuel vapor vent valve housing is removable
complete with the fitted components.
The fuel level vent valve is mounted in the fuel vapor vent valve housing via a bayonet fitting : it is turned
approximately 90 ° clockwise to release. The grade vent valve and pressure sensor are push in fits via sealing
grommets : note that, due to the tight fit, removal of these components may require cutting the grommets. The
fuel pump connector is push fitted and crimped into a location tube on the underside of the flange.
Evaporative Emission Canister, Evaporative Emission Canister Vent Solenoid and Fittings
The evaporative emission canisters are fixed to the underside of the vehicle either via semi-enclosed mounting
brackets. Two fixing bolts are used at the front of the bracket and a single rear bolt supports the evaporative
emission canister and the evaporative emission canister vent solenoid.
The vapor pipes to the canisters, other than the evaporative emission canister vent solenoid, use multi-tang
connectors which are push fitted and pulled out without the use of tools.
The evaporative emission canister vent solenoid has a stub pipe with 'O' ring seal which is a simple push fit into the
canister. A mounting bracket on the evaporative emission canister vent solenoid enables it to be secured to the
underbody via the canister rear mounting bolt.
A hose connects the evaporative emission canister vent solenoid to the bracket mounted adaptor into which the
vent system air filter is screwed.
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Item Description
1 Evaporative emission canister purge valve
2 Fuel vapor vent valve housing
3 Evaporative emission canister
This system uses one evaporative emission canister (two evaporative emission canisters and rochester valve fitted
on vehicles used in high altitude environments). The vapor outlet from the fuel tank is taken via a rollover valve
fitted to the removable flange at the top of the tank.
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Fuel Vapor Vent Valve Housing - Vehicles Without On-board Refueling Vapor Recovery
Item Description
1 Vapor vent / rollover protection valve
2 Fuel pump electrical connector
3 fuel vapor vent valve housing locking ring
The fuel vapor vent valve housing is fitted to the top of the tank via a seal and locking ring. The fuel vapor vent
valve housing is removable complete with the fitted components.
The vapor vent / rollover valve is a push fit via a sealing grommet. The fuel pump electrical connector is push
fitted and crimped into a location tube on the underside of the flange.
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Evaporative Emissions
Preliminary Inspection
2. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
3. 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 equipment
must be capable of testing to the 0.020 thou standard. (2001 my on).
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. For details of the drive cycles, <<303-14>> ECM
adaptations.
1. 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.)
2. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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.
3. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00.
NOTE:
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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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Symptom Chart
Driver Information
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for
possible sources and actions.
NOTE:
A trip is an ignition OFF, 30 seconds delay, ignition ON cycle, plus a minimum coolant temperature increase
of 22°C (40°F) after which the coolant temperature should reach a minmum 71°C (160°F)
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Diagnostic Trouble Code (DTC) index
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P0455 Leak detected (large) Filler cap missing Check filler cap,
system pipework,
Filler cap seal defective
fuel tank,
System leak (canister/pipework Goto <<A>>
damage) .
CCV stuck open
Purge valve to engine purge pipe,
damaged/blocked/leaking
Purge valve operating vacuum hose
leak/blockage
Purge valve failure
Fuel tank leak
Pinpoint Tests
NOTE:
For K-Line or Vacutec equipment connection, see bulletin 05.1-29, or Vacutec operating instructions
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Evaporative system monitor drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive
cycles' above.
-> No
INSTALL a new canister purge valve. <<Evaporative Emission Canister Purge Valve - >> CLEAR the
DTC. Carry out a full Evaporative system monitor drive cycle.
1. Disconnect the outlet pipe from the canister purge valve. (Pipe from purge valve to crankcase breather tube).
2. Using a hand-held vacuum pump, apply a vacuum to the outlet port of the canister purge valve
Does the canister purge valve hold vacuum?
-> Yes
No fault found with canister purge valve. CLEAR the DTC. Carry out a full Evaporative system monitor
drive cycle. Recheck DTCs. For additional information, see 'diagnostic drive cycles' above.
-> No
INSTALL a new canister purge valve. <<Evaporative Emission Canister Purge Valve - >> CLEAR the
DTC. Carry out a full Evaporative system monitor drive cycle. Recheck DTCs. For additional information,
see 'diagnostic drive cycles' above.
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-> No
INSTALL a new purge valve, CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle.
Recheck DTCs. For additional information, see 'diagnostic drive cycles' above. If the DTC is repeated,
contact dealer technical support for advice on possible ECM failure.
NOTE:
Depending on the severity of the blockage, it is possible that some level of difficulty has been experienced
during a fuel fill operation.
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NOTE:
This test will involve the use of a scan tool capable of reading fuel tank pressure.
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-> No
Goto <<G2>>
G2 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT CIRCUIT TO GROUND
G3 : CHECK THE FTP SENSOR SENSE CIRCUIT FOR SHORT CIRCUIT TO HIGH VOLTAGE
G4 : CHECK THE FTP SENSOR SIGNAL GROUND CIRCUIT FOR HIGH RESISTANCE
G5 : CHECK THE FTP SENSOR SIGNAL GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
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G6 : CHECK THE FTP SENSOR POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
G7 : CHECK THE FTP SENSOR WIRING FOR SHORT CIRCUIT TO EACH OTHER
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Removal WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
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Installation
1. NOTE:
Install new evaporative emission canister tube O-ring seals.
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Removal WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
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 FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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Installation
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3. Tighten to 6 Nm.
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Removal
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1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Remove the fuel tank. Refer to operation 19.55.15.
Do not install the fuel level sender unit, at this stage.
2. Tape back the insulation pads on top of the tank, to gain access to the evaporative loss flange.
3. Release the hose clip and disconnect the breather hose from the evaporative loss flange. Slide the hose
along the pipe.
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Installation
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Torque specification
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1. Whenever the battery is disconnected, the Engine Control Module (ECM) adaptations are reset to a 'green' ECM condition. In this condition, certain
functions of the ECM are inhibited, and the ECM must 'relearn' these functions. To enable the ECM to do this, the vehicle will have to perform some
maneuvres which it may, or may not, do during a normal road test. The routine in this procedure should be carried out at Pre-Delivery Inspection, and after
any emissions related rectification work involving the disconnection of the battery.
DTCs P1000/P1111
1. When the DTCs relating to a rectified concern are cleared, P1000 (system checks not complete since last memory clear) will be flagged. This DTC does
not indicate a failure, just that diagnostic drive cycles need to be performed. The vehicle's on-board diagnostic system will confirm that all the diagnostic drive
cycles are complete by flagging P1111, (system checks complete since last memory clear)
1. Make sure these conditions are checked and corrected, if necessary, before carrying out the adaptation procedure.
Mechanical Electrical
Engine oil level correct All Diagnostic Trouble Codes (DTCs) cleared
Coolant level correct All rectification work relating to DTCs completed
Fuel level greater than 30%, less than 80% Fuses
Fuel filler cap correctly fitted/secure, seal in good condition Harnesses
All rectification work relating to DTCs completed Electrical connectors
Fuel, ignition and cooling systems in good order
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1. Either the Jaguar approved diagnostic system (where available), or a scan tool should be connected to measure the Mass Air Flow rate. Most generic
scan tools should be capable of reading this parameter.
Depending on road conditions and dealer location, it may be difficult to achieve the road speeds necessary to reach the air flow indicated. It is possible to
reach these air flow figures by inducing a load on the vehicle, (making use of hills, using a lower gear ratio, etc) or, if no alternative is possible, by restraining
the vehicle and reaching the air flow figure stationery in D. WARNING:
THIS SHOULD NOT BE ATTEMPTED WITHOUT THE VEHICLE BEING IN A SAFE AREA AND SUITABLY CHOCKED. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Without using the Jaguar approved diagnostic system or a scan tool with system readiness capability, it will not be possible to confirm when the adaptations
are complete, unless P1111, (system checks complete since last memory clear) is flagged. If such equipment is not available, ALL the diagnostic monitors
will have to run to enable DTC P1111 to be flagged. In some US states, this code is a requirement for annual emissions tests.
1. The drive cycles detailed here will enable the monitors to run, but only after fuelling adaptations are complete.
Entry Conditions
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2. During the drive cycle, drive gently, avoiding hard acceleration, braking or cornering and rough roads.
1. Drive at 84 to 97 kph (52 to 60 mph) for 40 seconds.
2. Accelerate to 113 kph (70 mph).
3. Close the throttle, (ideally at the start of a descent) continue with closed throttle for 10 seconds. (* Fuel cut)
4. Drive at 56 to 64 kph (35 to 40 mph), holding the throttle as steady as possible, on a flat level road for 30 seconds minimum.
1. Make sure the 'conditions for adaptation' detailed at the start of this section are met.
1. Avoiding high engine loads, drive the vehicle steadily between 48 and 89 kph (30 and 55 mph) for 15 to 20 minutes after starting the engine.
(Depending on the amount of fuel vapor generated, the test may take longer than this).
2. Where possible, avoid body roll to minimise fuel movement.
3. If the scan tool being used is able to read TIDs, check TID 08 in mode 6. If the test has not completed, this TID will display '0'. Any other value
indicates that the test has successfully completed.
4. If the test has not completed, the drive cycle must be repeated.
5. If the scan tool being used is not able to read TIDs, the only way to confirm that the test has run is to check for P1111 after running the 20 thou test,
where applicable.
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1. This test needs to be completed within 50 minutes of starting the engine from cold. It should be run following the 40 thou test.
1. Continue driving the vehicle steadily between 48 and 89 kph, (30 and 55 mph) avoiding high engine loads for a further 15 minutes.
2. Avoiding excessive fuel movement, bring the vehicle to rest.
3. Allow to idle for two minutes.
4. Provided the vapor conditions are suitable, the test will complete.
5. If the scan tool being used is able to read TIDs, check TID 06 in mode 6. If the test has not completed, this TID will display '0'. Any other value
indicates that the test has successfully completed.
6. If the test has not completed, the drive cycle must be repeated.
7. Check for DTCs. P1111 will be flagged if all monitors have run.
8. Leak check drive cycles will only normally be necessary if an Evaporative Emissions related DTC is flagged.
9. Unless P1111 is required for the State inspection, fuelling adaptations will normally be all that is required for the vehicle to adapt itself and complete
diagnostic drive cycles in the course of it's normal use.
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Parts List
Item Description
1 Knock sensors (KS)
2 Engine coolant temperature (ECT) sensor
3 Variable camshaft timing oil control solenoid
4 Crankshaft position (CKP) sensor
5 Catalyst monitor sensor
6 Heated oxygen (HO2) sensor
7 Camshaft position (CMP) sensor
The engine management system provides optimum control of the engine under all operating conditions using
several strategically placed sensors and any necessary actuators. Electronic engine control consists of:
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The ECM incorporates a comprehensive monitoring and diagnostic capability including software variations to
ensure system compliance with the latest diagnostic and emissions legislation in different markets. The engine
control module controls the coil on plug ignition system, electronic fuel system, cruise control and the electronic
throttle control system.
The ECM responds to input signals received from sensors relating to engine operating conditions and provides
output signals to the appropriate actuators. These output signals are based on the evaluated input signals which
are compared with calibrated data tables or maps held within the ECM before the output signal is generated.
The ECM needs the following inputs to calibrate the engine properly:
camshaft position
engine rpm
engine coolant temperature
amount of engine detonation
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Parts List
Item Description
1 Throttle body
2 Throttle position (TP) sensor
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sends the ECM a signal indicating camshaft position for fuel synchronization purposes
is a variable reluctance device mounted on each cylinder head
generates a signal when the ring fitted to each intake camshaft passes the sensor
sends the ECM a signal indicating the temperature of the engine coolant
is a temperature dependent resistor with a negative temperature coefficient (resistance changes inversely
with respect to temperature) and is constantly monitored by the ECM
is a piezo-electric device which sends a signal to the ECM indicating engine detonation
Between 700 and 6800 rpm, the ECM will retard individual cylinder ignition timing when detonation occurs while
allowing the other cylinders to continue operating normally.
During acceleration, at critical load and speed conditions, the ECM retards ignition timing to prevent the onset of
detonation.
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.
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Location
The 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
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temperatures.
Vehicles with supercharger have an additional intake air temperature (IAT) sensor located on the right-hand
charge air cooler. The IAT sensor 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.
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2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
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6. 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.)
7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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:
If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be deleted following three cycles during which no
fault was present. This could result in a reported warning light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC
becomes permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which will occur during the owner's normal
use of the vehicle. No action on the part of the technician is necessary to perform this cycle. A drive cycle is a series of conditions needed to make the
on-board diagnostic routine run, and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
8. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
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Symptom Chart
Symptom Symptom (specific) Possible source Action
(general)
Non-Start Engine does not crank Starter relay Check relay dates. Check for DTCS. For starting system,
<<303-06>> For ECM relay tests,
ECM relay
Goto <<AL>>
Battery . For battery information, <<414-01>> For Park/Neutral
tests,
Park/Neutral switch
Goto <<AJ>>
Starting system . For engine information, <<303-01>>
Harness damage
Engine siezed
' Engine cranks, but does not fire Security system /Immobiliser engaged Contact Dealer technical support for information on
security system. For fuel system, <<303-04>> Contact
Harness damage
Dealer technical support for advice on possible ECM
Fuel system failure
ECM fault
' Engine cranks and fires, but will not Fuel pump relay For fuel pump relay tests,
start Goto <<AB>>
Fuel pump
. Check fuel pressure. Refer to Technical service bulletins.
Cylinder compression loss For ECT sensor tests,
(short-term. Refer to bulletin; 303-52) Goto <<C>>
. For ignition system, <<303-07>>
Engine coolant temperature (ECT)
sensor
Spark plugs fouled
Ignition coil failure(s)
HT short to ground (tracking) check
rubber boots for cracks/damage
Difficult to Difficult to start cold Battery For battery information, <<414-01>> Check fuel pressure.
start Refer to Technical service bulletins. For ignition system,
Fuel pump
<<303-07>>
Cylinder compression loss
(short-term. Refer to bulletin; 303-52)
Spark plugs fouled
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' Difficult to start hot Rochester valve For Rochester valve test,
Goto <<AO>>
Injector leak
. For injector leak test, REFER to technical service bulletin;
Purge valve 303-39. For evaporative emissions components,
<<303-13>> Check fuel pressure. For ECT sensor tests,
Fuel pump
Goto <<C>>
Engine coolant temperature (ECT) .
sensor
' ' Difficult to start after hot soak (vehicle Rochester valve
standing after engine has reached
Injector leak
operating temperature)
Purge valve
Fuel pump
Engine coolant temperature (ECT) sensor
' Engine cranks too fast/slow Battery For battery information, <<414-01>> For starting system.
<<303-06>> Refer to technical service bulletins.
Starting system
Cylinder compression loss (NA short
term only. Refer to technical service
bulletin; 303-39)
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Engine Engine stalls soon after start Fuel pump relay Check relay dates. Check for DTCS. For fuel pump relay
stalls tests,
ECM relay
Goto <<AB>>
Harness . For ECM relay tests,
Goto <<AL>>
Coolant sensor
. For ECT sensor tests,
Fuel lines Goto <<C>>
. For fuel system, <<303-04>> For intake system
Fuel pressure regulator
information, <<303-12>> Refer to technical service
Air leakage bulletins.
Cylinder compression loss (NA short
term only. Refer to technical service
bulletin; 303-39)
' Engine stalls on overrun ECM relay Check relay dates; For ECM relay tests,
Goto <<AL>>
Fuel pump relay
. For fuel pump relay tests,
Throttle sensors Goto <<AB>>
. For throttle sensor tests,
Goto <<D>>
, and
Goto <<N>>
.
' Engine stalls at steady speed, with or ECM relay For ECM relay circuit tests,
without cruise enabled Goto <<AL>>
Fuel pump relay
. For fuel pump relay circuit tests,
Stop lamp switch Goto <<AB>>
. For stop lamp switch circuit information, refer to the
Harness
electrical guides.
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' Engine stalls when maneuvering ECM relay For ECM relay tests,
Goto <<AL>>
Fuel pump relay
. For fuel pump relay tests,
Throttle sensors Goto <<AB>>
. For throttle position sensor tests,
Goto <<D>>
, and
Goto <<N>>
.
Poor Engine hesitates/poor Fuel pump Check fuel pressure. For intake system information,
driveability acceleration <<303-12>> For fuel pressure regulator, <<303-04>> For
Air leakage
fuel lines information, <<310-01>> For throttle position
Fuel pressure regulator sensor tests,
Goto <<D>>
Fuel lines
, and
Harness damage Goto <<N>>
. For throttle motor relay tests,
Throttle sensors
Goto <<AM>>
Throttle motor , and
Goto <<AN>>
Spark plugs fouled
. For ignition system, <<303-07>>
Ignition coil failure(s)
HT short to ground (tracking) check
rubber boots for cracks/damage
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' Engine backfires Fuel pump For fuel pump and lines, <<310-01>> For intake system,
<<303-12>> For MAF sensor tests,
Fuel lines
Goto <<A>>
Air leakage . For ignition system, <<303-07>>
MAF sensor
Spark plugs
HT short to ground (tracking) check
rubber boots for cracks/damage
Ignition coil failure(s)
' Engine surges Air leakage For intake system, <<303-12>> For fuel pump and lines
tests, <<303-04>> For MAF sensor tests,
Fuel pump
Goto <<A>>
Fuel lines . For throttle position sensor tests,
Goto <<D>>
MAF sensor
, and
Harness Goto <<N>>
. For ignition system, <<303-07>>
Throttle sensors
Throttle motor
Spark plugs
HT short to ground (tracking) check
rubber boots for cracks/damage
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' Engine detonates/knocks Fuel lines For fuel lines, <<310-01>> For fuel pressure regulator,
<<303-04>> For intake system, <<303-12>> For MAF
Fuel pressure regulator
sensor tests,
Air leakage Goto <<A>>
. For oxygen sensor tests, check for DTCs and refer to the
Mass air flow (MAF) sensor
pinpoint tests listed for the DTCs flagged. Check fuel
Oxygen sensors pressure.
Fuel pump
' No throttle response Traction control invoked For throttle position sensor tests,
Goto <<D>>
Throttle sensors
, and
Throttle motor Goto <<N>>
. For throttle motor relay tests,
Goto <<AM>>
, and
Goto <<AN>>
.
' Cruise control inhibited or Cruise control switch For cruise control switches, <<310-03>> For throttle
disabled position sensor tests,
Throttle sensors
Goto <<D>>
Stop lamp switch , and
Goto <<N>>
. Check electrical guides for stop light switch information.
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1999 XK RANGE - Electronic Engine Controls - 303-14
' Poor throttle response Throttle sensors For throttle position sensor tests,
Goto <<D>>
Throttle motor
, and
Air leakage Goto <<N>>
. For throttle motor relay tests,
Mass air flow (MAF) sensor
Goto <<AM>>
, and
Goto <<AN>>
. For MAF sensor tests,
Goto <<A>>
.
' Engine defaults, warning light and Engine misfire For transmission tests, <<307-01A>><<307-01B>> For
messages. Refer to the Driver Park/Neutral tests,
Transmission fault
Information table Goto <<AJ>>
Park/Neutral switch . For throttle position sensor tests,
Goto <<D>>
Throttle sensors
, and
MAF sensor Goto <<N>>
. For MAF sensor tests,
Engine coolant temperature (ECT)
Goto <<A>>
sensor
. For ECT sensor tests,
Knock sensors Goto <<C>>
. For knock sensor tests,
Harness
Goto <<O>>
, and
Goto <<P>>
.
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for possible sources and actions.
NOTE:
For definitions of Default Modes, see the foot of this table.
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No electronic throttle operation. (Mechanical operation for last quarter of pedal travel)
Maximum 25° throttle opening, depending on adjustment of throttle mechanical linkage.
Engine speed restricted to 3000 RPM maximum, by fuel cut-off.
High idle speed. (1200 RPM approx.)
Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders, as the strategy varies the cylinder cut)
Cruise Control Inhibited
REVERSE THROTTLE PROGRESSION ENABLED
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1999 XK RANGE - Electronic Engine Controls - 303-14
P0125 Engine coolant temperature (ECT) sensor response (for closed loop fuel control) Low/contaminated coolant For ECT sensor circuit tests,
Goto <<C>>
Thermostat failure
.
ECT sensor to ECM sensing circuit high resistance, open circuit or
short circuit to high voltage
P0131 Right-hand H02S sense circuit low current (universal oxygen sensor; lean condition at ECM - high H02S disconnected For Right-hand HO2S circuit tests,
current at sensor) Goto <<E>>
H02S to ECM variable current circuit fault. (HO2S pin 3)
.
ECM to HO2S constant current circuit fault (HO2S pin 4)
H02S failure
P0132 Right-hand H02S sense circuit high current (universal oxygen sensor; rich condition at ECM - low H02S disconnected For Right-hand HO2S circuit tests,
current at sensor) Goto <<E>>
H02S to ECM variable current circuit fault. (HO2S pin 3)
.
ECM to HO2S constant current circuit fault (HO2S pin 4)
H02S failure
P0133 Right-hand H02S sense circuit slow response Engine misfire For Right-hand HO2S circuit tests,
Goto <<E>>
H02S disconnected
. For heater circuit tests,
H02S mechanical damage Goto <<F>>
.
H02S to ECM wiring intermittent open circuit
H02S sensing circuit short circuit to high voltage
H02S short circuit to ground
H02S ground braided shield open circuit
H02S heater circuit fault
Exhaust leak
Low exhaust temperature
Injector flow partially blocked
Catalyst efficiency decrease
H02S failure
P0135 Right-hand H02S heater circuit malfunction H02S disconnected For Right-hand H02S heater circuit tests,
Goto <<F>>
H02S heater power supply open circuit
.
H02S heater to ECM wiring short circuit or open circuit
H02S heater failure
P0137 Right-hand catalyst monitor sensor sense circuit low voltage Catalyst monitor sensor disconnected For Right-hand catalyst monitor circuit tests,
Goto <<H>>
Catalyst monitor sensor to ECM wiring open circuit
.
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor failure
P0138 Right-hand catalyst monitor sensor sense circuit high voltage Catalyst monitor sensor sensing circuit short circuit to high voltage For Right-hand catalyst monitor circuit tests,
Goto <<G>>
Catalyst monitor sensor ground braided shield open circuit
.
Catalyst monitor sensor failure
P0140 Right-hand catalyst monitor sensor sense circuit no activity Catalyst monitor sensor disconnected For Right-hand catalyst monitor circuit tests,
Goto <<G>>
Catalyst monitor sensor mechanical damage
.
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor sensing circuit short circuit to high voltage
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor ground braided shield open circuit
Exhaust leak
Low exhaust temperature
Catalyst monitor sensor failure
P0141 Right-hand catalyst monitor sensor heater circuit malfunction Catalyst monitor sensor disconnected For Right-hand catalyst monitor sensor heater circuit tests,
Goto <<H>>
Catalyst monitor sensor mechanical damage
.
Catalyst monitor sensor to ECM wiring fault
Catalyst monitor sensor heater failure
P0151 Left-hand HO2S sense circuit low current (universal oxygen sensor; lean condition at ECM - high H02S disconnected For Left-hand catalyst monitor sensor circuit tests,
current at sensor) Goto <<M>>
H02S to ECM variable current circuit fault (HO2S pin 3)
.
ECM to HO2S constant current circuit fault (HO2S pin 4)
H02S failure
P0152 Left-hand H02S sense circuit high current (universal oxygen sensor; rich condition at ECM - low H02S disconnected For Left-hand catalyst monitor sensor circuit tests,
current at sensor) Goto <<M>>
H02S to ECM variable current circuit fault (HO2S pin 3)
.
ECM to HO2S constant current circuit fault (HO2S pin 4)
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1999 XK RANGE - Electronic Engine Controls - 303-14
P0153 Left-hand HO2S sense circuit slow response Engine misfire For Left-hand HO2S circuit tests,
Goto <<J>>
H02S disconnected
.
H02S mechanical damage
H02S to ECM wiring fault
H02S short circuit to ground
H02S to ECM variable current circuit shielding open circuit
H02S heater circuit fault
Exhaust leak
Low exhaust temperature
Injector flow partially blocked
Catalyst efficiency decrease
H02S failure
P0155 Left-hand HO2S heater circuit malfunction H02S disconnected For Left-hand HO2S heater circuit tests,
Goto <<J>>
H02S heater power supply open circuit
.
H02S heater to ECM wiring short circuit or open circuit
H02S heater failure
P0157 Left-hand catalyst monitor sensor sense circuit low voltage Catalyst monitor sensor disconnected For Left-hand catalyst monitor sensor circuit tests,
Goto <<M>>
Catalyst monitor sensor to ECM wiring open circuit
.
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor failure
P0158 Left-hand catalyst monitor sensor sense circuit high voltage Catalyst monitor sensor sensing circuit short circuit to high voltage For Left-hand catalyst monitor sensor circuit tests,
Goto <<M>>
Catalyst monitor sensor ground braided shield open circuit
.
Catalyst monitor sensor failure
P0160 Left-hand catalyst monitor sensor sense circuit no activity Catalyst monitor sensor disconnected For Left-hand catalyst monitor sensor circuit tests,
Goto <<M>>
Catalyst monitor sensor mechanical damage
.
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor sensing circuit short circuit to high voltage
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor ground braided shield open circuit
Exhaust leak
Low exhaust temperature
Catalyst monitor sensor failure
P0161 Left-hand catalyst monitor sensor heater circuit malfunction Catalyst monitor sensor disconnected For Left-hand catalyst monitor sensor heater circuit tests,
Goto <<K>>
Catalyst monitor sensor mechanical damage
.
Catalyst monitor sensor to ECM wiring fault
Catalyst monitor sensor heater failure
P0171 Right-hand cylinders combustion too lean Air intake leak between MAF sensor and throttle Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator,
<<303-04>><<309-00>> Refer to pinpoint tests for HO2S and other sensors listed.
Fuel filter system blockage
Fuel injector blockage
Fuel pressure regulator failure (low fuel pressure)
Low fuel pump output
H02S harness wiring fault
Exhaust leak (before catalyst)
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP
P0172 Right-hand cylinders combustion too rich Engine misfire Check for misfire detected DTCs. Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure
and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for sensors listed.
Blocked air filter
Fuel system return blockage
Leaking fuel injector(s)
Fuel pressure regulator failure (high fuel pressure)
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP
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P0174 Left-hand cylinders combustion too lean Air intake leak between MAF sensor and throttle Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure and regulator,
<<303-04>><<309-00>> Refer to pinpoint tests for HO2S and other sensors listed.
Fuel filter system blockage
Fuel injector blockage
Fuel pressure regulator failure (low fuel pressure)
Low fuel pump output
H02S harness wiring fault
Exhaust leak (before catalyst)
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP
P0175 Left-hand cylinders combustion too rich Engine misfire Check for misfire detected DTCs. Check air intake system, <<303-12>> Check fuel filter, <<310-00>> Check fuel injectors, fuel pressure
and regulator, <<303-04>><<309-00>> Refer to pinpoint tests for sensors listed.
Blocked air filter
Fuel system return blockage
Leaking fuel injector(s)
Fuel pressure regulator failure (high fuel pressure)
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP
P0196 Engine oil temperature (EOT) sensor range/performance EOT sensor to ECM sensing circuit high resistance when hot For EOT sensor circuit tests,
Goto <<L>>
EOT sensor to ECM sensing circuit intermittent high resistance
.
EOT sensor failure
P0197 Engine oil temperature (EOT) sensor sense circuit low voltage (high oil temperature) EOT sensor to ECM wiring short circuit to ground For EOT sensor circuit tests,
Goto <<L>>
EOT sensor failure
.
P0198 Engine oil temperature (EOT) sensor sense circuit high voltage (low oil temperature) EOT sensor disconnected For EOT sensor circuit tests,
Goto <<L>>
EOT sensor to ECM sensing circuit high resistance, open circuit or
.
short circuit to battery voltage
EOT sensor failure
P0201 Fuel injector circuit malfunction, Cyl 1 Injector disconnected For fuel injector circuit tests, <<303-04>>
Injector wiring open or short circuit
Injector failure
' ' P0202 Fuel injector circuit malfunction, Cyl 3
' ' P0203 Fuel injector circuit malfunction, Cyl 5
' ' P0204 Fuel injector circuit malfunction, Cyl 7
' ' P0205 Fuel injector circuit malfunction, Cyl 2
' ' P0206 Fuel injector circuit malfunction, Cyl 4
' ' P0207 Fuel injector circuit malfunction, Cyl 6
' ' P0208 Fuel injector circuit malfunction, Cyl 8
P0222 Throttle position (TP) sensor circuit 2 low voltage TP sensor to ECM sensing circuit 2 (TP sensor pin 2) open circuit or For TP sensor circuit tests,
high resistance Goto <<D>>
, and
TP sensor failure
Goto <<N>>
.
P0223 Throttle position (TP) sensor circuit 2 high voltage TP sensor to ECM sensing circuit 2 (TP sensor pin 2) short circuit to For TP sensor circuit tests,
battery voltage Goto <<D>>
, and
TP sensor failure
Goto <<N>>
.
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1999 XK RANGE - Electronic Engine Controls - 303-14
P0300 Random misfire detected ECM to ignition coil primary circuit faults (cylinder misfire detected For ignition system, <<303-07>> For injector circuit tests, <<303-04>> Check compressions. Check fuel pressure. For fuel injectors,
DTCs also logged) <<303-04>> For fuel tank and lines information, <<310-01>> Check PAS pulley bolt torque. (see Service Action S462) For engine
information, <<303-01>>
Ignition coil ground circuit; open circuit, high resistance
Fuel injector circuit fault(s) [injector DTCs also logged]
Ignition coil failure(s)
HT short to ground (tracking) check rubber boots for cracks/damage
Spark plug failure/fouled/incorrect gap
Cylinder compression low
Fuel delivery pressure (low/high)
Fuel injectors restricted/leaking
Fuel contamination
PAS pulley bolts loose (see Service Action S462)
Worn camshaft/broken valve springs
P0301 Misfire detected, Cyl 1 Refer to possible sources for P0300 Refer to actions for P0300
' ' P0302 Misfire detected, Cyl 3
' ' P0303 Misfire detected, Cyl 5
' ' P0304 Misfire detected, Cyl 7
' ' P0305 Misfire detected, Cyl 2
' ' P0306 Misfire detected, Cyl 4
' ' P0307 Misfire detected, Cyl 6
' ' P0308 Misfire detected, Cyl 8
P0327 Right-hand knock sensor (KS) sense circuit out of range (low voltage) Poor sensor contact with cylinder block For Right-hand KS circuit tests,
Goto <<O>>
KS to ECM sense circuit short circuit to ground
.
KS failure
P0328 Right-hand knock sensor (KS) sense circuit out of range (high voltage) Poor sensor contact with cylinder block For Right-hand KS circuit tests,
Goto <<O>>
KS to ECM sense circuit high resistance or open circuit
.
KS to ECM sense circuit short circuit to high voltage
KS failure
P0332 Left-hand knock sensor (KS) sense circuit out of range (low voltage) Poor sensor contact with cylinder block For Left-hand KS circuit tests,
Goto <<P>>
KS to ECM sense circuit short circuit to ground
.
KS failure
P0333 Left-hand knock sensor (KS) sense circuit out of range (high voltage) Poor sensor contact with cylinder block For Left-hand KS circuit tests,
Goto <<P>>
KS to ECM sense circuit high resistance or open circuit
.
KS to ECM sense circuit short circuit to high voltage
KS failure
P0335 Crankshaft position (CKP) sensor circuit malfunction CKP sensor disconnected For CKP sensor circuit tests,
Goto <<Q>>
CKP sensor air gap incorrect/foreign matter on face
.
CKP sensor sensing circuit open circuit, short circuit to ground, short
circuit to high voltage
CKP sensor failure
P0336 Crankshaft position (CKP) sensor range/performance CKP sensor reluctor (on drive plate) foreign matter/damaged teeth For CKP sensor circuit tests,
Goto <<Q>>
CKP sensor sensing circuit intermittent open circuit, short circuit to
.
ground, short circuit to high voltage
CKP sensor failure
P0340 Right-hand camshaft position (CMP) sensor circuit malfunction CMP sensor disconnected For Right-hand CMP sensor circuit tests,
Goto <<R>>
CMP sensor air gap incorrect/foreign matter on face
.
CMP sensor sensing circuit open circuit, short circuit to ground, short
circuit to high voltage
CMP sensor failure
P0341 Right-hand camshaft position (CMP) sensor range/performance (CMP sensor pulse not detected CMP sensor disconnected For Right-hand CMP sensor circuit tests,
at CKP sensor missing tooth) Goto <<R>>
CMP sensor air gap incorrect/foreign matter on face
.
CMP sensor sensing circuit open circuit, short circuit to ground, short
circuit to high voltage
CMP sensor failure
P0351 Ignition coil primary/secondary circuit malfunction, cyl 1 ECM to ignition coil circuit open circuit, short circuit to ground, high For ignition system pinpoint tests, <<303-07>>
resistance
Ignition coil ground circuit open circuit, high resistance
Ignition coil failure
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1999 XK RANGE - Electronic Engine Controls - 303-14
P0455 EVAP system leak detected - large Fuel filler cap missing For evaporative emissions pinpoint tests, <<303-13>>
Fuel filler cap seal defective
EVAP system leak (canister damage, pipework damage)
CCV leaking/stuck open
EVAP valve to engine purge pipe
damaged/blocked/leaking/disconnected
EVAP valve operating vacuum hose leak/blockage/disconnected
(stuck closed)
EVAP valve failure
Fuel tank leak
P0460 Fuel level sense signal performance Fuel level sensor to instrument cluster circuits intermittent short or For fuel level sensor circuit tests, <<303-04>>
open circuit
Fuel level sensor failure
Instrument cluster fault (incorrect fuel level data)
P0480 Radiator fans slow (series) circuit malfunction Radiator fan control relay module to ECM 'series' drive circuit (relay For radiator fan series circuit tests,
pin 9) fault Goto <<S>>
.
Relay coil ignition power supply open circuit
ECM ground circuit fault (relay coil drive)
ECT sensor circuit malfunction (refer to P0116)
P0482 Radiator fans fast (parallel) circuit malfunction Radiator fan control relay module to ECM 'parallel' drive circuit (relay For radiator fan parallel circuit tests,
pin 7) fault Goto <<T>>
.
Relay coil ignition power supply open circuit
ECM ground circuit fault (relay coil drive)
ECT sensor circuit malfunction (refer to P0116)
P0506 Idle RPM lower than expected Air intake blockage Inspect air intake system. <<303-12>> For accessory drive information, <<303-05>> For throttle body information, <<303-04>>
Accessory drive overload (defective/siezed component)
Throttle valve stuck closed
Throttle assembly failure
P0507 Idle RPM higher than expected Intake air leak between MAF sensor and throttle Inspect air intake system. <<303-12>> Check engine breather system, <<303-08>> For cruise control, <<310-03>> For throttle body
information, <<303-04>>
Intake air leak between throttle and engine
Engine breather leak
Cruise control vacuum failure
Throttle valve stuck open
Throttle assembly failure
P0560 Vehicle voltage malfunction ECM battery power supply open circuit, high resistance For ECM power supply tests,
Goto <<U>>
.
P0566 Cruise control CANCEL switch ON fault Cruise control switches internal steering wheel short circuit to ground For cruise control pinpoint tests, <<310-03>>
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
CANCEL switch failure (stuck ON)
P0567 Cruise control RESUME switch ON fault Cruise control switches internal steering wheel short circuit to ground For cruise control pinpoint tests, <<310-03>>
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
RESUME switch failure (stuck ON)
P0568 Cruise control switch ground malfunction Cruise control switches internal steering wheel open circuit For cruise control pinpoint tests, <<310-03>>
Steering wheel cassette reel open circuit or high resistance
Cassette reel to ECM circuit (ACCEL/DECEL) open circuit or high
resistance
(ACCEL/DECEL) switch failure
P0569 Cruise control DECEL/SET (SET-) switch ON fault Cruise control switches internal steering wheel short circuit to ground For cruise control pinpoint tests, <<310-03>>
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
DECEL/SET- switch failure (stuck ON)
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1999 XK RANGE - Electronic Engine Controls - 303-14
P0570 Cruise control ACCEL/SET (SET+) switch ON fault Cruise control switches internal steering wheel short circuit to ground For cruise control pinpoint tests, <<310-03>>
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
ACCEL/SET (SET+) switch failure (stuck ON)
P0603 ECM data corrupted ECM Contact dealer technical support for advice on possible ECM failure
P1000 System checks not complete since last memory clear OBD diagnostic monitors have not completed Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page.
P1104 Mass air flow (MAF) sensor ground malfunction MAF sensor to ECM reference ground circuit open circuit, short circuit For MAF ground circuit tests,
to high voltage, high resistance Goto <<V>>
, For MAF sensor sense circuit tests,
MAF sensor to ECM sensing circuit open circuit
Goto <<A>>
MAF sensor failure .
P1111 System checks complete since last memory clear OBD diagnostic monitors have completed No action necessary
P1121 Accelerator pedal position (APP) sensor circuit range/performance Accelerator pedal to APP sensor cable adjustment incorrect Check cable adjustment (refer to technical bulletins), for APP sensor circuit tests,
Goto <<W>>
APP sensor to ECM sense circuits 1 and 2 open circuit, short circuit or
, and
high resistance
Goto <<Z>>
Sensor power supply fault . For sensor power supply circuit tests,
Goto <<AC>>
Sensor reference ground fault
. For sensor ground circuit tests,
APP sensor failure Goto <<AD>>
.
P1122 Accelerator pedal position (APP) sensor circuit '1' low voltage APP sensor to ECM sense circuit '1' (sensor pin 4) open circuit or high For APP sensor circuit tests,
resistance Goto <<W>>
, and
Sensor power supply fault
Goto <<Z>>
APP sensor failure . For sensor power supply circuit tests,
Goto <<AC>>
.
P1123 Accelerator pedal position (APP) sensor circuit '1' high voltage APP sensor to ECM sense circuit '1' (sensor pin 4) short circuit to For APP sensor circuit tests,
battery voltage Goto <<W>>
, and
APP sensor failure
Goto <<Z>>
.
P1136 'Cool box' malfunction Cooling fan power supply fault For module cooling fan circuit tests,
Goto <<X>>
Cooling fan drive circuit fault
.
Cooling fan motor failure
P1143 Air assist close valve (AACV) range/performance AAI piping blocked Check AACV pipework and air channels, for AACV circuit tests,
Goto <<Y>>
Throttle body air channel blocked
.
AACV stuck
P1144 Air assist close valve (AACV) circuit malfunction AACV B+ power supply circuit fault For AACV circuit tests,
Goto <<Y>>
AACV ground circuit fault
.
AACV to ECM PWM drive circuit open circuit, short circuit or high
resistance
AACV failure
P1222 Accelerator pedal position (APP) sensor circuit '2' low voltage APP sensor to ECM sense circuit '2' (sensor pin 2) open circuit or high For APP sensor circuit tests,
resistance Goto <<W>>
, and
Sensor power supply fault
Goto <<Z>>
APP sensor failure .
P1223 Accelerator pedal position (APP) sensor circuit '2' high voltage APP sensor to ECM sense circuit '2' (sensor pin 2) short circuit to For APP sensor circuit tests,
battery voltage Goto <<W>>
, and
APP sensor failure
Goto <<Z>>
.
P1224 Throttle control position error Throttle position adaptions not performed after battery disconnect Carry out throttle adaptation procedure. For TP sensor circuit tests,
Goto <<D>>
TP sensor disconnected
, and
TP sensor to ECM sense circuits open circuit, high resistance Goto <<N>>
. For throttle motor relay circuit tests,
Throttle motor power relay failure
Goto <<AM>>
Throttle motor power relay to ECM circuit fault , and
Goto <<AN>>
Throttle motor power relay power supply open circuit
. For throttle body information, <<303-04>>
ECM ground circuit fault (relay coil drive)
Throttle motor to ECM drive circuits open circuit, short circuit, high
resistance
Throttle motor failure
Throttle assembly failure
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1999 XK RANGE - Electronic Engine Controls - 303-14
P1229 Throttle motor control circuit mallfunction Throttle motor disconnected For throttle motor circuit tests,
Goto <<AM>>
Throttle motor to ECM drive circuits short circuit or open circuit
, and
Throttle motor failure Goto <<AN>>
.
P1230 Fuel pump relay malfunction Fuel pump relay failure For fuel pump relay circuit tests,
Goto <<AB>>
Fuel pump to ECM circuit fault
.
Fuel pump relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
P1240 Sensor reference voltage malfunction (throttle sensors, fuel tank pressure sensor) (ECM pins ECM to sensors reference voltage short circuit to ground, short circuit For sensor reference voltage circuit tests,
EM82-01; EM83-05) to high voltage, open circuit, high resistance Goto <<AC>>
.
TP sensor, APP sensor, FTP sensor failure(s)
P1241 Sensor reference voltage low (throttle sensors, fuel tank pressure sensor) (ECM pins EM82-01; ECM to sensors reference voltage short circuit to ground For sensor reference voltage circuit tests,
EM83-05) Goto <<AC>>
TP sensor, APP sensor, FTP sensor failure(s)
.
P1242 Sensor reference voltage high (throttle sensors, fuel tank pressure sensor) (ECM pins EM82-01; ECM to sensors reference voltage circuit open circuit, high resistance, For sensor reference voltage circuit tests,
EM83-05) short circuit to high voltage Goto <<AC>>
.
TP sensor, APP sensor, FTP sensor failure(s)
P1243 Sensor reference ground malfunction (throttle sensors, fuel tank pressure sensor, ECT sensor, ECM to sensors reference ground circuit open circuit, high resistance For sensor reference ground circuit tests,
IAT sensor) (ECM pins EM82-01; EM83-13) Goto <<AD>>
TP, APP, ECT, IAT, FTP sensor failure(s)
.
P1245 Engine crank signal low voltage Starter relay coil to ECM/BPM circuit open circuit For starter relay circuit tests,
Goto <<AE>>
.
P1246 Engine crank signal high voltage Starter relay coil to ECM/BPM circuit short circuit to B+ voltage For starter relay circuit tests,
Goto <<AE>>
BPM failure
.
P1250 Throttle valve return spring malfunction Throttle return spring failure (throttle failure) INSTALL a new throttle body. <<303-04>>
P1251 Throttle motor power relay malfunction Throttle motor power relay failure For throttle motor control circuit tests,
Goto <<AA>>
Throttle motor power relay to ECM circuit fault
.
Throttle motor power relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
P1254 Throttle 'limp-home' spring malfunction Throttle limp-home spring failure (throttle failure) INSTALL a new throttle body <<303-04>>
P1260 Security input malfunction KTM to ECM circuit short circuit, high resistance or open circuit For KTM to ECM circuit tests,
Goto <<AF>>
Loss of ignition switched power supply to the ECM, pin EM82-09 for
. Check the ignition supply to the ECM. Contact dealer technical support for information on security system.
greater than 16 milliseconds
KTM failure
Security system incorrectly configured (KTM/ECM)
P1313 Misfire rate catalyst damage, Right-hand cylinders. NOTE. This DTC will flag only when Refer to possible causes for P0300-P0308 Refer to actions for P0300-P0308
accompanied by a random or individual cylinder misfire DTC; P0300, P0301 to P0308
' ' P1314 Misfire rate catalyst damage, Left-hand cylinders. NOTE. This DTC will flag only when accompanied by a random or individual cylinder
misfire DTC; P0300 to P0308
' ' P1316 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308
P1340 Left-hand camshaft position (CMP) sensor circuit malfunction CMP sensor disconnected For Left-hand CMP sensor circuit tests,
Goto <<AG>>
CMP sensor gap incorrect/foreign matter on sensor face
.
CMP sensor sensing circuit open circuit, short circuit to ground, short
circuit to high voltage
CMP sensor failure
P1341 Left-hand camshaft position (CMP) sensor range/performance (CMP sensor pulse not detected) CMP sensor disconnected For Left-hand CMP sensor circuit tests,
Goto <<AG>>
CMP sensor gap incorrect/foreign matter on sensor face
.
CMP sensor sensing circuit open circuit, short circuit to ground, short
circuit to high voltage
CMP sensor failure
2012-07-19
1999 XK RANGE - Electronic Engine Controls - 303-14
P1367 Ignition monitor; Group 1 Cylinders 1, 4, 6, and 7 Ignition monitoring circuit between splice and ECM open circuit, short For ignition system pinpoint tests, <<303-07>>
circuit to ground or short circuit to B+ voltage
Ignition coil group ground circuit fault
Ignition coil relay failure
P1368 Ignition monitor; Group 2 Cylinders 2, 3, 5, and 8 Ignition monitoring circuit between splice and ECM open circuit, short For ignition system pinpoint tests, <<303-07>>
circuit to ground or short circuit to B+ voltage
Ignition coil group ground circuit fault
Ignition coil relay failure
P1384 Right-hand variable camshaft timing (VCT) oil control solenoid malfunction VCT solenoid valve to ECM PWM drive circuit fault For Right-hand VCT circuit tests,
Goto <<AH>>
VCT solenoid valve to ECM ground circuit fault
.
VCT solenoid failure
VCT oil flow fault
VCT/camshaft mechanical failure
P1396 Left-hand variable camshaft timing (VCT) oil control solenoid malfunction VCT solenoid valve to ECM PWM drive circuit fault For Right-hand VCT circuit tests,
Goto <<AG>>
VCT solenoid valve to ECM ground circuit fault
.
VCT solenoid failure
VCT oil flow fault
VCT/camshaft mechanical failure
P1516 Gear change PARK/NEUTRAL driving malfunction Gear selector cable setting incorrect Check selector cable adjustment. For TR sensor circuit tests,
Goto <<AJ>>
Transmission rotary switch (TR sensor) to ECM circuit open circuit or
.
high resistance
TR sensor failure
D-4 switch to TCM circuit open circuit or high resistance
D-4 switch fault
P1517 Engine PARK/NEUTRAL cranking malfunction Gear selector cable setting incorrect Check selector cable adjustment. For TR sensor circuit tests,
Goto <<AJ>>
TR sensor to ECM circuit open circuit or high resistance
.
TR sensor failure
P1571 Brake switch malfunction Brake switch to ECM circuit open circuit, short circuit to ground, high For cruise control pinpoint tests, <<310-03>>
resistance
Brake switch ignition switched ground circuit open circuit
Brake switch failure
Brake cancel switch to ECM circuit open circuit, short circuit to
ground, high resistance
Brake cancel switch to cruise control switch circuit open circuit, short
circuit to ground, high resistance
Brake cancel switch ignition switched power supply open circuit
Brake cancel switch failure
Cruise control switch failure
P1582 Throttle monitor data available or inertia switch malfunction DTC indicates that the inertia switch has tripped (vehicle impact) If no For inertia switch fault circuit tests,
vehicle impact; Goto <<AK>>
.
Inertia switch to ECM circuit short circuit to ground
Inertia switch failure
P1606 Engine management system (EMS) control relay malfunction ECM control relay failure For ECM control relay circuit tests,
Goto <<AL>>
ECM control relay to ECM circuit fault
.
ECM control relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
P1609 ECM microprocessor-to-microprocessor communication failure ECM failure
P1611 ECM CPU 2 failure ECM failure Contact dealer technical support for advice on possible ECM failure
P1631 Throttle motor power relay coil activation circuit failure Throttle motor relay coil to ECM circuit open circuit, short circuit to For throttle motor relay circuit tests,
ground or short circuit to B+ voltage Goto <<AM>>
, and
ECM failure
Goto <<AN>>
.
P1633 ECM CPU 1 memory failure ECM failure Contact dealer technical support for advice on possible ECM failure
P1634 Throttle 'watchdog' circuit malfunction ECM failure Contact dealer technical support for advice on possible ECM failure
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P1637 CAN ABS/TCCM token missing CAN open circuit fault - ABS/TCCM to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
ABS/TCCM failure
ECM failure
P1638 CAN INST token missing CAN open circuit fault - INST to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
INST failure
ECM failure
P1642 CAN circuit malfunction CAN short circuit fault For network circuit tests, <<418-00>>
Control module failure - check for additional logged DTCs to locate
control module source
P1643 CAN TCM token missing CAN open circuit fault - TCM to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
TCM failure
ECM failure
P1646 ECM Right-hand HO2S control malfunction HO2S heater failure For Right-hand HO2S circuit tests,
Goto <<I>>
HO2S sensing circuit short circuit to ground or high voltage
.
HO2S sensing circuit open circuit
ECM failure
P1647 ECM Left-hand HO2S control malfunction HO2S heater failure For Left-hand HO2S circuit tests,
Goto <<J>>
HO2S sensing circuit short circuit to ground or high voltage
.
HO2S sensing circuit open circuit
ECM failure
P1648 ECM KS self-test failure ECM failure Contact dealer technical support for advice on possible ECM failure
P1649 ECM flash programming circuit malfunction ECM to DLC circuit, short circuit to ground or short circuit to battery For network circuit tests, <<418-00>>
voltage
P1656 Throttle position (TP) sensor amplifier circuit malfunction ECM failure Contact dealer technical support for advice on possible ECM failure
P1657 Throttle motor power relay coil circuit ON failure ECM failure Contact dealer technical support for advice on possible ECM failure
P1658 Throttle motor power relay ON failure Throttle motor power relay failure (contacts stuck on) For throttle motor relay circuit tests,
Goto <<AM>>
Throttle motor power relay to ECM coil circuit, short circuit to ground
, and
Throttle motor power relay to ECM supply circuit, short circuit to B+ Goto <<AN>>
voltage .
Pinpoint Tests
A : DTC P0101, P0102, P0103; MASS AIR FLOW (MAF) SENSOR RANGE/PERFORMANCE,
HIGH/LOW VOLTAGE
NOTE:
Before commencing this test, check the air filter for blockage, the engine air intake and breather systems for
leaks, and the TP sensor for additional DTCs.
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4. Measure the resistance between EM83, pin 28 (GY) and PI35, pin 03 (GY).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<A2>>
A2 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
INSTALL a new MAF sensor. CLEAR the DTC. TEST the system for normal operation.
B : DTC P0111, P0112, P0113; INTAKE AIR TEMPERATURE (IAT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
NOTE:
Before commencing this test, check the air filter for blockage and the engine air intake and breather systems for leaks.
B2 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between PI35, pin 04 (UP) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
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Goto <<B3>>
C : DTC P0116, P0117, P0118, P0125; ENGINE COOLANT TEMPERATURE (ECT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE,
RESPONSE
NOTE:
Before commencing this test, check the coolant level and condition, check the operation of the thermostat, rectify as necessary.
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C2 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
D : DTC P0121, P0122, P0123; THROTTLE POSITION (TP) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
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4. Measure the resistance between EM81, pin 10 (U) and PI06, pin 03 (U).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<D2>>
E : DTC P0131, P0132, P0133, P1646; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE/ECM CONTROL MALFUNCTION
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NOTE:
Before commencing this test, check the sensor connections and harness, check for exhaust leaks, engine misfire, etc. See 'visual inspection chart' and
'possible causes'.
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1. Measure the resistance between EM21, pin 04 (Y) and EM82, pin 10 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<E5>>
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-> 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.
F : DTC P0133, P0135, P1646; RIGHT-HAND H02S HEATER CIRCUIT MALFUNCTION/ECM CONTROL MALFUNCTION
F2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
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F3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
F4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
G : DTC P0137, P0138, P0140; RIGHT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY
G1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Disconnect the catalyst monitor sensor electrical connector, EM22.
3. Disconnect the ECM electrical connector, EM83.
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4. Measure the resistance between EM22, pin 04 (U) and EM83, pin 21 (U).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<G2>>
G2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between EM83, pin 21 (U) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<G3>>
G3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
G4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
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H2 : CHECK THE CATALYST MONITOR HEATER CONTROL CIRCUIT FOR HIGH RESISTANCE
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I : DTC P0151, P0152, P0153, P1647; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE/ECM CONTROL MALFUNCTION
NOTE:
Before commencing this test, check the sensor connections and harness, check for exhaust leaks, engine misfire, etc. See 'visual inspection chart' and
'possible causes'.
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-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<E3>>
1. Measure the resistance between EM23, pin 04 (W) and EM82, pin 11 (W).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<I5>>
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-> No
Goto <<I6>>
J : DTC P0153, P0155, P1647; LEFT-HAND H02S HEATER CIRCUIT MALFUNCTION/ECM CONTROL MALFUNCTION
J2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
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J3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between EM23, pin 01 (PS) and GROUND.
Is the voltage greater than 10 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<J4>>
J4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
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K2 : CHECK THE CATALYST MONITOR HEATER CONTROL CIRCUIT FOR HIGH RESISTANCE
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L : DTC P0196, P0197, P0198; ENGINE OIL TEMPERATURE (EOT) SENSOR RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
L2 : CHECK THE EOT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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M : DTC P0157, P0158, P0160; LEFT-HAND CATALYST MONITOR SENSOR LOW/HIGH VOLTAGE, NO ACTIVITY
M1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
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M2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
M3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
M4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
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-> No
INSTALL a new catalyst monitor sensor. CLEAR the DTC. TEST the system for normal operation.
N : DTC P0222, P0223; THROTTLE POSITION (TP) SENSOR CIRCUIT #2 LOW VOLTAGE
O : DTC P0327, P0328; RIGHT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
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NOTE:
Before commencing this test, make sure that the sensor is making a good electrical contact with the cylinder block. See 'possible causes'.
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P : DTC P0332, P0333; LEFT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW VOLTAGE)
NOTE:
Before commencing this test, make sure that the sensor is making a good electrical contact with the cylinder block. See 'possible causes'.
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-> No
Goto <<P3>>
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Goto <<Q3>>
-> No
CLEAN the sensor and wheel. INSTALL the sensor. Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
Q4 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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R : DTC P0340, P0341; RIGHT-HAND CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION
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R4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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S1 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR HIGH RESISTANCE
S2 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
S3 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO GROUND
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T1 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR HIGH RESISTANCE
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-> No
Goto <<S2>>
T2 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO HIGH VOLTAGE
T3 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT TO GROUND
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-> Yes
INSTALL a new radiator fan module. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal operation.
-> No
REPAIR the circuit between LF09, pin 08 (WP) and battery. This circuit includes the EMS fuse box, (fuse 12), the EMS relay, etc. For additional
information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
NOTE:
When checking the EMS switched supplies to the ECM in test P3, the EMS relay must be energised when testing EM10, pin 01 and EM14, pin 03.
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-> No
REPAIR the ignition switched power supply circuit. This circuit includes fuse 9 of the Right-Hand heelboard fuse box. For additional information, refer to
the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
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V2 : CHECK THE MAF SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
W : DTC P1121, P1122, P1123; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT '1' RANGE/PERFORMANCE, HIGH/LOW
VOLTAGE
W2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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-> No
Goto <<Y4>>
Z : DTC P1222, P1223; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT '2' RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
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4. Measure the resistance between EM81, pin 18 (R) and PI42, pin 02 (R).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<Z2>>
Z2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between PI42, pin 02 (R) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<Z3>>
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AA : DTC P1224, P1229, P1251; THROTTLE CONTROL POSITION SENSOR ERROR/THROTTLE MOTOR CONTROL CIRCUIT
MALFUNCTION/THROTTLE MOTOR POWER RELAY MALFUNCTION
NOTE:
Before commencing this test, check the TP sensor connections, perform the throttle adaptions procedure.
AA1 : CHECK THE TP SENSOR TO ECM SENSE CIRCUIT #1 FOR HIGH RESISTANCE
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AA4 : CHECK THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
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-> No
Goto <<AA5>>
AA6 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR HIGH RESISTANCE
AA7 : CHECK THROTTLE MOTOR TO ECM DRIVE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Measure the resistance between PI33, pin 02 (G) and EM80, pins 04 and 05 (G).
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AA8 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO HIGH VOLTAGE
AA9 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO GROUND
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AB1 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
AB2 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
AB3 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
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REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AB4>>
AB5 : CHECK THE FUEL PUMP RELAY IGNITION SWITCHED POWER SUPPLY
AB6 : CHECK THE FUEL PUMP RELAY ECM SWITCHED GROUND SUPPLY
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3. Check the resistance between the fuel pump relay base, pin 02 and GROUND.
Is the resistance greater than 5 ohm?
-> Yes
Contact dealer technical support for advice on possible ECM failure.
-> No
INSTALL a new fuel pump relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system for normal operation.
AC : DTC P1240, P1241, P1242; SENSOR REFERENCE VOLTAGE MALFUNCTION, HIGH/LOW VOLTAGE (THROTTLE SENSORS, APP
SENSOR, FTP SENSOR)
AC2 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
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Goto <<AC3>>
AC3 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AC4 : CHECK THE APP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
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Goto <<AC6>>
-> No
Goto <<AC7>>
AC6 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
AC7 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AC8 : CHECK THE TP SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
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-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AC9>>
AC9 : CHECK THE REFERENCE VOLTAGE AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the fuel tank pressure sensor electrical connector, FT02.
2. Reconnect the ECM electrical connector, EM83.
3. Turn the ignition switch to the ON position.
4. Measure the voltage between FT02, pin 03 (UW) and GROUND.
Is the voltage less than 5 volts?
-> Yes
Goto <<AC10>>
-> No
CHECK for DTCs associated with TP sensor, APP sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the
system for normal operation.
AC10 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH RESISTANCE
AC11 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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AC12 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position.
2. Measure the resistance between FT02, pin 03 (UW) and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
CHECK for DTCs associated with TP sensor, APP sensor, or FTP sensor. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the
system for normal operation.
AD : DTC P1243; SENSOR REFERENCE GROUND MALFUNCTION (THROTTLE SENSORS, FUEL TANK PRESSURE SENSOR, ECT
SENSOR, IAT SENSOR)
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Goto <<AD3>>
AD2 : CHECK THE THROTTLE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
AD4 : CHECK THE APP SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
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3. Measure the resistance between PI42, pin 03 (BG) and EM82, pin 07 (BG).
4. Measure the resistance between PI42, pin 03 (BG) and EM83, pin 13 (BG).
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AD5>>
AD5 : CHECK THE SENSOR REFERENCE GROUND AT THE FUEL TANK PRESSURE SENSOR
1. Disconnect the FTP sensor electrical connector, FT02.
2. Reconnect the ECM electrical connectors, EM82 and EM83.
3. Reconnect the battery negative terminal.
4. Measure the resistance between FT02, pin 01 (BG) and GROUND.
Is the resistance greater than 5 ohms?
-> Yes
Goto <<AD6>>
-> No
Goto <<AD7>>
AD6 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
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Goto <<AD7>>
AD8 : CHECK THE ECT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
AD9 : CHECK THE SENSOR REFERENCE GROUND AT THE IAT SENSOR (MAF)
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AD10 : CHECK THE IAT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Disconnect the ECM electrical connectors, EM82 and EM83.
3. Measure the resistance between PI35, pin 05 (BG) and EM82, pin 07 (BG).
4. Measure the resistance between PI35, pin 05 (BG) and EM83, pin 13 (BG).
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
CHECK for DTCs associated with TP sensor, APP sensor, FTP sensor , ECT sensor, IAT sensor. INSTALL a new sensor as indicated by the DTC.
CLEAR the DTC. TEST the system for normal operation.
AE1 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR SHORT TO B+
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REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AE2>>
AE2 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR HIGH RESISTANCE
NOTE:
This DTC can only be cleared following an ignition OFF/ON cycle after rectification. Attempts to clear without cycling the ignition will result in the DTC
reflagging 3-4 seconds after clearing.
NOTE:
P1260 can be flagged as a result of a time-out situation within the security system. If the engine cranks with P1260 flagged, clear the code and recheck the
DTCs.
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4. Measure the resistance between EM82, pin 16 (Y) and FC22, pin 17 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
INSTALL a new KTM. CLEAR the DTC. TEST the system for normal operation.
AG : DTC P1340, P1341; LEFT-HAND CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION
AG3 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
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AG4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AG5 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
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AH : DTC P0010, P1384; RIGHT-HAND VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID CIRCUIT OPEN/SHORT CIRCUIT
AH1 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR HIGH RESISTANCE
AH2 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO HIGH VOLTAGE
AH3 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO GROUND
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AH4 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Measure the resistance between PI31, pin 02 (RY) and EM81, pin 02 (RY).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AH5>>
AH5 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR SHORT TO HIGH VOLTAGE
AI : DTC P0020, P1396; LEFT-HAND VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID CIRCUIT OPEN/SHORT CIRCUIT
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AI1 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR HIGH RESISTANCE
AI2 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO HIGH VOLTAGE
AI3 : CHECK ECM TO VCT SOLENOID VALVE + CIRCUIT FOR SHORT TO GROUND
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REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AI4>>
AI4 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR HIGH RESISTANCE
AI5 : CHECK ECM TO VCT SOLENOID VALVE - CIRCUIT FOR SHORT TO HIGH VOLTAGE
AJ1 : CHECK THE TRANSMISSION RANGE (TR) SENSOR TO ECM CIRCUIT FOR HIGH RESISTANCE
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AJ2 : CHECK THE TRANSMISSION RANGE (TR) SENSOR PARK/NEUTRAL SWITCHING ACTION
AJ3 : CHECK THE D-4 SWITCH TO TCM CIRCUIT FOR HIGH RESISTANCE
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AK1 : CHECK THE INERTIA SWITCH TO ECM CIRCUIT FOR SHORT CIRCUIT TO GROUND
AL2 : CHECK THE EMS RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
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AM : DTC P1631; THROTTLE MOTOR POWER RELAY COIL ACTIVATION CIRCUIT FAILURE
AM1 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Remove the throttle motor relay.
3. Disconnect the ECM electrical connector, EM80.
4. Measure the resistance between the throttle motor relay base, pin 05 and EM80, pins 08 and 09.
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AM2>>
AM2 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
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-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<AM3>>
AM3 : CHECK THE THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position.
2. Measure the resistance between the throttle motor relay base, pin 05 and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
-> No
INSTALL a new throttle body. <<303-04>> CLEAR the DTC. TEST the system for normal operation.
NOTE:
Before beginning this test, make sure the relay contacts are not stuck on.
AN1 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR HIGH RESISTANCE
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AN2 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR SHORT TO HIGH VOLTAGE
AN3 : CHECK THE THROTTLE MOTOR RELAY TO ECM COIL CIRCUIT FOR SHORT TO GROUND
AN4 : CHECK THE THROTTLE MOTOR RELAY TO ECM SUPPLY CIRCUIT FOR SHORT TO BATTERY +
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2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
Mechanical Electrical
Engine oil level Fuses
Cooling system coolant Wiring harness
level
Electrical connector(s)
Fuel Contamination
Sensor(s)
Throttle body
Engine control module (ECM)
Poly-vee belt
Transmission control module
Check spark plug type. Only resisted plugs should be fitted. Refer to
specifications section for gap
Relay date codes. If the date on the relay is between R6 k1 and R6 k8, replace
the relay
6. 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.)
7. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use 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:
If the DTC flagged was not present for two or more consecutive cycles, it is classed as temporary, and will be
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deleted following three cycles during which no fault was present. This could result in a reported warning
light/message with no stored DTCs. If a fault is present for three consecutive cycles, the DTC becomes
permanent, and will remain in the module's memory for 40 drive cycles. (A cycle is an ignition ON/OFF, which
will occur during the owner's normal use of the vehicle. No action on the part of the technician is necessary to
perform this cycle. A drive cycle is a series of conditions needed to make the on-board diagnostic routine run,
and may need a specific action on the part of the technician. See the DTC summaries for drive cycle routines)
8. 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.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit,
part number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Symptom Chart
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' Engine cranks and Rochester valve For rochester valve tests,
fires, but will not Goto <<BV>>
Fuel pump relay
start For fuel pump relay tests,
Throttle contaminated Goto <<BK>>
. Check bulletins for throttle cleaning
Purge valve
procedure. Check fuel pressure. Refer
Fuel pump to Technical service bulletins. For ECT
sensor tests,
Engine coolant
Goto <<AR>>
temperature (ECT) sensor
. For ignition system, <<303-07>>
Spark plugs fouled Check bulletins and service actions.
Cylinder compression
loss (short-term. Refer to
bulletin; 303-52)
Refer to service action
S491
Difficult to Difficult to start cold Throttle contaminated For Rochester valve test,
start Goto <<BV>>
Rochester valve
. For battery information, <<414-01>>
Blocked part-load Check bulletins for throttle cleaning
breather (service action procedure. Check fuel pressure. For
S474) ECT sensor circuit tests,
Goto <<AR>>
Cylinder compression
. For evaporative emissions tests,
loss (short-term. Refer to
<<303-13>> Refer to bulletins for
bulletin; 303-52)
compression information, and service
Fuel pump actions for part-load breather procedure
and compressions.
Battery
Engine coolant
temperature (ECT) sensor
Purge valve
Refer to service action
S491
' Difficult to start hot Rochester valve For Rochester valve test,
Goto <<BV>>
Throttle contaminated
. For evaporative emissions tests,
Injector leak <<303-13>> Check bulletins for throttle
cleaning procedure. Check fuel
Purge valve
pressure. For ECT sensor circuit tests,
Fuel pump Goto <<AR>>
. Refer to Service action S474 for
Engine coolant
part-load breather procedure. For
temperature (ECT) sensor
injector leak test, Refer to technical
Blocked part-load service bulletin 303-39.
breather (service action
S474)
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' Engine stalls on Throttle contaminated Check bulletins for throttle cleaning
overrun procedure. Check relay dates. For ECM
ECM relay
relay tests,
Fuel pump relay Goto <<BT>>
. For fuel pump relay tests,
CMP/CKP sensor
Goto <<BK>>
synchronization
. For CMP sensor circuit tests,
malfunction
Goto <<BD>>
, for CKP sensor circuit tests,
Goto <<BC>>
.
' Engine stalls at steady Throttle contaminated Check bulletins for throttle cleaning
speed, with or without procedure. Check relay dates. For ECM
ECM relay
cruise enabled relay circuit tests,
Fuel pump relay Goto <<BT>>
. For fuel pump relay circuit tests,
CMP/CKP sensor
Goto <<BK>>
synchronization
. For CMP sensor circuit tests,
malfunction
Goto <<BD>>
Harness , for CKP sensor circuit tests,
Goto <<BC>>
Blocked part-load
. Check service actions.
breather (service action
S474)
' Engine stalls when ECM relay Check relay dates. For ECM relay
maneuvering circuit tests,
Fuel pump relay
Goto <<BT>>
CMP/CKP sensor . For fuel pump relay circuit tests,
synchronization Goto <<BK>>
malfunction . For CMP sensor circuit tests,
Goto <<BD>>
, for CKP sensor circuit tests,
Goto <<BC>>
.
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Poor Engine hesitates/poor Exhaust gas recirculation Check fuel pressure. For EGR
driveability acceleration (EGR) where fitted information, <<303-08>> For intake
system information, <<303-12>> For
Fuel pump
stop lamp switch information, refer to
Air leakage the wiring diagrams. For throttle position
sensor tests,
Spark plugs fouled
Goto <<AS>>
HT short to ground . For throttle motor control circuit tests,
(tracking) check rubber Goto <<BI>>
boots for cracks/damage . For ignition system, <<303-07>> For
ECM circuit tests,
Ignition coil failure(s)
Goto <<BT>>
Throttle sensors .
Throttle motor
' Engine backfires Fuel pump Check fuel pressure. For intake system
information, <<303-12>> For MAF
Air leakage
sensor circuit tests,
MAF sensor Goto <<AP>>
. For HO2 sensor circuit tests, check for
HO2 sensors
DTC indicating which sensor and follow
Spark plugs indicated pinpoint test. For ignition
system, <<303-07>>
Check for water ingress
into spark plug wells (SC
only)
HT short to ground
(tracking) check rubber
boots for cracks/damage
Ignition coil failure(s)
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' Engine surges Air leakage For intake system, <<303-12>> Check
fuel pressure. For stop lamp
Fuel pump
information, refer to the wiring
Stop lamp switch diagrams. For MAF sensor tests,
Goto <<AP>>
MAF sensor
. For throttle position sensor tests,
Harness Goto <<AS>>
, and
Throttle sensors
Goto <<AZ>>
Throttle motor . For throttle motor circuit tests,
Goto <<BI>>
Spark plugs
. For ignition system, <<303-07>> For
Check for water ingress ECM circuit tests,
into spark plug wells (SC Goto <<BT>>
only) .
HT short to ground
(tracking) check rubber
boots for cracks/damage
ECM failure
' Engine Fuel pump Check fuel pressure. For HO2 sensor
detonates/knocks circuit tests, check for DTC indicating
HO2 sensors
which sensor and follow indicated
Air leakage pinpoint test. For intake system
information, <<303-12>> Check service
Blocked part-load
action S474. For MAF sensor tests,
breather (service action
Goto <<AP>>
S474)
.
Mass air flow (MAF)
sensor
' No throttle response Traction control invoked For throttle position sensor tests,
Goto <<AS>>
Throttle sensors
, and
Throttle motor Goto <<AZ>>
. For throttle motor circuit tests,
Goto <<BI>>
.
' Cruise control inhibited Cruise control switch For cruise control switches,
or disabled <<310-03>> For throttle position sensor
Throttle sensors
tests,
Stop lamp switch Goto <<AS>>
, and
Goto <<AZ>>
. For stop light switch information, refer
to the wiring diagrams.
NOTE:
For definitions of Default Modes, see the foot of this table.
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No electronic throttle operation. (Mechanical operation for last quarter of pedal travel)
Maximum 25° throttle opening, depending on adjustment of throttle mechanical linkage.
Engine speed restricted to 3000 RPM maximum, by fuel cut-off.
High idle speed. (1200 RPM approx.)
Misfire at idle, due to cylinder cut as a means of controlling idle speed. (The misfire will switch cylinders,
as the strategy varies the cylinder cut)
Cruise Control Inhibited
REVERSE THROTTLE PROGRESSION ENABLED
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P0131 Right-hand H02S sense circuit low voltage H02S disconnected For Right-hand HO2S circuit tests,
Goto <<AT>>
H02S to ECM wiring open circuit
H02S short circuit to ground
H02S failure
P0132 Right-hand H02S sense circuit high voltage H02S sensing circuit short circuit to high voltage For Right-hand HO2S circuit tests,
Goto <<AT>>
H02S ground braided shield open circuit
H02S failure
P0133 Right-hand H02S sense circuit slow response Engine misfire Check for 'engine misfire detected' DTCs. For HO2S circuit tests,
Goto <<AT>>
H02S disconnected
.
H02S mechanical damage Goto <<AU>>
. Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
H02S to ECM wiring intermittent open circuit
H02S sensing circuit short circuit to high voltage
H02S short circuit to ground
H02S ground braided shield open circuit
H02S heater circuit fault
Exhaust leak
Low exhaust temperature
Injector flow partially blocked
Catalyst efficiency decrease
H02S failure
P0135 Right-hand H02S heater circuit malfunction H02S disconnected For Right-hand HO2S heater circuit tests,
Goto <<AU>>
H02S heater power supply open circuit
H02S heater to ECM wiring short circuit or open circuit
H02S heater failure
P0137 Right-hand catalyst monitor sensor sense circuit low voltage Catalyst monitor sensor disconnected For Right-hand catalyst monitor sensor circuit tests,
Goto <<AV>>
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor failure
P0138 Right-hand catalyst monitor sensor sense circuit high voltage Catalyst monitor sensor sensing circuit short circuit to high voltage For Right-hand catalyst monitor sensor circuit tests,
Goto <<AV>>
Catalyst monitor sensor ground braided shield open circuit
Catalyst monitor sensor failure
P0140 Right-hand catalyst monitor sensor sense circuit no activity Catalyst monitor sensor disconnected For Right-hand catalyst monitor sensor circuit tests,
Goto <<AV>>
Catalyst monitor sensor mechanical damage
Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor sensing circuit short circuit to high voltage
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor ground braided shield open circuit
Exhaust leak
Low exhaust temperature
Catalyst monitor sensor failure
P0151 Left-hand H02S sense circuit low voltage H02S disconnected For Left-hand HO2S circuit tests,
Goto <<AW>>
H02S to ECM wiring open circuit
H02S short circuit to ground
H02S failure
P0152 Left-hand H02S sense circuit high voltage H02S sensing circuit short circuit to high voltage For Left-hand HO2S circuit tests,
Goto <<AW>>
H02S ground braided shield open circuit
H02S failure
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P0153 Left-hand H02S sense circuit slow response Engine misfire Check for 'engine misfire detected' DTCs. For HO2S circuit tests,
Goto <<AW>>
H02S disconnected
Check for exhaust leaks, <<309-00>> Check injectors, <<303-04>>
H02S mechanical damage
H02S to ECM wiring intermittent open circuit
H02S sensing circuit short circuit to high voltage
H02S short circuit to ground
H02S ground braided shield open circuit
H02S heater circuit fault
Exhaust leak
Low exhaust temperature
Injector flow partially blocked
Catalyst efficiency decrease
H02S failure
P0155 Left-hand H02S heater circuit malfunction H02S disconnected For Left-hand HO2S heater circuit tests,
Goto <<AX>>
H02S heater power supply open circuit
H02S heater to ECM wiring short circuit or open circuit
H02S heater failure
P0157 Left-hand catalyst monitor sensor sense circuit low voltage Catalyst monitor sensor disconnected For Left-hand catalyst monitor sensor circuit tests,
Goto <<AY>>
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor failure
P0158 Left-hand catalyst monitor sensor sense circuit high voltage Catalyst monitor sensor sensing circuit short circuit to high voltage For Left-hand catalyst monitor sensor circuit tests,
Goto <<AY>>
Catalyst monitor sensor ground braided shield open circuit
Catalyst monitor sensor failure
P0160 Left-hand catalyst monitor sensor sense circuit no activity Catalyst monitor sensor disconnected For Left-hand catalyst monitor sensor circuit tests,
Goto <<AY>>
Catalyst monitor sensor mechanical damage
Check for exhaust leaks, <<309-00>>
Catalyst monitor sensor to ECM wiring open circuit
Catalyst monitor sensor sensing circuit short circuit to high voltage
Catalyst monitor sensor short circuit to ground
Catalyst monitor sensor ground braided shield open circuit
Exhaust leak
Low exhaust temperature
Catalyst monitor sensor failure
P0171 Right-hand cylinders combustion too lean Air intake leak between MAF sensor and throttle Check air intake system for leaks, <<303-12>> Check the fuel filter, <<310-01>> Check the fuel injectors and fuel pressure regulator,
<<303-04>> Check the fuel pressure. Check the exhaust system for leaks, <<309-00>> Refer to pinpoint tests for sensors listed.
Air leak via other systems
Fuel pressure regulator failure (low fuel pressure)
Fuel filter system blockage
Fuel injector blockage
Exhaust leak (before catalyst)
Low fuel pump output
H02S harness wiring fault
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP.
P0172 Right-hand cylinders combustion too rich Engine misfire Check for 'engine misfire detected' DTCs. Check the air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel
injectors and fuel pressure regulator, <<303-04>> Refer to pinpoint tests for sensors listed.
Fuel pressure regulator failure (high fuel pressure)
Leaking fuel injector(s)
Blocked air filter
Fuel system return blockage
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP.
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P0174 Left-hand cylinders combustion too lean Air intake leak between MAF sensor and throttle Check the eir intake system for leaks, <<303-12>> Check the fuel filter, <<310-01>> Check the fuel injectors and fuel pressure regulator,
<<303-04>> Check the fuel pressure. For HO2S circuit tests,
Air leak via other systems
Goto <<AW>>
Fuel pressure regulator failure (low fuel pressure) , and
Goto <<AX>>
Fuel filter system blockage
. Check the exhaust system for leaks, <<309-00>> Refer to pinpoint tests for sensors listed.
Fuel injector blockage
Exhaust leak (before catalyst)
Low fuel pump output
H02S harness wiring fault
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP.
P0175 Left-hand cylinders combustion too rich Engine misfire Check for 'engine misfire detected' DTCs. Check air filter element, <<303-12>> Check the fuel lines, <<310-01>> Check the fuel injectors
and fuel pressure regulator, <<303-04>> Refer to pinpoint tests for sensors listed.
Fuel pressure regulator failure (high fuel pressure)
Leaking fuel injector(s)
Blocked air filter
Fuel system return blockage
ECM receiving incorrect signal from one or more of the following
sensors - ECT, MAF, IAT, TP.
P0201 Fuel injector circuit malfunction, Cyl 1 Injector disconnected For fuel injector circuit tests, <<303-04>>
Injector wiring open or short circuit
Injector failure
' ' P0202 Fuel injector circuit malfunction, Cyl 3
' ' P0203 Fuel injector circuit malfunction, Cyl 5
' ' P0204 Fuel injector circuit malfunction, Cyl 7
' ' P0205 Fuel injector circuit malfunction, Cyl 2
' ' P0206 Fuel injector circuit malfunction, Cyl 4
' ' P0207 Fuel injector circuit malfunction, Cyl 6
' ' P0208 Fuel injector circuit malfunction, Cyl 8
P0222 Throttle position (TP) sensor circuit 2 low voltage TP sensor to ECM sensing circuit 2 (TP sensor pin 2) open circuit For TP sensor circuit tests,
or high resistance Goto <<AZ>>
TP sensor failure
P0223 Throttle position (TP) sensor circuit 2 high voltage TP sensor to ECM sensing circuit 2 (TP sensor pin 2) short circuit For TP sensor circuit tests,
to battery voltage Goto <<AZ>>
TP sensor failure
P0300 Random misfire detected ECM to ignition module primary circuit faults (cylinder misfire For ignition circuit tests, <<303-07>> For engine information, <<303-00>> For fuel system information, <<303-04>>
detected DTCs also logged)
Ignition module to ignition coil primary circuit fault(s) (cylinder
misfire DTC also logged)
Ignition module ground circuit; open circuit, high resistance
Ignition coil failure(s)
Ignition module failure(s)
Check for water ingress into spark plug wells
HT short to ground (tracking) check rubber boots for
cracks/damage
Spark plug failure/fouled/incorrect gap
Cylinder compression low
Fuel injector circuit fault(s) [injector DTCs also logged]
Fuel delivery pressure (low/high)
Fuel injectors restricted/leaking
Fuel contamination
P0301 Misfire detected, Cyl 1 Refer to possible sources for P0300 Refer to actions for P0300
' ' P0302 Misfire detected, Cyl 3
' ' P0303 Misfire detected, Cyl 5
' ' P0304 Misfire detected, Cyl 7
' ' P0305 Misfire detected, Cyl 2
' ' P0306 Misfire detected, Cyl 4
' ' P0307 Misfire detected, Cyl 6
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P0442 Evaporative emissions system (EVAP) leak detected Fuel filler cap missing For evaporative emissions pinpoint tests, <<303-13>>
Fuel filler cap seal faulty
EVAP system leak (canister damage, pipework damage)
EVAP valve to ECM drive circuit open circuit, short circuit, high
resistance
EVAP valve to engine purge pipe damaged/blocked/leaking
EVAP operating vacuum hose leak/blockage
EVAP valve failure
P0444 Evaporative emissions system (EVAP) valve circuit open circuit EVAP to ECM drive circuit open circuit or high resistance For evaporative emissions pinpoint tests, <<303-13>>
EVAP failure
P0445 Evaporative emissions system (EVAP) valve circuit short circuit EVAP to ECM drive circuit short circuit to ground For evaporative emissions pinpoint tests, <<303-13>>
EVAP failure
P0447 Canister close valve (CCV) circuit open circuit CCV to ECM drive circuit open circuit, high resistance or short For evaporative emissions pinpoint tests, <<303-13>>
circuit to ground
EVAP failure
P0448 Canister close valve (CCV) circuit short circuit CCV to ECM drive circuit short circuit to high voltage For evaporative emissions pinpoint tests, <<303-13>>
CCV failure
P0452 Fuel tank pressure (FTP) sensor circuit low voltage FTP sensor disconnected For evaporative emissions pinpoint tests, <<303-13>>
FTP sensor to ECM sense circuit open circuit or short circuit to
ground
FTP sensor to ECM power supply circuit open circuit or short
circuit to ground
FTP sensor failure
P0453 Fuel tank pressure (FTP) sensor circuit high voltage FTP sensor to ECM signal ground circuit open circuit <<303-13>>
FTP sensor to ECM wiring (supply, sense, signal, ground) short
circuit to each other
FTP sensor to ECM sense circuit short circuit to high voltage
FTP sensor failure
P0460 Fuel level sense signal performance Fuel level sensor to instrument cluster circuits intermittent short or For fuel level sensor circuit tests, <<303-04>>
open circuit
Fuel level sensor failure
Instrument cluster fault (incorrect fuel level reading)
P0506 Idle RPM lower than expected Air intake blockage Check the air intake system. <<303-12>> Check the accessory drive components, <<303-05>> For throttle body information, <<303-04>>
Accessory drive overload (defective/siezed component)
Throttle valve stuck closed
Throttle assembly failure
P0507 Idle RPM higher than expected Intake air leak between MAF sensor and throttle Check the air intake system. <<303-12>> Check the engine breather system, <<303-08>> For cruise control information, <<310-03>> For
throttle body information, <<303-04>>
Intake air leak between throttle and engine
Engine breather leak
Cruise control vacuum failure
Throttle valve stuck open
Throttle assembly failure
P0560 Vehicle voltage malfunction ECM battery power supply open circuit, high resistance For ECM power supply circuit tests,
Goto <<BE>>
P0566 Cruise control CANCEL switch ON fault Cruise control switches internal steering wheel short circuit to For cruise control circuit tests, <<310-03>>
ground
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
CANCEL switch failure (stuck ON)
P0567 Cruise control RESUME switch ON fault Cruise control switches internal steering wheel short circuit to For cruise control circuit tests, <<310-03>>
ground
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
RESUME switch failure (stuck ON)
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P0568 Cruise control switch ground malfunction Cruise control switches internal steering wheel open circuit For cruise control circuit tests, <<310-03>>
Steering wheel cassette reel open circuit or high resistance
Cassette reel to ECM circuit ACCEL/DECEL open circuit or high
resistance
ACCEL/DECEL switch failure
P0569 Cruise control DECEL/SET (SET-) switch ON fault Cruise control switches internal steering wheel short circuit to For cruise control circuit tests, <<310-03>>
ground
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
DECEL/SET switch failure (stuck ON)
P0570 Cruise control ACCEL/SET (SET+) switch ON fault Cruise control switches internal steering wheel short circuit to For cruise control circuit tests, <<310-03>>
ground
Steering wheel cassette reel short circuit to ground
Cassette reel to ECM circuit short circuit to ground
ACCEL/SET switch failure (stuck ON)
P0603 ECM data corrupted ECM failure Contact dealer technical support for advice on possible ECM failure.
P1000 System checks not complete since last memory clear OBD diagnostic monitors have not completed Carry out comprehensive component monitor drive cycle. Refer to the DTC section of JTIS, accessed by the icon on the opening page.
P1104 Mass air flow (MAF) sensor ground malfunction MAF sensor to ECM reference ground circuit open circuit, short For MAF sensor circuit tests,
circuit to high voltage, high resistance Goto <<AP>>
MAF sensor to ECM sensing circuit open circuit
MAF sensor failure
P1111 System checks complete since last memory clear OBD diagnostic monitors have completed No action necessary
P1112 Intake air temperature (IAT) sensor 2 sense circuit high voltage (low charge air temperature) IAT sensor 2 disconnected For IAT sensor 2 circuit tests,
Goto <<BF>>
IAT sensor 2 to ECM sensing circuit high resistance, open circuit
or short circuit to high voltage
IAT sensor 2 failure
P1113 Intake air temperature (IAT) sensor 2 sense circuit low voltage (high charge air temperature) Supercharger intercooler failure For IAT sensor 2 circuit tests,
Goto <<BF>>
IAT sensor 2 to ECM sensing circuit short circuit to ground
IAT sensor 2 failure
P1121 Accelerator pedal position (APP) sensor circuit 'A' range/performance APP sensor to ECM sense circuit 'A' (sensor pin 5) open circuit, For APP sensor circuit tests,
short circuit or high resistance Goto <<BG>>
Sensor power supply fault
Sensor reference ground fault
APP sensor failure
P1122 Accelerator pedal position (APP) sensor circuit 'A' low voltage APP sensor to ECM sense circuit 'A' (sensor pin 5) open circuit or For APP sensor circuit tests,
high resistance Goto <<BG>>
Sensor power supply fault
APP sensor failure
P1123 Accelerator pedal position (APP) sensor circuit 'A' high voltage APP sensor to ECM sense circuit 'A' (sensor pin 5) short circuit to For APP sensor circuit tests,
high voltage Goto <<BG>>
APP sensor failure
P1221 Accelerator pedal position (APP) sensor circuit 'B' range/performance APP sensor to ECM sense circuit 'B' (sensor pin 3) open circuit, For APP sensor circuit tests,
short circuit or high resistance Goto <<BH>>
Sensor power supply fault
Sensor reference ground fault
APP sensor failure
P1222 Accelerator pedal position (APP) sensor circuit 'B' low voltage APP sensor to ECM sense circuit 'B' (sensor pin 3) open circuit or For APP sensor circuit tests,
high resistance Goto <<BH>>
Sensor power supply fault
APP sensor failure
P1223 Accelerator pedal position (APP) sensor circuit 'B' high voltage APP sensor to ECM sense circuit 'B' (sensor pin 3) short circuit to For APP sensor circuit tests,
high voltage Goto <<BH>>
APP sensor failure
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P1224 Throttle control position error Throttle position adaptations not performed after battery Carry out throttle adaptation procedure. For TP sensor circuit tests,
disconnect Goto <<AS>>
, and
TP sensor disconnected
Goto <<AZ>>
TP sensor to ECM sense circuits open circuit, high resistance . For throttle motor circuit tests,
Goto <<BI>>
Throttle motor power relay failure
. For throttle body information, <<303-04>>
Throttle motor power relay to ECM circuit fault
Throttle motor power relay power supply open circuit
ECM ground circuit fault (relay coil drive)
Throttle motor to ECM drive circuits open circuit, short circuit, high
resistance
Throttle motor failure
Throttle assembly failure
P1226 Mechanical guard sensor range/performance Mechanical guard sensor to ECM sense circuit open circuit, short For mechanical guard circuit tests,
circuit or high resistance Goto <<BJ>>
. For sensor power supply circuit tests,
Sensor power supply fault
Goto <<BL>>
Sensor reference ground fault . For sensor ground circuit tests,
Goto <<BM>>
Mechanical guard sensor failure
. For throttle body information, <<303-04>>
Mechanical guard actuator seized/spring broken
P1227 Mechanical guard sensor circuit low voltage Mechanical guard sensor to ECM sense circuit open circuit or high For mechanical guard circuit tests,
resistance Goto <<BJ>>
. For sensor power supply circuit tests,
Sensor power supply fault
Goto <<BL>>
Mechanical guard sensor failure . For throttle body information, <<303-04>>
P1228 Mechanical guard sensor circuit high voltage Mechanical guard sensor to ECM sense circuit short circuit to high For mechanical guard circuit tests,
voltage Goto <<BJ>>
. For throttle body information, <<303-04>>
Mechanical guard sensor failure
P1229 Throttle motor control circuit mallfunction Throttle motor disconnected For throttle motor circuit tests,
Goto <<BI>>
Throttle motor to ECM drive circuits short circuit or open circuit
.
Throttle motor failure
P1230 Fuel pump relay malfunction. NOTE. This DTC covers the S/C system fuel pump 1 Fuel pump relay failure For fuel pump relay circuit tests,
Goto <<BK>>
Fuel pump to ECM circuit fault
Fuel pump relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
P1235 Vacuum switching valve (VSV) 1 circuit range/performance (mechanical guard position) Vacuum leak/blockage between the throttle elbow and the throttle Carry out mechanical checks for vacuum leak/blockage, failed vacuum actuator, and broken/siezed actuator spring
vacuum actuator
Vacuum actuator failure
Mechanical guard actuator seized/spring broken
P1236 Vacuum switching valve (VSV) 1 (vacuum) circuit failure VSV 1 disconnected For VSV tests, <<310-03>>
VSV 1 to ECM drive circuit high resistance, open circuit or short
circuit
VSV 1 power supply open circuit
VSV 1 failure
P1237 Vacuum switching valve (VSV) 2 (atmosphere) circuit failure VSV 2 disconnected For VSV tests, <<310-03>>
VSV 2 to ECM drive circuit high resistance, open circuit or short
circuit
VSV 2 power supply open circuit
VSV 2 failure
P1238 Vacuum switching valve (VSV) 3 (release) circuit failure VSV 3 disconnected For VSV tests, <<310-03>>
VSV 3 to ECM drive circuit high resistance, open circuit or short
circuit
VSV 3 power supply open circuit
VSV 3 failure
P1240 Sensor reference voltage malfunction (throttle sensors, fuel tank pressure sensor) (ECM pins ECM to sensors reference voltage short circuit to ground, short For sensor reference voltage circuit tests,
EM10-21; EM11-8) circuit to high voltage, open circuit, high resistance Goto <<BL>>
.
TP sensor, pedal position and mechanical guard sensor(s), fuel
tank pressure sensor failure(s)
P1241 Sensor reference voltage low (throttle sensors, fuel tank pressure sensor) (ECM pins EM10-21; ECM to sensors reference voltage short circuit to ground For sensor reference voltage circuit tests,
EM11-8) Goto <<BL>>
TP sensor, APP and mechanical guard sensor(s), fuel tank
.
pressure sensor failure(s)
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P1242 Sensor reference voltage high (throttle sensors, fuel tank pressure sensor) (ECM pins EM10-21; ECM to sensors reference voltage circuit open circuit, high For sensor reference voltage circuit tests,
EM11-8) resistance, short circuit to high voltage Goto <<BL>>
.
TP sensor, APP and mechanical guard sensor(s), fuel tank
pressure sensor failure(s)
P1243 Sensor reference ground malfunction (throttle sensors, fuel tank pressure sensor, ECT sensor, IAT ECM to sensors reference ground circuit open circuit, high For sensor reference ground circuit tests,
sensor, IAT sensor 2) (ECM pins EM10-20; EM11-12) resistance Goto <<BM>>
.
Throttle sensors, fuel tank pressure sensor, ECT sensor, IAT
sensor, IAT sensor 2 failures
P1245 Engine crank signal low voltage Starter relay coil to ECM/BPM circuit open circuit For engine crank circuit tests,
Goto <<BN>>
.
P1246 Engine crank signal high voltage Starter relay coil to ECM/BPM circuit short circuit to B+ voltage For engine crank circuit tests,
Goto <<BN>>
BPM failure
.
P1250 Engine load malfunction Throttle valve spring failure Install a new throttle body, <<303-04>>
P1251 Throttle position malfunction (engine off) TP sensor to ECM wiring open circuit or high resistance For TP sensor circuit tests,
Goto <<AS>>
TP sensor to ECM sensing circuits ('1' or '2') short circuit to high
, and
voltage
Goto <<AZ>>
TP sensor failure . For throttle motor circuit tests,
Goto <<BI>>
Throttle motor disconnected
. For throttle body information, <<303-04>>
Throttle motor to ECM drive circuits short circuit or open circuit
Throttle motor failure
Throttle assembly failure
P1252 Mechanical guard position malfunction (cruise control) VSV 1, 2, 3 vacuum and/or electrical circuit fault(s) open circuit, See pinpoint tests for components listed.
short circuit or high resistance
Mechanical guard sensor to ECM sense circuit
Mechanical guard sensor failure
Mechanical guard actuator siezed/spring broken
Throttle vacuum actuator fault
P1253 Mechanical guard position malfunction (engine off) VSV 1, 2, 3 vacuum and/or electrical circuit fault(s) See pinpoint tests for components listed.
Mechanical guard sensor to ECM sense circuit
Mechanical guard sensor failure
Mechanical guard actuator siezed/spring broken
Throttle vacuum actuator fault
P1260 Security input malfunction KTM to ECM circuit short circuit, high resistance or open circuit For KTM circuit tests,
Goto <<BO>>
KTM failure
P1313 Misfire rate catalyst damage, Right-hand. NOTE. This DTC will flag only when accompanied by a Refer to possible causes for P0300-P0308 Refer to actions for P0300-P0308
random or individual cylinder misfire DTC; P0300, P0301 to P0304
' ' P1314 Misfire rate catalyst damage, Left-Hand. NOTE. This DTC will flag only when accompanied by a random or individual cylinder misfire
DTC; P0300 to P0308
' ' P1316 Misfire excess emission. NOTE. This DTC will flag only when accompanied by an individual cylinder misfire DTC; P0300 to P0308
P1336 Crankshaft position (CKP) sensor / camshaft position (CMP) sensor synchronization malfunction CKP sensor/CMP sensor disconnected For CKP sensor circuit tests,
Goto <<BC>>
CKP sensor/CMP sensor gap incorrect/foreign matter on sensor
. For CMP sensor circuit tests,
face
Goto <<BD>>
CKP sensor/CMP sensor sensing circuit open circuit, short circuit
to ground, short circuit to high voltage
CKP sensor/CMP sensor failure
P1367 Ignition monitor (ignition module 1) Ignition module 1 disconnected For ignition circuit tests, <<303-07>>
Ignition module 1 to ECM circuits open circuit, short circuit to
ground or short circuit to B+ voltage
Ignition module 1 ground circuit fault
Ignition coil relay failure
Ignition coil open/short circuit
Ignition module 1 failure
P1368 Ignition monitor (ignition module 2) Ignition module 2 disconnected For ignition circuit tests, <<303-07>>
Ignition module 2 to ECM circuits open circuit, short circuit to
ground or short circuit to B+ voltage
Ignition module 2 ground circuit fault
Ignition coil relay failure
Ignition coil open/short circuit
Ignition module 2 failure
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P1474 Intercooler coolant pump relay malfunction Intercooler pump relay failure For intercooler pump relay circuit tests,
Goto <<BP>>
Intercooler pump relay to ECM drive circuit fault
Intercooler pump relay coil ground circuit fault
ECM power supply fault
P1475 Radiator fans slow (series) circuit malfunction Radiator fan control relay module to ECM 'series' drive circuit For radiator fan series circuit tests,
(relay pin 9) fault Goto <<BQ>>
Relay coil ignition power supply open circuit
ECM ground circuit fault (relay coil drive)
ECT sensor circuit malfunction (refer to P0116)
P1476 Radiator fans fast (parallel) circuit malfunction Radiator fan control relay module to ECM 'parallel' drive circuit For radiator fan parallel circuit tests,
(relay pin 7) fault Goto <<BR>>
Relay coil ignition power supply open circuit
ECM ground circuit fault (relay coil drive)
ECT sensor circuit malfunction (refer to P0116)
P1516 Gear change PARK/NEUTRAL driving malfunction Transmission range (TR) sensor to ECM circuit open circuit or For PARK/NEUTRAL tests,
high resistance Goto <<BS>>
TR sensor failure
D-4 switch to TCM circuit open circuit or high resistance
D-4 switch fault
P1517 Engine PARK/NEUTRAL cranking malfunction Transmission range (TR) sensor to ECM circuit open circuit or For PARK/NEUTRAL tests,
high resistance Goto <<BS>>
TR sensor failure
P1571 Brake switch malfunction Brake switch to ECM circuit open circuit, short circuit to ground, For cruise control circuit tests, <<310-03>>
high resistance
Brake switch ignition switched ground circuit open circuit
Brake switch failure
Brake cancel switch to ECM circuit open circuit, short circuit to
ground, high resistance
Brake cancel switch to cruise control switch circuit open circuit,
short circuit to ground, high resistance
Brake cancel switch ignition switched power supply open circuit
Brake cancel switch failure
Cruise control switch failure
P1606 Engine management system (EMS) control relay malfunction ECM control relay failure For ECM relay circuit tests,
Goto <<BT>>
ECM control relay to ECM circuit fault
ECM control relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
P1609 ECM microprocessor-to-microprocessor communication failure ECM failure Contact dealer technical support for advice on possible ECM failure.
P1611 Throttle angle malfunction TP sensor circuit fault (refer to P0121) See pinpoint tests for components listed. For throttle body information, <<303-04>> Contact dealer technical support for advice on
possible ECM failure.
APP sensor circuit fault (refer to P0121)
Throttle assembly failure
ECM failure
P1612 Throttle offset malfunction TP sensor circuit fault (refer to P0121) See pinpoint tests for components listed. For throttle body information, <<303-04>> Contact dealer technical support for advice on
possible ECM failure.
APP sensor circuit fault (refer to P0121)
Throttle assembly failure
ECM failure
P1637 CAN ABS/TCCM token missing CAN open circuit fault - ABS/TCCM to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
ABS/TCCM failure
ECM failure
P1638 CAN INST token missing CAN open circuit fault - INST to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
INST failure
ECM failure
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P1642 CAN circuit malfunction CAN short circuit fault For network circuit tests, <<418-00>>
Control module failure - check for additional logged DTCs to
locate control module source
P1643 CAN TCM token missing CAN open circuit fault - TCM to ECM For network circuit tests, <<418-00>>
CAN short circuit fault
TCM failure
ECM failure
P1646 Fuel pump 2 relay malfunction. NOTE. This DTC applies only to the S/C fuel pump 2 Fuel pump 2 relay failure For fuel pump 2 relay circuit tests,
Goto <<BU>>
Fuel pump 2 relay to ECM circuit fault
Fuel pump 2 relay coil power supply open circuit
ECM ground circuit fault (relay coil drive)
Pinpoint Tests
AP : DTC P0101, P0102, P0103; MASS AIR FLOW (MAF) SENSOR RANGE/PERFORMANCE,
HIGH/LOW VOLTAGE
NOTE:
Before commencing this test, check the air filter for blockage, the engine air intake and breather systems for
leaks, and the TPS for additional DTCs.
AP1 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
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-> No
Goto <<AP2>>
AP2 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AP3 : CHECK THE MAF SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
NOTE:
The short to GROUND may be intermittent. Move the wiring to attempt to reproduce the conditions under
which the DTC was logged, and visually inspect the harness for any signs of chafing, see 'visual inspection
chart'.
AP5 : CHECK THE MAF SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE
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NOTE:
Before commencing this test, check the air filter for blockage and the engine air intake and breather systems
for leaks.
AQ1 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
AQ2 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AQ3 : CHECK THE IAT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
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NOTE:
Before commencing this test, check the coolant level and condition, check the operation of the thermostat,
rectify as necessary.
AR1 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
AR2 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AR3 : CHECK THE ECT SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
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-> No
INSTALL a new ECT sensor. <<303-03A>><<303-03B>> CLEAR the DTC. TEST the system for normal
operation.
AS2 : CHECK THE TP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
AT : DTC P0131, P0132, P0133; RIGHT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE
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NOTE:
Before commencing this test, check the sensor connections and harness, check for exhaust leaks, engine
misfire, etc. See 'visual inspection chart' and 'possible causes'.
AT2 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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-> Yes
REPAIR the circuit. (This is a braided lead which would require different repair techniques to standard
wiring). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
-> No
INSTALL a new H02S. CLEAR the DTC. TEST the system for normal operation.
AU2 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
AU3 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH
VOLTAGE
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AU4 : CHECK THE H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
AV1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
AV2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH
VOLTAGE
AV3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
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AV4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
AW : DTC P0151, P0152, P0153; LEFT-HAND H02S LOW/HIGH VOLTAGE, SLOW RESPONSE
NOTE:
Before commencing this test, check the sensor connections and harness, check for exhaust leaks, engine
misfire, etc. See 'visual inspection chart' and 'possible causes'.
AW2 : CHECK THE H02S SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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-> No
Goto <<AW3>>
AX2 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR HIGH RESISTANCE
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3. Measure the resistance between EM15, pin 01 (PS) and EM23, pin 01 (PS).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<AX3>>
AX3 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO HIGH VOLTAGE
AX4 : CHECK H02S HEATER CONTROL CIRCUIT FROM ECM FOR SHORT TO GROUND
AY1 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
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AY2 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO HIGH
VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between EM12, pin 16 (N) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<AY3>>
AY3 : CHECK THE CATALYST MONITOR SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
AY4 : CHECK THE CATALYST MONITOR SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
AZ : DTC P0222, P0223; THROTTLE POSITION (TP) SENSOR CIRCUIT 2 LOW VOLTAGE
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BA : DTC P0327, P0328; RIGHT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW
VOLTAGE)
NOTE:
Before commencing this test, make sure that the sensor is making a good electrical contact with the cylinder
block. See 'possible causes'.
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REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BA3>>
BB : DTC P0332, P0333; LEFT-HAND KNOCK SENSOR (KS) CIRCUIT OUT OF RANGE (LOW
VOLTAGE)
NOTE:
Before commencing this test, make sure that the sensor is making a good electrical contact with the cylinder
block. See 'possible causes'.
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BC3 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
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-> No
Goto <<BC4>>
BC4 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
BC5 : CHECK THE CKP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
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-> Yes
Goto <<BC3>>
-> No
CLEAN the sensor and wheel. INSTALL the sensor. CLEAR the DTCs. TEST the system for normal
operation.
BD3 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Disconnect the ECM electrical connector, EM13.
3. Measure the resistance between EM13, pin 20 (B) and PI15, pin 01 (B).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<BD3>>
BD4 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
BD5 : CHECK THE CMP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
NOTE:
When checking the EMS switched supplies to the ECM in test P3, the EMS relay must be energised when
testing EM10, pin 01 and EM14, pin 03.
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BF : DTC P1112, P1113; INTAKE AIR TEMPERATURE (IAT) SENSOR #2 SENSE CIRCUIT
HIGH/LOW VOLTAGE
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BF2 : CHECK IAT SENSOR 2 SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between PI03, pin 02 (UP) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BF3>>
BG : DTC P1121, P1122, P1123; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT 'A'
RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
BG1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
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-> No
Goto <<BG2>>
BG2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
BG3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
BG4 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE AT THE SENSOR
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BH : DTC P1221, P1222, P1223; ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT 'B'
RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
BH1 : CHECK THE APP SENSOR SENSE CIRCUIT FOR HIGH RESISTANCE
BH2 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
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BH3 : CHECK THE APP SENSOR SENSE CIRCUIT FOR SHORT TO GROUND
1. Turn the ignition switch to the OFF position.
2. Measure the resistance between PI42, pin 03 (R) and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BH4>>
BH4 : CHECK THE APP SENSOR COMMON REFERENCE VOLTAGE AT THE SENSOR
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NOTE:
Before commencing this test, check the TP sensor connections, perform the throttle adaptions procedure.
BI1 : CHECK THE TP SENSOR TO ECM SENSE CIRCUIT 1 FOR HIGH RESISTANCE
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-> Yes
Goto <<BI3>>
-> No
REPAIR the circuit. This circuit includes the EMS fuse box, fuse 09. For additional information, refer to
the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
BI4 : CHECK THROTTLE MOTOR RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
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BI6 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR HIGH RESISTANCE
BI7 : CHECK THROTTLE MOTOR TO ECM DRIVE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Measure the resistance between PI33, pin 02 (G) and EM14, pins 11 and 12 (G).
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<BI8>>
BI8 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO HIGH
VOLTAGE
BI9 : CHECK THROTTLE MOTOR TO ECM DRIVE SUPPLY CIRCUIT FOR SHORT TO GROUND
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INSTALL a new throttle motor. <<303-04>> CLEAR the DTC. TEST the system for normal operation.
BJ1 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR HIGH RESISTANCE
BJ2 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR SHORT TO HIGH VOLTAGE
BJ3 : CHECK THE MECHANICAL GUARD SENSE CIRCUIT FOR SHORT TO GROUND
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BK1 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the battery negative terminal.
2. Remove the fuel pump relay.
3. Disconnect the ECM electrical connector, EM13.
4. Measure the resistance between EM13, pin 01 (KN) and the relay base, pin 02.
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<BK2>>
BK2 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
BK3 : CHECK THE FUEL PUMP RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
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BK5 : CHECK THE FUEL PUMP RELAY IGNITION SWITCHED POWER SUPPLY
BK6 : CHECK THE FUEL PUMP RELAY ECM SWITCHED GROUND SUPPLY
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BL6 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR HIGH
RESISTANCE
BL7 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR
SHORT TO HIGH VOLTAGE
BL8 : CHECK THE THROTTLE POSITION SENSOR REFERENCE VOLTAGE CIRCUIT FOR
SHORT TO GROUND
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BL9 : CHECK THE REFERENCE VOLTAGE AT THE FUEL TANK PRESSURE SENSOR
BL10 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR
HIGH RESISTANCE
BL11 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR
SHORT TO HIGH VOLTAGE
BL12 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE VOLTAGE CIRCUIT FOR
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SHORT TO GROUND
1. Turn the ignition switch to the OFF position.
2. Measure the resistance between FP01, pin 03 (UW) and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
CHECK for DTCs associated with TP sensor,APP/mechanical guard sensor, or FTP sensor. INSTALL a
new sensor as indicated by the DTC. CLEAR the DTC. TEST the system for normal operation.
BM2 : CHECK THE THROTTLE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH
RESISTANCE
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Goto <<BM4>>
-> No
Goto <<BM5>>
BM5 : CHECK THE SENSOR REFERENCE GROUND AT THE FUEL TANK PRESSURE SENSOR
BM6 : CHECK THE FUEL TANK PRESSURE SENSOR REFERENCE GROUND CIRCUIT FOR HIGH
RESISTANCE
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BM8 : CHECK THE ECT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
BM9 : CHECK THE SENSOR REFERENCE GROUND AT THE IAT SENSOR (MAF)
BM10 : CHECK THE IAT SENSOR REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
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BM12 : CHECK THE IAT SENSOR #2 REFERENCE GROUND CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connectors, EM10 and EM11.
2. Measure the resistance between PI03, pin 01 (BG) and EM10, pin 20 (BG).
3. Measure the resistance between PI03, pin 01 (BG) and EM11, pin 12 (BG).
Is either resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
CHECK for DTCs associated with TPS, APP/mechanical guard sensor, FTP sensor, ECT sensor, IAT
sensor, or IAT sensor #2. INSTALL a new sensor as indicated by the DTC. CLEAR the DTC. TEST the
system for normal operation.
BN1 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR SHORT TO B+
1. Measure the voltage between the relay base, pin 02 and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BN2>>
BN2 : CHECK THE STARTER RELAY SIGNAL CIRCUIT FROM ECM AND BPM FOR HIGH
RESISTANCE
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REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
INSTALL a new BPM. CLEAR the DTC. TEST the system for normal operation.
NOTE:
Early production vehicles have connector pin numbers that differ from the volume production pin numbers
shown. Use the wire color code for pin identification on early production vehicles.
BP1 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR HIGH
RESISTANCE
BP2 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR SHORT TO HIGH
VOLTAGE
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-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BP3>>
BP3 : CHECK THE INTERCOOLER PUMP RELAY TO ECM DRIVE CIRCUIT FOR SHORT TO
GROUND
1. Turn the ignition switch to the OFF position.
2. Measure the resistance between the relay base, pin 01 and GROUND.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BP4>>
1. Measure the resistance between the relay base, pin 02 and GROUND.
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Check the ECM power supplies.
Goto <<BE>>
BQ1 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR HIGH
RESISTANCE
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BQ2 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO
HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between EM13, pin 15 (W) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BQ3>>
BQ3 : CHECK THE RADIATOR FAN MODULE TO ECM 'SERIES' DRIVE CIRCUIT FOR SHORT TO
GROUND
BR1 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR HIGH
RESISTANCE
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BR2 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT
TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between EM13, pin 16 (WU) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<BR3>>
BR3 : CHECK THE RADIATOR FAN MODULE TO ECM 'PARALLEL' DRIVE CIRCUIT FOR SHORT
TO GROUND
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14), the EMS relay, etc. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
BS1 : CHECK THE TRANSMISSION RANGE (TR) SENSOR TO ECM CIRCUIT FOR HIGH
RESISTANCE
BS2 : CHECK THE TRANSMISSION RANGE (TR) SENSOR PARK/NEUTRAL SWITCHING ACTION
BS3 : CHECK THE D-4 SWITCH TO TCM CIRCUIT FOR HIGH RESISTANCE
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BT2 : CHECK THE EMS RELAY TO ECM CIRCUIT FOR HIGH RESISTANCE
NOTE:
This DTC applies only to the supercharged system fuel pump 2.
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-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
INSTALL a new fuel pump 2 relay. CLEAR the DTC. TEST the system for normal operation.
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Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
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WARNING:
WASH HANDS THOROUGHLY AFTER 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 IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. NOTE:
Place an absorbent cloth under the fuel connection to absorb any spillages.
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NOTE:
Cap the fuel line and fuel injection supply manifold to prevent contamination.
5. Detach the fuel injector supply manifold from the retaining clip.
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6. Detach the fuel injector supply manifold from the intake manifold.
7. NOTE:
Cap the intake manifold injector ports.
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8. Detach the camshaft position (CMP) sensor wiring harness from the throttle body elbow.
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Installation
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3. Attach the CMP sensor wiring harness to the throttle body elbow.
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4. CAUTION:
Make sure the fuel injectors are correctly installed to the intake manifold. Failure to follow these
instructions may result in damage to the vehicle.
NOTE:
Install new fuel injector O-ring seals.
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7. NOTE:
Uncap the fuel line and fuel injection supply manifold.
NOTE:
Remove and dispose of absorbent cloth whilst complying to local health and safety standards.
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Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION.
WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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Installation
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3. CAUTION:
Make sure the fuel injectors are correctly installed to the lower intake manifold. Failure to follow
these instructions may result in damage to the vehicle.
NOTE:
Install new injector O-ring seals.
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3. Detach the camshaft position (CMP) sensor wiring harness from the throttle body elbow.
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Installation
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3. Attach the CMP sensor wiring harness to the throttle body elbow.
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Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELEASED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL IS TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION.
WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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Installation
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3. CAUTION:
Make sure the fuel injectors are correctly installed to the lower intake manifold. Failure to follow
these instructions may result in damage to the vehicle.
NOTE:
Install new injector O-ring seals.
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2. Release the catalyst monitor sensor electrical connector from the mounting bracket and disconnect.
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4. WARNING:
MAKE SURE THE COMPONENTS ARE COOL BEFORE REMOVING THE CATALYST MONITOR
SENSOR. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
Using the Snap-on tool S6176, remove the catalyst monitor sensor.
Installation
1. CAUTION:
Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this
instruction may result in damage to the vehicle.
To install, reverse the removal procedure.
Tighten to 45 Nm.
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2. NOTE:
Left-hand shown, right-hand similar.
Release the catalyst monitor sensor electrical connector from the mounting bracket and disconnect.
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3. WARNING:
MAKE SURE THE COMPONENTS ARE COOL BEFORE REMOVING THE CATALYST MONITOR
SENSOR. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
NOTE:
Left-hand shown, right-hand similar.
Using the Snap-on tool S6176, remove the catalyst monitor sensor.
Installation
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1. CAUTION:
Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this
instruction may result in damage to the vehicle.
NOTE:
Left-hand shown, right-hand similar.
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Installation
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
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Installation
1. NOTE:
A replacement ECM may only be obtained from an authorised Jaguar dealer and MUST be ordered
against the VIN.
NOTE:
Check condition of housing seals and replace as necessary.
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2. WARNING:
ENSURE THAT THE ENGINE IS COLD BEFORE COMMENCING WORK.
Slacken the coolant reservoir cap to relieve coolant pressure and re-tighten.
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Installation
1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used and
tighten the sensor as specified.
1. Fit the sensor and new sealing washer.
2. Connect the harness plug to the sensor.
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1. WARNING:
ENSURE THAT THE EXHAUST AND CATALYST ARE COLD BEFORE COMMENCING WORK
Disconnect the battery ground lead.
2. CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
From inside the engine compartment, release the relevant sensor(s) multiplug from its mounting bracket
and disconnect the plug.
3. To gain access to the sensor(s) the front muffler assembly must be displaced for clearance; refer to
<<30.10.18>>.
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4. CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
NOTE:
Right-hand shown, left-hand similar.
Installation
1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used.
2. CAUTION:
Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this
instruction may result in damage to the vehicle.
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NOTE:
Right-hand shown, left-hand similar.
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1. WARNING:
ENSURE THAT THE EXHAUST AND CATALYST ARE COLD BEFORE COMMENCING WORK
Disconnect the battery ground lead.
2. CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
NOTE:
Left-hand shown, right-hand similar.
From inside the engine compartment, release the relevant sensor(s) multiplug from its mounting bracket
and disconnect the plug.
3. To gain access to the sensor(s) the front muffler assembly must be displaced for clearance; refer to
<<30.10.18>>.
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4. CAUTION:
Make sure the wiring harness is not twisted or damaged on removal. Failure to follow this
instruction may result in damage to the vehicle.
Installation
1. Fitting is the reverse of the removal procedure, noting that a new sealing washer should be used.
2. CAUTION:
Make sure the wiring harness is not twisted or damaged on installation. Failure to follow this
instruction may result in damage to the vehicle.
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2. Remove sensor.
Remove sensor using a deep socket.
Discard sealing washer.
Installation
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5. CAUTION:
Make sure the KS is detached from the retaining stud before removal. Failure to follow this
instruction may result in damage to the vehicle.
Installation
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Installation
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4. CAUTION:
Make sure the KS is detached from the retaining stud before removal. Failure to follow this
instruction may result in damage to the vehicle.
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Installation
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Installation
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Installation
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Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Lubricants, Fluids, Sealants and Adhesives - ZF Automatic Transmission (Normally Aspirated Vehicles)
Unit Specification
Transmission fluid Esso ATF LT 71141
Torque converter spigot Molycote or equivalent
Unit Liters
Transmission fluid (with torque converter) 10,0
Component Nm
Locking ferrule - Shift knob 7 - 10
Plug - Drain fluid pan 27 - 33
Plug - Level / fill (transmission case M18 x 1.5) 32 - 38
Tube nut - Cooler pipe to transmission unit 17 - 23
Bolt - Drive plate to torque converter 43 - 57
Bolt - Driveshaft coupling to transmission 75 - 88
Bolt - Fluid filter to valve block 4,5 - 5,5
Bolt - Fluid pan to transmission case 9 - 11
Bolt - Rear extension housing to transmission case 21 - 25
Bolt - Rear engine (isolation) mounting to mounting bracket 22 - 28
Bolt - Rear engine mounting bracket to body 22 - 28
Bolt - Rear engine mounting bracket to transmission rear extension 30 - 40
Bolt - Selector cable bracket to transmission case 7 - 10
Bolt - Transmission unit to engine 43 - 57
Nut - Transmission drive flange 108 - 132
Nut - Selector cable inner to shift lever 1,5 - 2,5
Nut - Selector cable inner to selector lever 7 - 10
Nut - Selector cable outer to bracket 22 - 28
Nut - Selector lever pivot shaft 7 - 10
Nut - Shift interlock solenoid to housing 5-7
Nut - Shift interlock solenoid actuating lever 11 - 13
Screw - Input sensor bracket to transmission case (M5) 4,5 - 5,5
Screw - Output sensor bracket to transmission case (M6) 7,5 - 8,5
Screw - Solenoid / regulator plate to valve body 4,5 - 5,5
Screw - Valve block to transmission case 7,5 - 8,5
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Internal Gear Ratios - ZF Automatic Transmission (Normally Aspirated Vehicles)
Gear Ratio
1st 3,571:1
2nd 2,2:1
3rd 1,508:1
4th 1,00:1
5th 0,803:1
Reverse 4,063:1
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Syringe
Removal
2. NOTE:
This procedure will not remove residual fluid from the torque converter.
WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT
CAPACITY.
Carefully remove the drain plug and drain the transmission fluid.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
3. Refit the drain plug and tighten to the specified torque figure.
Use a new O-ring.
Installation
2. CAUTION:
It is essential that only the specified fluid is used.
Using a syringe dedicated to transmission fluid only (not used for any other type of oil or fluids), inject
transmission fluid until it overflows from the plug orifice.
Wait until the flow of fluid has reduced to a trickle.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
6. From above.
7. NOTE:
Ensure that the TCM is connected and functioning correctly.
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9. From below.
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CAUTION:
The fluid temperature MUST NOT exceed 50°C.
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11. Refit the filler / level plug and tighten to the specified torque figure.
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Transmission Description
Transmission Assembly
Introduction
Item Description
1 Torque converter housing
2 Transmission casing
3 Fluid pan
4 Transmission breather
5 Rear extension housing
6 16-way connector
7 Gear selector shaft
Component Descriptions
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Is located in the lower part of the unit, within the fluid pan.
Is controlled by the TCM (transmission control module), and the manual selector valve which is cable
operated.
Regulates the flow of fluid to the geartrain clutches via three solenoid-operated valves and the manual
selector valve.
Has five pressure regulators for controlling fluid pressures within the system.
Is connected to the TCM via a 16-way connector mounted on the left-hand side of the transmission
casing. Refer to Connector Pins Identification, Section <<307-01A>>.
The hydraulic system pump:
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Transmission Torque Converter
Operation
The Transmission Control Module (TCM) is able to monitor the state of the torque converter clutch at all times.
3. Slip control - The TCM monitors slip and may apply sufficient pressure to allow a small degree of slip.
This mode maximises economy by reducing slip to a minimum whilst providing isolation from drive-line shunt
and vibration.
The TCM constantly measures the slip within the torque converter by comparing engine speed (via CAN) and
input (turbine speed). Differences in these speeds indicate the amount of slip.
The TCM supplies an internally switched +12V supply to the #4 pressure regulator. The regulator is operated by
switching the other side of the operating winding to ground. Hydraulic pressure is controlled by 'pulse width
modulation' (PWM) of the ground switching signal i.e. the duty cycle; the time that the pressure regulator is
switched on.
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Item Description
1 Shift Solenoid #3
2 Shift Solenoid #2
3 Shift Solenoid #1
4 Pressure Regulator #5
5 Pressure Regulator #4
6 Pressure Regulator #3
7 Pressure Regulator #2
8 Pressure Regulator #1
Operation
Fluid flow within the transmission assembly is controlled by three solenoid valves and five pressure regulators.
The TCM supplies an internally switched +12V supply to each shift solenoid and pressure regulator. Hydraulic
pressure from the pressure regulators is controlled by 'pulse width modulation' (PWM) of the ground switching
signal i.e. the duty cycle; the time that the pressure regulator is switched on. Control of the solenoids is effected by
switching one side to ground through the TCM.
During normal operation the TCM monitors 'Switch On' of the solenoids, the regulators and the TCM output
stages, but does not check the output stage 'Switch Off'.
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Voltage is monitored at the regulators and solenoids for continuity and shorts. For example, when a solenoid is
ON the voltage on the TCM side should be ground, when OFF the voltage should be +12.
Shift Solenoid
The function of the three solenoid valves is to control the flow of transmission oil to the various transmission
components. Three solenoid valves are located within the transmission assembly, and are closed when not
energized.
Pressure Regulator
The function of the five pressure regulators is to modulate the oil pressure to the various transmission
components. The regulators are pulse width modulated by the TCM, switching to ground potential. The other side
of the regulators being connected, via an internal TCM relay, to battery voltage. The regulator is closed when not
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Operation
The transmission fluid temperature sensor is integrated into the internal harness within the fluid pan.
It should be noted that this component is not serviceable, necessitating the renewal of the internal harness should
a fault occur.
Following engine start-up, if the fluid temperature is < 20°C and does not increase by 10°C after 180 seconds, a
failure judgement is made. A similar judgement is made should the temperature change by more than 5°C in
<100 milliseconds. The MIL is illuminated if the failure judgement is made on two successive trips.
Sensor output is continuously monitored for out of range values. If a sustained high, or low input is sensed,
indicating a harness or connector fault, a failure judgement is made.
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Location of Sensor Within The Harness
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Operation
There are two speed sensors within the transmission assembly; one on the input shaft or convertor turbine and the
other on the output shaft.
Both sensors are of the inductive type and sense toothed wheels; the input wheel having 30 teeth and the output
36 teeth.
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Input speed is monitored by the TCM with a rationality check being made against output speed. A fault will be
flagged if the indicated input speed exceeds 7400 rpm. Additionally, a failure judgement will be made if the
indicated input speed is <160 rpm with engine speed >608 rpm and output speed >224 rpm
The procedure is similar for the output speed diagnostic. A fault (non OBDII) will be flagged if the indicated input
speed exceeds 6712 rpm. Additionally a failure judgement will be made if the indicated output speed is <160 rpm
and the average road wheel speed exceeds 100 rpm.
Under normal circumstances after the output speed diagnostic fault code has been set, the TCM uses rear wheel
speed information to compute its calculations, this has no effect on transmission operation. However, should a
second fault occur, in the ABS system, thus making rear wheel speed information unavailable, an additional fault
code will be logged.
Control Systems
Introduction
Gear selection is achieved by controlling the flow of transmission fluid to internal multi-disc clutches.
The three solenoid valves direct the transmission fluid flow to the selected clutches and the pressure regulators
control the fluid pressure to each component. One pressure regulator serves as a master pressure control for the
entire system and a second is used exclusively for torque converter clutch lock-up operation.
The TCM controls the internal components thus determining gear selection and shift pattern.
In the event of an electronic system fault the basic functions Park, Reverse Neutral and Drive Fourth are retained
by the hydraulic system.
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Transmission Control Module (TCM)
The TCM is located in the same housing as the ECM and is accessed in the same manner.
The TCM performs several 'self check' procedures to ensure correct operation. It is possible due to the nature of
these faults that the module will fail to communicate with other nodes. However, condemnation of the TCM should
not take place until any CAN or power supply related problems have been resolved.
1. Check on ROM by calculating a checksum and comparing this with a known stored value.
2. Check on non-volatile diagnostic memory by writing a test pattern and then reading it back.
A permanent supply is used to maintain a battery backed 'memory'. Should this supply be cut, due to battery
disconnection perhaps, the 'adaptive shift' values will be lost. This will result in a small reduction in shift quality for
a period until the adaptions are 're-learned'
The TCM will adopt 'limp home' mode as a result of the supply voltage being >16V or <7V with an engine speed
>1600 rpm.
Should the ignition supply be >7V but <9V the TCM will hold the gear that it has currently selected. If after 2.5
seconds, with the engine speed >1600 rpm, the voltage remains at this level, 'limp home' mode will be adopted.
The 2.5 second delay is built in to prevent reaction to a momentary voltage fluctuation.
Operation
CAUTION:
Disconnection of the TCM and / or the vehicle battery will cause system adaptions to be lost; this may be
apparent by shift quality degradation. Following reconnection, a period of 'varied' driving will reinstate
adaptions and thus normal operation. Please ensure that the customer is made aware that the adaption
period is variable and may occur after handover, as the transmission re-learns the prevailing driving style.
NOTE:
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Should the TCM fail, please ensure that the control housing cooling fan is operating correctly. Failure of the
cooling fan MUST be rectified before renewing the TCM and details of a fan failure should accompany the
returned TCM.
The TCM processes information received in both analogue and digital form, such as:
The TCM uses the various sensors and inputs to monitor the correct operation of the system and is programmed
to take default action and inform the operator when a fault occurs.
Safety Functions
The safety functions are designed to safeguard against inappropriate actions by the operator as well as against
system malfunctions. The system prevents reverse gear from being engaged at high forward speeds and prevents
manual downshifting at excessive engine speeds; these functions are not operational in mechanical limp-home
mode.
The TCM constantly monitors the transmission for faults. In the event of a problem the TCM will adopt a 'limp
home' mode in which only P R N D - (selector in D but only fourth gear is enabled) are available. The operator will
be made aware of certain faults by an instrument panel warning.
The electrical and diagnostic system has been designed such that system integrity is protected at all times, the
safety concept being based on the following three points:
1. The hydraulic system has 'fail-safe' characteristics regarding its electrical operation, such that should the
power supply be lost to the electro-hydraulic actuators the transmission will initiate a limp-home mode.
2. Recognition of critical shift operation by monitoring the last element in the signal path, ie the solenoid
valve, and checking by means of redundant measured variables, ie engine speed, input speed and output
speed.
3. Each time the vehicle is started there is a check on the entire safety hardware and the associated
program parts and signal paths. A malfunction in this part of the system, or triggering of the safety circuit, is
communicated to the operator through the illumination of the transmission warning lamp.
TCM Inputs
The input speed sensor provides the TCM with transmission input shaft speed information. This signal is produced
from an inductive pick-up, generating 30 pulses per revolution.
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The output speed sensor provides the TCM with transmission output shaft speed information. This signal is
produced from an inductive pick-up, generating 36 pulses per revolution.
A thermistor which provides an electrical indication of the oil temperature to the TCM. The signal is measured as a
voltage with reference to analogue ground in the TCM.
Kickdown is intended to provide maximum vehicle acceleration, via the appropriate downshift(s), when the
operator uses full throttle. A kickdown switch provides an electrical signal to the TCM when the accelerator pedal
is fully pressed. The switch is normally open, connected to vehicle ground. Should the switch fail the TCM will
detect kickdown using the accelerator pedal position.
This component, used where the kickdown switch is not fitted, limits throttle pedal travel .in the same way. The
kickdown feature is retained, but is controlled by throttle position only. The pedal stop must be set, using the PDU,
in the same way as the kickdown switch to optimize performance.
The mode selection switch is a two position switch indicating to the TCM the current performance mode selected
by the driver. The switch generates a two-bit digital input to the TCM.
The rotary position switch detects the position of the transmission selector shaft. The switch is supplied as part of a
new transmission assembly, mounted on the transmission body. The switch is used to indicate to the TCM the six
positions of the shaft: Park, Reverse, Neutral, Drive, Third and Second. The switch provides a four-bit input to the
TCM.
Detects the movement of the selector lever from Drive to Fourth position. The selector cable, and therefore the
transmission selector shaft, does not move as the lever is operated between these two positions. The switch is
located within the 'J-gate' assembly, producing a digital output to indicate to the TCM that the lever has moved
from D to 4 ..
The TCM is an integral part of the CAN system which facilitates the interchange of real-time data between control
modules and sensors. Please see section <<303-14>> for a full description of CAN.
OBDII Interface
Data concerning OBDII related transmission failures is stored in the ECM for access via the J1962 socket.
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System Functions
Range Selection
The selector lever is connected to the transmission via a bowden cable, which operates the transmission selector
shaft between all positions except Drive to 4 .
The TCM detects the gear selected by means of a rotary position switch fitted to the transmission selector shaft. A
separate Drive to 4 switch is located within the 'J' gate' assembly.
Movement of the selector lever between Park, Reverse, Neutral and Drive manually directs the flow of
transmission oil; the TCM having control of the forward gears selected while the lever is in the Drive position.
The gearshift points are selected, by the TCM, as a function of the output speed, engine load, selector position
and shift program selected. The operator has control over the shift points via the selector lever, throttle pedal
movement, kickdown function and mode switch.
Mode Switch
This switch allows the driver to select one of two base shift maps; Normal and Sport modes, the switch being
illuminated when Sport is selected.
These specific condition shift maps are available to enhance the operation of the vehicle under specific driving
conditions. and are listed below in order of priority / title and operating condition.
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5. Manual: Shift map when the LH side of the 'J gate' is used
Three specific condition shift maps have a higher priority than the two base shift maps and will intervene when
appropriate conditions prevail for traction, gradient or cruise.
When traction control (engine or brake system derived) is operational the TCM will implement the traction map to
maximise control of wheel slip.
The gradient maps are intended to enhance vehicle drivability when towing or climbing a gradient. The TCM will
implement the maps when increased driving resistance is detected and enhanced drivability, cooling and
increased performance is appropriate.
The cruise map is intended to minimize unwanted gearshifts and 'hunting' and is activated when cruising near to
the set speed, or resuming.
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Diagnostic Strategy
Condition(s):
Action(s) to take:
GO to P0721
GO to P1603
GO to P0742
Action(s) to take:
GO to P0790
Action(s) to take:
GO to P0790
Action(s) to take:
GO to EMS
Possible Source(s):
Transmission temperature sensor circuit
Action(s) to take:
GO to P0710
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Action(s) to take:
GO to P1731
Action(s) to take:
GO to P0743
Possible Source(s):
Mechanical fault, should P R 4 be OK
Action(s) to take:
GO to P0741
Action(s) to take:
GO to P0742
Action(s) to take:
GO to P0702
Possible Source(s):
NOTE:
If the code logs when 3rd is selected, then the D to 4 switch is the most probable cause If the code logs
when D is selected from the LH side of the gate, then check selector cable adjustment
Action(s) to take:
GO to P0706
Possible Source(s):
Input speed sensor circuit fault
Input speed sensor faulty
Action(s) to take:
GO to P0715
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Possible Source(s):
Solenoid #1 circuit fault
Action(s) to take:
GO to P0753
Possible Source(s):
Solenoid #2 circuit fault
Action(s) to take:
GO to P0758
Possible Source(s):
Solenoid #3 circuit fault
Action(s) to take:
GO to P0763
Possible Source(s):
TCM faulty
Action(s) to take:
GO to P1605 and P1608
Possible Source(s):
ABS fault
CAN circuit fault between ABS/TCCM and TCM
Output speed sensor circuit fault
Action(s) to take:
GO to P1720
Possible Source(s):
Mechanical fault (check all other operations)
Action(s) to take:
GO to P1726
Possible Source(s):
Pressure regulator, solenoid or speed sensor circuit fault
Mechanical fault - transmission defaulted to 5th?
Action(s) to take:
GO to P1734
Possible Source(s):
Pressure regulator #1 circuit fault
Action(s) to take:
GO to P1745
Possible Source(s):
Pressure regulator #2 circuit fault
Action(s) to take:
GO to P1746
Possible Source(s):
Pressure regulator #3 circuit fault
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Action(s) to take:
GO to P1747
Possible Source(s):
Pressure regulator #4 circuit fault
Action(s) to take:
GO to P0743
Possible Source(s):
Pressure regulator #5 circuit fault
Action(s) to take:
GO to P1748
Possible Source(s):
Mechanical fault - transmission defaulted during 2nd to 3rd or 3rd to 4th shift?
Action(s) to take:
GO to P1779
Possible Source(s):
Power (ignition) supply fault to TCM
Vehicle battery charging system fault
Action(s) to take:
GO to P1789 and P1793
Possible Source(s):
Incompatible ECM, ABS/TCCM, TCM or INST - check part number
Action(s) to take:
GO to P1795
Possible Source(s):
CAN circuit fault
Check fault code(s) in ECM, ABS/TCCM or INST and rectify as required
Action(s) to take:
GO to P1796
Possible Source(s):
Faulty ECM
CAN circuit fault between ECM and TCM
Action(s) to take:
GO to P1797
Action(s) to take:
GO to P1722
Possible Source(s):
Output / input speed sensor circuit fault
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Mechanical fault (check operation of transmission in 2nd, 3rd and 4th gears)
Action(s) to take:
GO to P1730
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Engine support
303-021
Removal
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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6. Remove the air intake tube, MAFM and air cleaner cover assy, (19.10.30).
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16. Locate a transmission jack, Epco V - 100 or similar, under the transmission unit.
Adjust the angle of the jack to suit the transmission.
Secure the side clamps.
Pass the safety chain over the transmission unit and secure.
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CAUTION:
Under no circumstances remove the driveshaft to flexible coupling fixings.
19. Lower the transmission unit by carefully releasing the engine support beam and by lowering the
transmission jack.
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20. Detach the gear selector cable from the transmission unit.
1. Remove the selector cable ball pin to selector lever nut.
2. Remove the selector cable to transmission casing bolts.
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24. Remove the three bolts which secure the torque converter to the drive plate.
1. Remove the access cover.
2. Rotate the crankshaft and hold to prevent movement, and remove the bolts.
25. Remove the LH and RH catalyst mounting brackets from the transmission case.
Remove the bolts.
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26. Remove the bolts which secure the engine harness connector mounting bracket and move the bracket
aside for access.
28. NOTE:
Viewed from the rear of the vehicle.
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29. NOTE:
Viewed from the rear of the vehicle.
31. NOTE:
Viewed from the rear of the vehicle.
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32. NOTE:
Viewed from the rear of the vehicle.
33. NOTE:
Do not allow the converter to detach from the transmission.
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Engine support
303-021
Installation
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2. Keeping the dot within the sector, align the nearest converter fixing hole to the access aperture.
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6. Reposition the mounting bracket for the engine harness connector and fit the securing bolts.
7. Connect the drive shaft, aligning any marks made when removing - if applicable. Tighten the bolts to the
specified torque figure.
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8. Fit the engine rear mounting and tighten the centre bolt and outer bolts to the specified torque figures.
Check that the hooks of the engine support beam are not trapped, before tightening the rear mounting.
Check that the safety chain on the transmission jack will not be trapped when the mounting is fitted.
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10. Fit the three bolts which secure the torque converter to the drive plate.
1. Loosely assemble all three drive plate to torque converter bolts. Whilst preventing crankshaft
rotation, tighten the three converter bolts to the specified torque figure.
2. Fit the blanking plug.
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12. Connect the selector cable to the selector lever and fit the abutment bracket to the transmission casing.
Tighten the nut and two bolts to the specified torque figure.
13. Refit the rotary switch and tighten the two screws to the specified torque figure. Locate the switch
harness into the clips.
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16. Refit the RH downpipe catalytic converter. Refer to Operation 17.50.09 and 17.50.10
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20. Reposition the coolant header tank and tighten the securing bolt to the specified torque figure.
21. Refit the air intake tube, MAFM and air cleaner cover assembly. Refer to Operation 19.10.30.
24. Refill the transmission with new fluid. Refer to Operation <<44.24.02>>.
25. Remove the protection sheets and close the engine compartment.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
Raise the vehicle on a suitable lift.
Carefully remove the drain plug and drain the transmission fluid.
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7. Remove the nine screws from the pressure regulator / solenoid retaining plate.
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Installation
1. Installation is the reverse of the removal procedure, noting that a new pressure regulator 'O' ring MUST
be used.
Fit the nine screws securing the pressure regulator / solenoid retaining plate and tighten to the specified
torque figure.
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2. Refit the RH rear valve body securing screws and tighten to the specified torque figure.
3. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the fixings to the specified torque figure.
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Removal
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4. Using a punch, knock back the two staked areas of the coupling nut.
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Installation
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3. Use tool 307 - 356 to tighten the coupling nut to the specified torque figure.
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1. Select N position.
4. Locate a transmission jack, Epco V - 100 or similar, under the transmission unit.
Adjust the angle of the jack to suit the transmission.
Secure the side clamps.
Pass the safety chain over the transmission unit and secure.
Take the weight of the transmission and engine.
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7. CAUTION:
Under no circumstances remove the driveshaft to flexible coupling fixings.
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Installation
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2. Align the driveshaft with the transmission drive flange using the marks made on removal.
Tighten the three bolts to the specified torque figure.
4. Fit the engine rear mounting and tighten the centre bolt and outer bolts to the specified torque figures.
Check that the safety chain on the transmission jack will not be trapped when the mounting is fitted.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
Raise the vehicle for access.
Carefully remove the drain plug and drain the transmission fluid.
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1. Remove the screw from the input speed sensor securing bracket and pull the sensor clear.
Disconnect the harness multiplug.
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1. Remove the screw from the output speed sensor securing bracket and pull the sensor clear.
Disconnect the harness multiplug.
8. Disconnect the five pressure regulator connectors and three solenoid connectors.
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Installation
1. Installation is the reverse of the removal procedure, noting the following steps.
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3. NOTE:
M6 fixing.
Fit the output speed sensor and tighten the retaining screw to the specified torque figure..
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4. NOTE:
M5 fixing.
Fit the input speed sensor and tighten the retaining screw to the specified torque figure..
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6. Connect the five pressure regulator connectors and three solenoid connectors.
7. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
Raise the vehicle on a lift.
Carefully remove the drain plug and drain the transmission fluid.
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1. Release the screw which secures the output speed sensor bracket and pull the sensor clear.
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Installation
1. NOTE:
M6 fixing.
Connect the multiplug, install the output speed sensor and securing bracket. Tighten the screw to the
specified torque figure.
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2. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
Raise the vehicle on a lift.
Carefully remove the drain plug and drain the transmission fluid.
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7. Remove the nine screws which secure the solenoid / pressure regulator retaining plate.
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Installation
1. Installation is the reverse of the removal procedure, noting the specific tightening of fixings and related
procedures.
Fit the nine screws securing the pressure regulator / solenoid retaining plate and tighten to the specified
torque figure.
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2. Refit the RH rear valve body securing screws and tighten to the specified torque figure.
3. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified torque figure.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Release the fixings and remove the cover from the ECM / TCM housing.
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Installation
1. NOTE:
A replacement TCM may only be obtained from an authorized Jaguar dealer and MUST be ordered
against the VIN.
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Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
3. Tighten the two bolts to the specified torque figure, to secure the filter .
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Raise the vehicle for access and drain the transmission fluid.
3. Discard the fluid pan gasket and clean the mating faces.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Raise the vehicle for access and drain the transmission fluid.
3. Discard the fluid pan gasket and clean the mating faces.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Release the screw which secures the input speed sensor bracket and pull the sensor clear.
Disconnect harness multiplug.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Release the screw which secures the output speed sensor bracket and pull the sensor clear.
Disconnect harness multiplug.
7. Remove the selector cable abutment bracket fixings and reposition the bracket for access to the multiplug.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
11. Release the internal harness from the retaining clips and remove the harness.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
3. Lubricate the harness connector 'O' rings with transmission fluid prior to fitting.
Fit the new 'O' rings, the harness connector and the retaining clip
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
5. NOTE:
M5 fixing.
Refit the input speed sensor and tighten the retaining screw to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
6. NOTE:
M6 fixing.
Refit the output speed sensor and tighten the retaining screw to the specified torque figure.
7. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the twenty-two bolts to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. Remove selector cable abutment bracket fixings (2) and reposition the bracket for access to the multiplug.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
3. Tighten the securing bolts, selector cable bracket to transmission casing, to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
1. Fitting a new rotary switch is the reverse of the removal procedure noting that the fixings must be
tightened to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED.
Raise the vehicle on a lift.
Carefully remove the drain plug and drain the transmission fluid.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
1. Release the screw which secures the input speed sensor bracket and pull the sensor clear.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Installation
1. NOTE:
M5 fixing.
Connect the multiplug, install the input speed sensor and securing bracket. Tighten the screw to the
specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
2. NOTE:
Ensure extreme cleanliness and never reuse transmission fluid.
Using a new gasket, install the fluid pan and tighten the twenty-two fixings to the specified. torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
Lifting handle
307-139
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles Without: Supercharger
5. CAUTION:
Use extreme care NOT to damage the oil seal with the converter spigot.
CAUTION:
Ensure that the converter is fully located.
6. Check that the three converter fixing boss faces are approximately 8,0 mm proud of the transmission
mounting face.
8. Install the transmission unit; refer to Operation <<44.20.01>>, noting especially the alignment instructions.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Unit Specification
Transmission fluid Shell ATF 3403 - M115
Unit Liters
Transmission assembly (with torque converter) 9,5
Component Nm
Bolt - EMS bracket to cylinder head 43 - 53
Bolt - Driveshaft coupling to transmission 75 - 88
Bolt - Fluid pan (clamp) to transmission case 8 - 10
Bolt - Harness heatshield to case and fluid pan clamp 9 - 11
Bolt - Muffler bracket to transmission case 43 - 57
Bolt - Rear engine (isolation) mounting to mounting bracket 22 - 28
Bolt - Rear engine mounting bracket to adapter (transmission case) 39 - 51
Bolt - Rear engine mounting bracket to body 22 - 28
Bolt - Torque converter to drive plate 43 - 57
Bolt - Transmission unit to engine 43 - 57
Bolt - Valve body to transmission case 7-9
Bolt - 'W' clip (fluid cooler pipe) to cylinder block 7-9
Banjo bolt - Cooler pipe to transmission unit 30 - 40
Nut - Coolant header tank to bracket 4-5
Nut - Selector cable abutment to transmission case 7 - 10
Nut - Selector cable ball end to selector lever 7 - 10
Nut - Transmission output shaft flange 200
Plug - Fluid pan drain 20 - 24
Screw - Coolant header tank to bracket 4-5
Screw - Filler tube to transmission case 14 - 18
Gear Ratio
1st 3,59:1
2nd 2,19:1
3rd 1,41:1
4th 1,00:1
5th 0,83:1
Reverse -1,93 (Normal mode)
Reverse -3,165 (Sport mode)
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Dipstick
307-379
3. NOTE:
This procedure will not remove residual fluid from the torque converter.
WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT
CAPACITY.
Carefully remove the drain plug and discard the sealing washer.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
4. Refit the drain plug and tighten to the specified torque figure.
Use a new sealing washer.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
7. CAUTION:
It is essential that only the specified fluid is used.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
11. NOTE:
Temperature will ONLY be displayed in D or R.
Check the transmission fluid temperature to select the appropriate dipstick calibration.
1. MAX and MIN marks at 25°C fluid temperature.
2. MAX and MIN marks at 80°C fluid temperature.
13. Correct the fluid level as required, noting that excess fluid MUST be removed.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Engine support
303-021
Removal
4. Remove the air intake tube, MAFM and air cleaner cover assembly. Refer to Operation 19.10.30.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
10. Fit engine lifting bracket 303 - 536 at the rear LH.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
15. Remove the RH downpipe catalytic converter. Refer to Operation 17.50.09 and 17.50.10.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
17. Locate an Epco V-100, or similar lift, under the transmission unit.
Adjust the angle of the lift to suit the transmission.
Secure the side clamps.
Pass the safety chain over the transmission unit and tighten the clamp to secure the assembly.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
19. Detach the driveshaft (prop-shaft) from the transmission drive flange.
If the transmission is to be refitted, mark the position of the coupling relative to the drive flange.
CAUTION:
Under no circumstances remove the driveshaft to flexible coupling fixings.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
21. Detach the gear selector cable from the transmission unit.
1. Remove the selector cable ball pin to selector lever nut.
2. Lower the transmission lift for access.
3. Remove the selector cable to transmission casing bolts.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
25. Remove the three bolts which secure the torque converter to the drive plate.
1. Remove the access cover.
2. Rotate the crankshaft for access to each bolt and hold to prevent movement. Remove each bolt.
26. Remove the LH and RH catalyst mounting brackets from the transmission case.
Remove the two bolts from each side.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
28. NOTE:
Viewed from the rear of the vehicle.
29. NOTE:
Viewed from the rear of the vehicle.
Remove the two bolts which secure the starter motor power cable clip.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
30. NOTE:
Viewed from the rear of the vehicle.
32. NOTE:
Viewed from the rear of the vehicle.
Remove the bolt which secures the cooler upper pipe clip to the transmission case.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
33. NOTE:
Viewed from the rear of the vehicle.
Remove the six remaining bolts from the transmission case to cylinder block.
34. NOTE:
Do not allow the converter to detach from the transmission.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Engine support
303-021
Installation
1. CAUTION:
A new transmission requires a NEW torque converter.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
4. Fit the screw (lower) securing the harness link lead heatshield. Tighten to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
6. Fit the mounting bracket for the front muffler. Tighten the two bolts to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
10. Refit the harness connector support bracket and tighten the two bolts to the specified torque figure,
noting that one fixing also retains the dipstick upper tube.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
11. Connect the selector cable. Tighten the bolts and one nut to the specified torque figure.
12. Connect the driveshaft (prop-shaft) aligning the marks made when it was removed. Tighten the bolts to
the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
13. Fit the rear crossmember. Tighten the bolts to the specified torque figure.
14. Refit the coolant header tank. Tighten to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
15. Fit the harness and clip (transmission link harness) to the rear of the cylinder head. Tighten to the
specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Driveshaft wrench
205-053
Removal
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
CAUTION:
Under no circumstances remove the driveshaft to flexible coupling fixings.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
6. Secure the driveshaft wrench 205 - 053 to the output shaft flange.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
4. Refit the bolts securing the driveshaft and tighten to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
5. Refit the the rear mounting crossmember and tighten the securing bolts to the specified torque figures.
6 2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT
CAPACITY.
Carefully remove the drain plug and discard the sealing washer.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Installation
3. Tighten the nine bolts securing the valve body, to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
4. Refit the dowel (leaf spring to valve body) and the leaf spring. Fit and tighten the securing bolt to the
specified torque figure.
5. Tighten the centre retaining bolt of the electrical connector to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Installation
1 2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT
CAPACITY.
Carefully remove the drain plug and discard the sealing washer.
1 2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Remove the six bolts and clamps which secure the fluid pan to the transmission.
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
2. Refit and tighten the drain plug to the specified torque figure.
Use a new sealing washer.
3 2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. WARNING:
TRANSMISSION FLUID MAY CAUSE SEVERE BURNS, ENSURE THAT ALL SAFETY
PROCEDURES ARE OBSERVED AND THAT THE RECEPTACLE FOR WASTE HAS SUFFICIENT
CAPACITY.
Drain the transmission fluid.
Carefully remove the drain plug and discard the sealing washer.
1 2012-07-19
1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
4. Tighten the centre retaining bolt of the electrical connector guide bush to 2.25 to 2.75 Nm.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
5. Remove the RH and LH catalytic converters, refer to Operation 17.50.09 and 17.50.10.
8. Remove the torque converter from the transmission unit, refer to Operation <<44.17.07>>.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
CAUTION:
If the transmission is to be renewed, renew the torque converter also.
1. Remove the transmission unit from the vehicle; refer to Operation <<44.20.01>>.
3. Remove lifting handles 307 - 139 (JD-105) from the torque converter.
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1999 XK RANGE - Automatic Transmission/Transaxle - Vehicles With: Supercharger - 307-
5. CAUTION:
Use extreme care NOT to damage the oil seal with the converter spigot.
CAUTION:
Ensure that the converter is fully located.
6. Check that the converter fixing boss faces are approximately 8,0 mm proud of the transmission mounting
face.
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1999 XK RANGE - Transmission/Transaxle Cooling - Vehicles Without: Supercharger - 307
Transmission Cooling
The transmission fluid cooling system maintains fluid temperature within specified limits.
Parts List
Item Description
1 Fluid pipe, oil FROM cooler
2 Fluid pipe, oil TO cooler
Component Descriptions
Transfer fluid from the transmission to the cooler under the action of the hydraulic system pump.
Return the cooled fluid from the cooler to the transmission.
The transmission fluid cooler:
Overheating Protection
If the engine coolant or transmission fluid temperatures exceed their predefined limits, the transmission control
module locks the torque converter clutch. By reducing slip, this minimises the amount of heat transferred to the
engine cooling system from the transmission fluid.
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1999 XK RANGE - Transmission/Transaxle Cooling - Vehicles With: Supercharger - 307-02
Transmission Cooling
The transmission fluid cooling system maintains the fluid temperature within specified limits. The cooling element
is located in the engine cooling radiator LH end tank.
General Layout
Overheating Protection
If the engine coolant or transmission fluid temperatures exceed their predefined limits, the transmission control
module locks the torque converter clutch. By reducing slip, this minimises the amount of heat transferred to the
engine cooling system from the transmission fluid.
1 2012-07-20
1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
7. NOTE:
Assistance from another person is required.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
3. With PDU connected, running and the message 'EXISTING COMPONENTS TO BE TESTED YES / NO'
displayed;
1. Select YES.
2. Select ENTER.
3. Follow the messages given on the screen.
6. If the target 90 % throttle open specification is NOT achieved the switch must be adjusted as follows:
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
10. With the PDU instructions completed, connect the Kickdown switch multiplug.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
7. Slacken the selector cable locking nuts away from the abutment.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
11. NOTE:
When setting the selector cable, ensure that the transmission selector does not move from the N
position.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
External Controls
Introduction
Parts List
Item Description
1 Gear selector lever
2 Drive-to-fourth switch connector
3 Neutral position switch connector
4 Park position switch connector
5 Gear selector illumination module
6 Gear selector interlock solenoid
7 Security system Active LED
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Has seven positions: Park, Reverse, Neutral, Drive, Fourth, Third and Second.
Operates the transmission selector shaft and rotary switch, in all positions (except Drive-to-fourth) by
means of a Bowden cable.
Passes driver gearshift requests to the transmission control module via the rotary switch.
The Drive-to-fourth switch:
Detects when the gear selector lever is moved from Drive to Fourth.
Is hard-wired to the transmission control module.
The Neutral position switch:
Provides illumination of the gear selector surround, which is dimmable via a CAN signal from the
instrument cluster.
Provides red illumination, on the gear selector surround, of the gear selected, by CAN signals from the
instrument cluster.
Illuminates the security system Active LED on the gear selector surround, in response to an input from the
body processor module.
Is connected to the fascia harness via a 12-way connector. Refer to Connector Pins Identification,
307-00A.
The gear selector interlock solenoid:
Prevents the gear selector lever from being moved from the Park position, unless the ignition switch is in
position II, and the brake pedal is depressed.
Is controlled by an input from the body processor module.
The seven gear selector positions are:
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Provides maximum acceleration on driver demand, by signalling the transmission control module to
select the lowest gear to give maximum wheel torque.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Transmission Switches
Location, Rotary Switch
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Location, Drive to 4th Switch
Operation
NOTE:
The rotary position switch is NOT adjustable.
The position of the gear selector lever is detected by the range sensor; a system which consists of two sensors
(switch systems).
1. The rotary position switch, which is located on the RH side of the transmission case and is coaxial with the
selector shaft.
When the selector is moved across the gate to engage 4, or back from that side towards D the selector cable
does not move. In order that this change of state be registered by the TCM the D to 4 switch is incorporated.
The rotary switch in isolation provides a 4-bit code, which, when added to the D to 4 switch becomes a 5-bit code.
The TCM will make a failure judgement if it detects an 'illegal' code.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Item Description
1 Drive to 4th switch
2 Switch L1
3 Switch L2
4 Switch L3
5 Switch L4
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
External Controls
Special Service tools
Digital multimeter
Generic scantool
Symptom Chart
Condition(s):
Action(s) to take:
GO to <<Pinpoint Test A>>
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
A : P0706
A1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
2. Move the selector lever slowly from P to 2 and back, noting the illumination / position relationship as follows:
Does state illumination match the lever position in each direction of travel?
-> Yes
GO to A4
-> No
GO to A3
With lever at D (when moving from 2 to P ) is 3 or 4 illuminated?
-> Yes
GO to A3
-> No
GO to A5
With lever moved from P , to position 4, is D illuminated?
-> Yes
GO to A4
-> No
GO to A5
1.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
2. With EM007 and FC083 disconnected, measure the resistance between FC083/003 and EM007/028
3. Repeat for FC083/001 and EM007/013
Is the resistance < 0.5 OHM?
-> Yes
GO to A5
-> No
Inspect EM007 and FC083 EM001 for corrosion, bent / pushed back pins or locate and repair the
harness / splice EMS25 and FCS62. - test the system for normal operation
A5 : CHECK D TO 4 SWITCH
NOTE:
Engage position 2 firmly
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1.
2. With FC083 disconnected, measure the resistance between switch pins 001 and 003
With the selector lever at 4, 3, 2 is the resistance < 0.5 OHM?
With the selector lever at P, R, N, D is the resistance < >50 KOHM?
-> Yes
GO to A6
-> No
Renew D to 4 switch and test the system for normal operation
1.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
2. With EM007, EM047, Fc083 and AC027 (kickdown switch) disconnected, measure the resistance between
EM007/028 to EM047/00E
Is the resistance < 0.5 OHM?
-> Yes
GO to A7
-> No
Inspect EM007, EM047, Fc083 and AC027 for corrosion, bent / pushed back pins or locate and repair
the harness / splice EMS25 - test the system for normal operation
A7 : CHECK SWITCH L1
1.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/036
With the selector lever at P, N, D, 4 is the resistance < 0.5 OHM?
With the selector lever at R, 3, 2 is the resistance >50 KOHM?
-> Yes
GO to A8
-> No
Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness
EM007/036 to EM047/00A
OK, but fault still present?
-> Yes
Renew rotary position switch and test the system for normal operation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
A8 : CHECK SWITCH L2
1.
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/008
With the selector lever at R, N, 3 is the resistance < 0.5 OHM?
With the selector lever at P, D, 4, 2 is the resistance >50 KOHM?
-> Yes
GO to A9
-> No
Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness
EM007/008 to EM047/00B - test the system for normal operation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
A9 : CHECK SWITCH L3
1.
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/037
With the selector lever at N, D, 4, 3 is the resistance < 0.5 OHM?
With the selector lever at P, R, 2 is the resistance >50 KOHM?
-> Yes
GO to A10
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
-> No
Inspect EM007 and EM047 for corrosion, bent / pushed back pins or locate and repair the harness
EM007/037 to EM047/00C - test the system for normal operation
OK, but fault still present?
-> Yes
Renew rotary position switch and test the system for normal operation
1.
2. With EM007 disconnected, measure the resistance between EM007/028 and EM007/009
With the selector lever at D, 4, 3, 2 is the resistance < 0.5 OHM?
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- Vehicles Without: Supercharger
A11 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
11. Detach the selector cable from the gear shift assembly.
1. Remove the inner cable to shift lever nut.
2. Slacken the outer cable locknuts.
12. Push the outer cable grommet through the transmission tunnel aperture.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Using a thin plastic lever and exercising care to avoid damaging veneer surface, release the four surround
tangs from the 'J' gate.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
4. Disconnect multiplugs from Sport mode and Cruise Control on/off switches.
5. Noting orientation of switches, depress tangs and remove switches from surround.
Installation
1. Ensuring correct orientation, fit and fully seat Sport mode and Cruise Control on/off switches in surround.
3. Position surround over 'J' gate and press firmly to fully seat tangs.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles Without: Supercharger
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- Vehicles Without: Supercharger
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- Vehicles Without: Supercharger
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- Vehicles Without: Supercharger
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- Vehicles Without: Supercharger
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- Vehicles Without: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
1. Ensure that the throttle cable is correctly adjusted; refer to Operation <<19.20.06>>.
3. With PDU connected, running and the message 'EXISTING COMPONENTS TO BE TESTED YES / NO'
displayed:
Select YES.
Select ENTER.
Follow the messages given on the screen.
6. If the target 90% throttle open specification is NOT achieved the switch must be adjusted as follows.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
10. With the PDU instructions completed, connect the kickdown switch multiplug.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
6. Slacken the selector cable locking nuts and screw them away from the abutment.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
9. NOTE:
When setting the selector cable, ensure that the transmission selector does not move from the (N)
position.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
External Controls
Introduction
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Operator's Selector Module ('J' Gate)
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- Vehicles With: Supercharger
Parts List
Item Description
Selector lever:
The interlock system which locks the selector in P and prevents the ignition key from being removed, may be
manually overridden in the event of an emergency.
4. Push the screwdriver downwards, gently, and hold whilst simultaneously moving the selector from P
towards R , but do not engage R until the tool has been removed
6. With the selector in N and the access blank replaced,,the vehicle may be started
Range Selection
The selector lever transmits operator demand to the transmission and TCM by means of a cable and
Dual-Linear Switch (DLS).
The lever operates the transmission assembly selector shaft, only for P R N D , by means of a cable.
Movement of the lever across the gate to 4, 3 and 2 positions disengages the cable from the selector lever
and engages the DLS which controls gear selection electronically.
Provides illumination of the decal relevant to the gear selected. This information is provided by CAN from
the TCM, thus obviating the need for a dedicated illumination switch.
Illuminates the security system Active LED on the gear selector surround, in response to an output from
the BPM.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
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Transmission Switches
'Sport' mode allows 1 st gear engagement from rest and modifies values in the TCM shift point calculations to
provide higher upshift speeds and enhanced availability of downshifts.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Kickdown Switch
Prevents the gear selector lever from being moved from P , unless the ignition switch is in position II, and
the brake pedal is depressed.
Is controlled by an input from the BPM
The TCM detects gear selection by means of a switch fitted to the 'J' gate; the DLS contains two multi-track slider
switches, of which the upper controls P R N D and the lower 4 3 2 .
Output from the DLS is changed as the selector lever is moved, thus indicating selected gear position. The
parallel signal is input to the TCM by 4 discrete logic wires W0, W1, W2 and W3. The particular sequence, or grey
code, will indicate which shift position is selected, as shown in the following table where 0 = low and 1 = high:
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Grey code
Selector Position W3 W2 W1 W0
P 0 1 1 1
R 1 1 1 0
N 1 1 0 1
D 0 1 0 0
4 1 0 0 0
3 0 0 1 0
2 0 0 0 1
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
External Controls
Condition(s):
Shift stuck in P
Possible Source(s):
Selector cable seized
Action(s) to take:
GO to <<44.15.08>>
Possible Source(s):
Interlock solenoid not operating
Action(s) to take:
GO to PDU
Possible Source(s):
Interlock latch seized
Transmission faulty
Action(s) to take:
Mechanical check
Possible Source(s):
Operator sequence error
Action(s) to take:
Correct the sequence
Vehicle rolls on P
Possible Source(s):
Incorrect cable adjustment
Action(s) to take:
GO to <<44.15.07>>
Possible Source(s):
Faulty parking pawl (transmission internal)
Action(s) to take:
Mechanical check
Action(s) to take:
GO to <<44.15.07>>
Possible Source(s):
Transmission fluid level incorrect
Action(s) to take:
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
GO to <<44.24.02>>
N not achieved
Possible Source(s):
Incorrect cable adjustment
Transmission faulty
Action(s) to take:
GO to <<44.15.07>>
Action(s) to take:
GO to <<44.15.07>>
Possible Source(s):
Transmission fluid level incorrect
Action(s) to take:
GO to <<44.24.02>>
Possible Source(s):
Transmission faulty
Action(s) to take:
Mechanical check
Action(s) to take:
GO to PDU
Action(s) to take:
GO to <<44.15.07>>
Shift lever has no effect upon the transmission and resistance cannot be felt
Possible Source(s):
Cable disconnected or broken
Transmission selector problem
Shift lever drive pin adrift
Action(s) to take:
Mechanical check
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Shift lever position not align correctly following manual selection of lower ratios
Possible Source(s):
Sliding block drive pin displaced - following road debris contact
Action(s) to take:
Mechanical check. Renew the selector if damaged, or re-align the drive pin and sliding
block
Action(s) to take:
GO to Renew the DLS
Action(s) to take:
Mechanical check
Possible Source(s):
Solenoid permanently activated
Action(s) to take:
GO to PDU
Action(s) to take:
GO to <<44.15.07>>
Action(s) to take:
Mechanical check
Action(s) to take:
Clean
Possible Source(s):
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Worn 'J' gate track gasket allowing lever and moulding to contact
Loose selector disc seal
Action(s) to take:
GO to <<44.15.05>>
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
3. Disconnect the solenoid multiplug.
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
12. Detach the selector cable from the gear shift assembly.
1. Remove the inner cable to shift lever nut.
2. Slacken the outer cable locknuts.
13. Push the outer cable grommet through the transmission tunnel aperture.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
2. Fit the cable to the transmission and tighten the fixings to the specified torque figure.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Using a thin plastic lever and exercising care to avoid damaging veneer surface, release the four surround
tangs from the 'J' gate.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
4. Disconnect multiplugs from Sport mode and Cruise Control on/off switches.
5. Noting orientation of switches, depress tangs and remove switches from surround.
Installation
1. Ensuring correct orientation, fit and fully seat Sport mode and Cruise Control on/off switches in surround.
3. Position surround over 'J' gate and press firmly to fully seat tangs.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2. Position the selector to 'N' to provide clearance for removing the console.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
9. Position the selector to 'P' to align the mechanism for installing the new linear switch.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Installation
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
5. NOTE:
When setting the selector cable, ensure that the selector lever on the transmission casing is still in the
'N' position.
6. Check that all released connectors are safely insulated and connect the vehicle battery.
8. Adjust the position of the linear switch so that the selector 'N' position graphic illuminates. Tighten the four
screws to 0,7-1 Nm.
9. Move the gear selector to 'R' to confirm that the 'R' position graphic illuminates.
10. Check that the engine will start when the gear selector is in the 'N' and 'P' positions, but not in any other
position.
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
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1999 XK RANGE - Automatic Transmission/Transaxle External Controls
- Vehicles With: Supercharger
Installation
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1999 XK RANGE - Exhaust System - 309-00
Description mm
Intermediate muffler - Rear inside edge of muffler to rear suspension A-frame 116
Tailpipe to bumper aperture - Vertical 25 - 35
Tailpipe trim position - Vertical (permissible variation LH to RH) 0-6
Tailpipe trim position - Horizontal (permissible variation LH to RH) 0-6
Tailpipe trim surface to inside of bumper aperture 35 - 45
Torques
Component Nm
Nut - Downpipe to exhaust manifold 14 - 18
Bolt - Downpipe to bracket 39 - 51
Torca clamp assembly 60 - 80
Tie strap fixings 22 - 28
Bolt - Grass shield fixings (Japanese market only) 8,5 - 11,5
Bolt - Over-axle mounting cradle to rear suspension A-frame 22 - 28
Bolt - Tailpipe mounting rubber upper support to body 17 - 23
Oxygen sensor to downpipe 40 - 50
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Exhaust System
Exhaust Components
Item Description
1 Downpipe catalytic converter assembly
2 Front muffler
3 Intermediate muffler
4 Rear muffler
5 Tie strap
6 Grass shields (Japanese market only)
All vehicles are fitted with a five-muffler, stainless steel exhaust system which features:
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1999 XK RANGE - Exhaust System - 309-00
Downpipe Assembly
Item Description
1 Downpipe catalytic converter
2 Upstream heated oxygen sensor
3 Downstream oxygen sensor (North American markets only)
4 Temperature sensor (Japanese market only)
5 Engine mounting bracket (LHS and RHS)
Catalytic converter with palladium/rhodium coated elements. The elements are uncoated for markets with
only leaded fuel.
Exhaust manifold fixing by four threaded studs. Joint-to-joint sealing is with a gasket.
Engine-mounted bracket providing downpipe mounting by two nuts to torque converter and two bolts to
downpipe.
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1999 XK RANGE - Exhaust System - 309-00
Front Muffler Assembly
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1999 XK RANGE - Exhaust System - 309-00
The left- and right-hand intermediate muffler assemblies comprise:
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1999 XK RANGE - Exhaust System - 309-00
Joints and Clamps
Catalyst Monitoring
Monitoring Procedure
A calculation of the average value of the downstream O2 sensor high frequency amplitude is made; this is normal
if the value falls below a given threshold. Should a failure judgement occur, the main feedback frequency will be
adjusted and the response delay time from the upstream to downstream feedback signal monitored. If the
response delay time is greater than the threshold then a normal judgement will be made, less will incur a failure
judgement.
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1999 XK RANGE - Exhaust System - 309-00
Oxygen Sensor (O2
Location
Parts List
Item Description
1 Heated oxygen sensor (upstream)
2 Oxygen sensor (downstream)
3 Catalytic converter
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1999 XK RANGE - Exhaust System - 309-00
Operation
The upstream heated oxygen sensor is located at the catalytic converter inlet and detects the concentration of
oxygen in the raw exhaust gases; an internal heater reduces the warm up time of the sensor output.
The ECM receives input signals from the sensors and varies the fuel injector duration (mixture) to provide
optimum gas emissions.
Monitoring Procedure
The sensor outputs are monitored during steady driving with a fully warm engine.
If the downstream sensors indicate lean Air / Fuel Ratio (AFR) and the fuel system has judged that the fueling is
rich, then the upstream sensor is judged to have failed high voltage.
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1999 XK RANGE - Exhaust System - 309-00
The upstream sensor is judged to have failed low voltage by comparison of its output with that of the downstream
sensor.
Upstream slow response judgements are made when any of the following switching rates remain above a
threshold: low to high switch time from one mid point of the switching cycle to the next mid point.
Downstream sensor slow, high and no activity judgements are similar to upstream but the mapped values are
different. If no activity is seen the AFR is enriched to force a response, and a failure judgement is made should this
be unsuccessful.
Downstream high and low voltage judgements are made after the sensor has remained above or below
predetermined thresholds for a long period.
Heater circuit judgements are made by comparing the expected heater drive state with the actual state. If these
states are different for too long then the heater circuits are judged to be faulty.
For all the above diagnostics, the relevant DTC is stored if the failure judgement is made on two successive trips.
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1999 XK RANGE - Exhaust System - 309-00
Circuit Diagram, O2 Sensors / ECM
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1999 XK RANGE - Exhaust System - 309-00
Item Description
1 To Fuse F14 (10A)
1. Check for open and short circuit in harness and connector faults between the O2 sensor and ECM.
1. Verify that the resistance between the heater terminals is between 4OHM and 10OHM at -20°C to 100°C.
Performance Check
1. Run the engine at 2500 RPM for two minutes, to heat up the O2 sensor.
2. Check the voltage of the sensor output: Alternates between less than 0.4V at feed back engine conditions
and in excess of 0.5V, see graph.
3. Check that cycle of the upstream sensor output is in accordance with the appropriate pinpoint test.
4. Check that cycle of the downstream sensor output is in accordance with the appropriate pinpoint test.
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1999 XK RANGE - Exhaust System - 309-00
Exhaust System
Special Service tools
Digital multimeter
Generic scantool
Catalyst Monitoring
Condition(s):
Action(s) to take:
See DTC P0137, P0138 and P0140
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1999 XK RANGE - Exhaust System - 309-00
Action(s) to take:
See DTC P0157, P0158 and P0160
Condition(s):
Action(s) to take:
GO to <<Pinpoint Test A>>
Action(s) to take:
GO to <<Pinpoint Test A>>
Action(s) to take:
GO to <<Pinpoint Test B>>
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Harness failure
Connector pin(s) bent or tracking between connections.
ECM failure
Action(s) to take:
GO to <<Pinpoint Test A>>
Action(s) to take:
GO to <<Pinpoint Test C>>
Action(s) to take:
GO to <<Pinpoint Test C>>
Action(s) to take:
GO to <<Pinpoint Test D>>
Condition(s):
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Action(s) to take:
GO to <<Pinpoint Test E>>
Action(s) to take:
GO to <<Pinpoint Test E>>
Action(s) to take:
GO to <<Pinpoint Test F>>
Action(s) to take:
GO to <<Pinpoint Test E>>
Action(s) to take:
GO to <<Pinpoint Test G>>
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Possible Source(s):
O2 sensor failure to B+
Sensor ground fault
Harness failure
Connector pin(s) bent or tracking between connections.
ECM failure
Action(s) to take:
GO to <<Pinpoint Test G>>
Action(s) to take:
GO to <<Pinpoint Test H>>
Action(s) to take:
GO to <<Pinpoint Test G>>
GO to <<Pinpoint Test H>>
A1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
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1999 XK RANGE - Exhaust System - 309-00
1.
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1999 XK RANGE - Exhaust System - 309-00
2. With EM021 disconnected, measure the resistance between EM021/001 and EM021/002.
Is the resistance between 4 and 10OHM?
-> Yes
GO to A3
-> No
Renew O2 sensor; reconnect plug(s)
GO to A6
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1999 XK RANGE - Exhaust System - 309-00
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. With EM021 disconnected, measure the voltage between EM021/003 and EM021/004.
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to A4
-> No
Renew O2 sensor; reconnect plug(s)
GO to A6
1.
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1999 XK RANGE - Exhaust System - 309-00
2. With the conditions held as A4, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to A7
-> No
Renew O2 sensor; reconnect plug(s)
GO to A6
A6 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
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1999 XK RANGE - Exhaust System - 309-00
-> Yes
STOP
-> No
Contact Jaguar Service
1.
2. With EM021 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 003 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to A9
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-> No
Renew the O2 sensor and reconnect plug(s)
GO to A8
A8 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
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2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to A10
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to A11
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1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to A12
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to A11
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1999 XK RANGE - Exhaust System - 309-00
A11 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM021 disconnected, measure the resistance between EM012/015 and EM021/003
Is the resistance < 0.5OHM?
-> Yes
GO to A13
-> No
Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s).
GO to A18
1.
16 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM021 disconnected, measure the resistance between EM012/022 and EM021/004
Is the resistance < 0.5OHM?
-> Yes
GO to A14
-> No
Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s).
GO to A18
1.
17 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015
Is the voltage 0 (zero) V?
-> Yes
GO to A15
-> No
Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s).
GO to A18
1.
18 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0 (zero) V?
-> Yes
GO to A16
-> No
Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s).
GO to A18
1.
19 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
20 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002
Is the voltage B+?
-> Yes
Remove link lead and reconnect all connectors
GO to A18
-> No
Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made
GO to A18
21 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
A18 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
B : P0133
B1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1. Check the engine and exhaust system for normal running temperature
Is the engine and exhaust system up to normal running temperature?
-> Yes
GO to B3
22 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> No
Rectify possible leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine
cooling system operation. Test the system for correct operation
GO to B8
1.
2. With EM021 disconnected, measure the resistance between EM021/001 and EM021/002.
Is the resistance between 4 and 10OHM?
-> Yes
GO to B4
-> No
23 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. Measure the voltage between EM021/003 and EM021/004.
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to B5
-> No
Renew O2 sensor, reconnect plug(s)
24 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to B8
1.
25 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as B5, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to B7
-> No
Renew O2 sensor, reconnect plug(s)
GO to B8
26 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as in B6, run the engine at 1500 rpm for approximately 2 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 4
seconds?
-> Yes
GO to B9
-> No
Renew O2 sensor, reconnect plug(s)
GO to B8
27 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
B8 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
28 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM021 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 003 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to B11
-> No
Renew the O2 sensor and reconnect plug(s)
GO to B10
B10 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
29 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
30 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to B12
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect earthing stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s)
GO to B13
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
31 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> Yes
GO to B14
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect earthing stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s)
GO to B13
1.
2. With EM012 and EM021 disconnected, measure the resistance between EM012/015 and EM021/003
32 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM021 disconnected, measure the resistance between EM012/022 and EM021/004
Is the resistance < 0.5OHM?
33 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> Yes
GO to B15
-> No
Inspect connectors EM012, and EM021 for corrosion, damaged / pushed back pins or repair the harness,
reconnect plug(s)
GO to B19
1.
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015
Is the voltage 0 (zero) V?
-> Yes
34 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to B16
-> No
Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the
harness, reconnect plug(s)
GO to B19
1.
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltatage 0 (zero) V?
-> Yes
GO to B17
35 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> No
Inspect connectors EM010, EM012, and EM021 for corrosion, damaged / pushed back pins or repair the
harness, reconnect plug(s)
GO to B19
1.
36 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002
37 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
B19 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
C : P0137, P0138
C1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
38 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. Measure the voltage between EM022/001 and EM022/002
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to C3
-> No
Renew O2 sensor and reconnect plug(s)
GO to C6
39 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
40 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as C3, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to C5
-> No
Renew O2 sensor and reconnect plug(s)
GO to C6
41 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as in C4, run the engine at 1500 rpm for approximately 3 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180
seconds?
-> Yes
GO to C7
-> No
Renew O2 sensor and reconnect plug(s)
GO to C6
42 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
C6 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
43 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002
Is the resistance < 0.5OHM?
-> Yes
GO to C8
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to C10
1.
44 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/022 and EM022/001
Is the resistance < 0.5OHM?
-> Yes
GO to C9
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to C10
1.
45 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM022 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 002 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to C11
-> No
Renew the O2 sensor and reconnect all plugs
GO to C10
C10 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
46 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
47 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to C12
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to C13
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
48 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> Yes
GO to C14
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to C13
C13 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
49 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002
Is the resistance < 0.5OHM?
-> Yes
GO to C15
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to C20
1.
50 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/022 and EM022/001
Is the resistance < 0.5OHM?
-> Yes
GO to C16
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to C20
1.
51 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/017
Is the voltage 0 (zero) V?
-> Yes
GO to C17
-> No
Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to C20
1.
52 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0 (zero) V?
-> Yes
GO to C18
-> No
Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to C20
1.
53 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
54 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
C20 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
55 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
D : P0140
D1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1. Check the engine and exhaust system for correct operation and normal running temperature
Is the engine and exhaust system operating correctly and up to normal running temperature?
-> Yes
GO to D3
-> No
Rectify leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system
operation and test the system for correct operation
GO to D7
56 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. Measure the voltage between EM022/001 and EM022/002
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to D4
-> No
Renew O2 sensor; reconnect plug(s)
GO to D7
57 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
58 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as D4, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to D6
-> No
Renew O2 sensor; reconnect plug(s)
GO to D7
59 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as in D5, run the engine at 1500 rpm for approximately 3 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180
seconds?
-> Yes
GO to D8
-> No
Renew O2 sensor; reconnect plug(s)
GO to D7
60 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
D7 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
61 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002
Is the resistance < 0.5OHM
-> Yes
GO to D9
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to D11
1.
62 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/022 and EM022/001
Is the resistance < 0.5OHM?
-> Yes
GO to D10
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to D11
1.
63 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM022 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 002 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to D12
-> No
Renew the O2 sensor and reconnect all plugs
GO to D11
D11 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
64 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
65 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to D13
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to D14
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
66 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> Yes
GO to D15
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to D14
D14 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
67 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/017 and EM022/002
Is the resistance < 0.5OHM?
-> Yes
GO to D16
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to D21
1.
68 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM022 disconnected, measure the resistance between EM012/022 and EM022/001
Is the resistance < 0.5OHM?
-> Yes
GO to D17
-> No
Inspect connectors EM012, and EM022 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to D21
1.
69 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/015
Is the voltage 0V?
-> Yes
GO to D18
-> No
Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to D21
1.
70 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0V?
-> Yes
GO to D19
-> No
Inspect connectors EM010, EM012, and EM022 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to D21
1.
71 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 and EM022 disconnected, measure the insulation resistance between EM012/017 and
ground EM010/023
Is the resistance > 10 MOHM?
-> Yes
GO to D20
-> No
Inspect EM012, EM022 for corrosion, bent / pushed back pins or locate and repair the harness / connector
fault; reconnect plug(s)
GO to D21
1.
72 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
D21 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
73 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
E1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1.
74 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM023 disconnected, measure the resistance between EM023/001 and EM023/002.
Is the resistance between 4 and 10OHM?
-> Yes
GO to E3
-> No
Renew O2 sensor; reconnect plug(s)
GO to E7
75 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. With EM023 disconnected, measure the voltage between EM023/003 and EM023/004.
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to E4
-> No
Renew O2 sensor; reconnect plug(s)
GO to E7
1.
76 2012-07-21
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77 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With the conditions held as E4, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to E5
-> No
Renew O2 sensor; reconnect plug(s)
GO to E6
E6 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
78 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> Yes
STOP
-> No
Contact Jaguar Service
1.
2. With EM023 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 003 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to E9
79 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> No
Renew the O2 sensor and reconnect plug(s)
GO to E8
E8 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
80 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to E10
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to E11
81 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to E12
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to E11
82 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
E11 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
83 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM023 disconnected, measure the resistance between EM012/014 and EM023/003
Is the resistance < 0.5OHM?
-> Yes
GO to E13
-> No
Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s).
GO to E18
1.
84 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM012 and EM023 disconnected, measure the resistance between EM012/022 and EM023/004
Is the resistance < 0.5OHM?
-> Yes
GO to E14
-> No
Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s).
GO to E18
1.
85 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/014
Is the voltage 0 (zero) V?
-> Yes
GO to E15
-> No
Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s).
GO to E18
1.
86 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0 (zero) V?
-> Yes
GO to E16
-> No
Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s).
GO to E18
1.
87 2012-07-21
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88 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/001
Is the voltage B+?
-> Yes
Remove link lead and reconnect all connectors
GO to E18
-> No
Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made
GO to E18
89 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
E18 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
F : P0153
F1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1. Check the engine and exhaust system for normal running temperature
Is the engine and exhaust system up to normal running temperature?
-> Yes
GO to F3
90 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
-> No
Rectify possible leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine
cooling system operation. Test the system for correct operation
GO to F8
1.
2. With EM023 disconnected, measure the resistance between EM023/001 and EM023/002.
Is the resistance between 4 and 10OHM?
-> Yes
GO to F4
-> No
91 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. Measure the voltage between EM023/003 and EM023/004.
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to F5
-> No
Renew O2 sensor, reconnect plug(s)
92 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
GO to F8
1.
93 2012-07-21
1999 XK RANGE - Exhaust System - 309-00
1.
2. With the conditions held as F5, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to F7
-> No
Renew O2 sensor, reconnect plug(s)
GO to F8
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1.
2. With the conditions held as in F6, run the engine at 1500 rpm for approximately 2 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 4
seconds?
-> Yes
GO to F9
-> No
Renew O2 sensor, reconnect plug(s)
GO to F8
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F8 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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2. With EM023 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 003 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to F11
-> No
Renew the O2 sensor and reconnect plug(s)
GO to F10
F10 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
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1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
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GO to F12
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect earthing stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s)
GO to F13
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to F14
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect earthing stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground, reconnect plug(s)
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GO to F13
1.
2. With EM012 and EM023 disconnected, measure the resistance between EM012/014 and EM023/003
Is the resistance < 0.5OHM?
-> Yes
GO to F14
-> No
Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness,
reconnect plug(s)
GO to F19
1.
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2. With EM012 and EM023 disconnected, measure the resistance between EM012/022 and EM023/004
Is the resistance < 0.5OHM?
-> Yes
GO to F15
-> No
Inspect connectors EM012, and EM023 for corrosion, damaged / pushed back pins or repair the harness,
reconnect plug(s)
GO to F19
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/014
Is the voltage 0 (zero) V?
-> Yes
GO to F16
-> No
Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the
harness, reconnect plug(s)
GO to F19
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltatage 0 (zero) V?
-> Yes
GO to F17
-> No
Inspect connectors EM010, EM012, and EM023 for corrosion, damaged / pushed back pins or repair the
harness, reconnect plug(s)
GO to F19
1.
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1.
2. With EM010 and EM015 disconnected, measure the voltage between EM010/023 and EM015/002
Is the voltage B+?
-> Yes
Remove link lead and reconnect all connectors
GO to F19
-> No
Check EMS fuse F14 and that EMS control relay (relay 1) is energized and with all connections made
GO to F19
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F19 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
G : P0157, P0158
G1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1.
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2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. Measure the voltage between EM024/001 and EM024/002
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to G3
-> No
Renew O2 sensor and reconnect plug(s)
GO to G6
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1.
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2. With the conditions held as G3, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to G5
-> No
Renew O2 sensor and reconnect plug(s)
GO to G6
1.
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2. With the conditions held as in G4, run the engine at 1500 rpm for approximately 3 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180
seconds?
-> Yes
GO to G7
-> No
Renew O2 sensor and reconnect plug(s)
GO to G6
G6 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
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-> Yes
STOP
-> No
Contact Jaguar Service
1.
2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002
Is the resistance < 0.5OHM?
-> Yes
GO to G8
-> No
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Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to G10
1.
2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001
Is the resistance < 0.5OHM?
-> Yes
GO to G9
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
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reconnect plug(s)
GO to G10
1.
2. With EM024 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 002 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to G11
-> No
Renew the O2 sensor and reconnect all plugs
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GO to G10
G10 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to G12
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to G13
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1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
GO to G14
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to G13
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G13 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002
Is the resistance < 0.5OHM?
-> Yes
GO to G15
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to G20
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001
Is the resistance < 0.5OHM?
-> Yes
GO to G16
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to G20
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/016
Is the voltage 0 (zero) V?
-> Yes
GO to G17
-> No
Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to G20
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0 (zero) V?
-> Yes
GO to G18
-> No
Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to G20
1.
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1.
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G20 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
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H : P0160
H1 : RETRIEVE DTCS
NOTE:
Battery and or ECM disconnection prior to scanning will erase all data, ensure that the correct DTC is present
1.
1. Check the engine and exhaust system for correct operation and normal running temperature
Is the engine and exhaust system operating correctly and up to normal running temperature?
-> Yes
GO to H3
-> No
Rectify leaking exhaust manifold / catalyst, general causes of an over rich mixture and engine cooling system
operation and test the system for correct operation
GO to H7
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1.
2. Run the engine for a period to warm the sensor and then maintain a steady speed of approximately 2500 rpm
3. With EM024 disconnected. measure the voltage between EM024/001 and EM024/002
Is the voltage between 600mV and 1.0 Volt?
-> Yes
GO to H4
-> No
Renew O2 sensor; reconnect plug(s)
GO to H7
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1.
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1.
2. With the conditions held as H4, suddenly accelerate to approximately 2500 rpm
Has the voltage risen to between 600mV and 1 volt?
-> Yes
GO to H6
-> No
Renew O2 sensor; reconnect plug(s)
GO to H7
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1.
2. With the conditions held as in H5, run the engine at 1500 rpm for approximately 3 minutes
Does the displayed voltage drop below 400mV and rise above 500 mV, cycling approximately every 180
seconds?
-> Yes
GO to H8
-> No
Renew O2 sensor; reconnect plug(s)
GO to H7
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H7 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002
Is the resistance < 0.5OHM
-> Yes
GO to H9
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to H11
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001
Is the resistance < 0.5OHM?
-> Yes
GO to H10
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to H11
1.
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2. With EM024 disconnected measure the insulation resistance between sensor pin 001 and sensor body
3. Repeat for pin 002 and sensor body
Is the resistance > 10 MOHM?
-> Yes
GO to H12
-> No
Renew the O2 sensor and reconnect all plugs
GO to H11
H11 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
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1.
2. With EM010 and EM014 disconnected, measure the resistance between EM010/023 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
-> Yes
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GO to H13
-> No
Inspect connector EM010 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to H14
1.
2. With EM010 and EM014 disconnected, measure the resistance between EM014/004 and chassis ground EM1BR
(EM2BR)
Is the resistance < 0.5OHM?
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-> Yes
GO to H15
-> No
Inspect connector EM014 for corrosion, damage, or pushed back pin
Inspect ground stud EM1BR (EM2BR) for corrosion
Repair as required, harness, splice EMS38, connector or ground; reconnect plug(s)
GO to H14
H14 : STOP
1. Perform appropriate service drive cycle and check for the presence of DTC
Has the fault code cleared?
-> Yes
STOP
-> No
Contact Jaguar Service
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/016 and EM024/002
Is the resistance < 0.5OHM?
-> Yes
GO to H16
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to H21
1.
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2. With EM012 and EM024 disconnected, measure the resistance between EM012/022 and EM024/001
Is the resistance < 0.5OHM?
-> Yes
GO to H17
-> No
Inspect connectors EM012, and EM024 for corrosion, damaged / pushed back pins or repair the harness;
reconnect plug(s)
GO to H21
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/016
Is the voltage 0V?
-> Yes
GO to H18
-> No
Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to H21
1.
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2. With EM010 and EM012 disconnected, measure the voltage between EM010/023 and EM012/022
Is the voltage 0V?
-> Yes
GO to H19
-> No
Inspect connectors EM010, EM012, and EM024 for corrosion, damaged / pushed back pins or repair the
harness; reconnect plug(s)
GO to H21
1.
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2. With EM010 and EM012 and EM024 disconnected, measure the insulation resistance between EM012/016 and
ground EM010/023
Is the resistance > 10 MOHM?
-> Yes
GO to H20
-> No
Inspect EM012, EM024 for corrosion, bent / pushed back pins or locate and repair the harness / connector
fault; reconnect plug(s)
GO to H21
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H21 : END
1. Perform appropriate service drive cycle and check for the presence of DTC
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3. CAUTION:
Note the position of the upstream and downstream oxygen sensor multiplugs for reassembly.
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Installation
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3. CAUTION:
Note the position of the upstream and downstream oxygen sensor multiplugs for reassembly.
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Installation
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2. Move the front muffler forward to allow the intermediate mufflers to be displaced.
Slacken the muffler to catalytic converter securing clamps (left- and right-hand sides).
3. Slacken the front to intermediate muffler securing clamps (left - and right-hand sides).
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Installation
2. Tighten the front to intermediate muffler securing clamps (left - and right-hand sides).
Correctly position the muffler joints.
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2. Raise the rear of the vehicle and support on two suitable vehicle stands.
4. Remove the rear muffler/tailpipe assembly; refer to the procedure in this section.
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6. Move the front muffler forward to allow the intermediate muffler to be removed.
Slacken the front muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
Installation
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4. NOTE:
If necessary, rotate the intermediate muffler at the front to intermediate muffler joint to achieve the
tailpipe trim settings; refer to Specifications in this section.
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2. Raise the rear of the vehicle and support on two suitable vehicle stands.
4. Remove the rear muffler/tailpipe assembly; refer to the procedure in this section.
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6. Move the front muffler forward to allow the intermediate muffler to be removed.
Slacken the front muffler to downpipe catalytic converter securing clamps (left- and right-hand sides).
Installation
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4. NOTE:
If necessary, rotate the intermediate muffler at the front to intermediate muffler joint to achieve the
tailpipe trim settings; refer to Specifications in this section.
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Installation
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Installation
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1999 XK RANGE - Fuel System - General Information - 310-00
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 WORK AREA
DISCONNECT THE BATTERY BEFORE WORKING ON THE FUEL SYSTEM
AVOID SPARKS
MAKE SURE SUITABLE FIRE EXTINGUISHERS ARE AT HAND
MAKE SURE ABSORBENT MATERIAL IS AT HAND TO SOAK UP ANY SPILLAGE
MAKE SURE THE WORK AREA IS WELL VENTILATED
MAKE SURE THAT THE GAUGE IS CORRECTLY CONNECTED, AND THAT ALL CONNECTIONS
ARE SECURE BEFORE STARTING THE ENGINE
DO NOT DISCONNECT THE GAUGE FROM THE SCHRADER VALVE WHILE THE ENGINE IS
RUNNING
MAKE SURE THE SCHRADER VALVE RESEALS ONCE THE GAUGE IS DISCONNECTED
1. Make sure the vehicle is in Park for vehicles with automatic transmission, Neutral for vehicles with
manual transmission.
3. Place suitable absorbent material around the schrader valve to absorb any spillage when connecting the
gauge set.
NOTE:
Depending on the design of the gauge set, there may be a drain valve and tube. Make sure this valve is
closed, and the drain tube placed in a suitable container BEFORE connecting the gauge to the schrader valve.
7. Disconnect and plug the vacuum hose from the pressure regulator.
9. With the engine still running, reconnect the vacuum hose to the pressure regulator and record the reading.
The pressure should drop to approximately 2.6 bar (38 psi) when the vacuum hose is reconnected.
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12. Where fitted, open the drain valve and allow the fuel from the gauge and line to flow into the container to
depressurize the system.
13. Disconnect and remove the gauge set and any adaptors.
14. Clean up any fuel which may have been spilt and remove the absorbent material. Dispose of safely.
15. Refit and secure the protective cap to the schrader valve.
17. Start the engine and make sure there are no leaks.
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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:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
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WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
All vehicles
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Vehicles without supercharger
All vehicles
NOTE:
Vehicles without supercharger shown, vehicles with supercharger similar.
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5. WARNING:
MAKE SURE THE TAP OF THE SPECIAL TOOL IS ROTATED FULLY CLOCKWISE BEFORE
INSTALLING THE SPECIAL TOOL TO THE FUEL SYSTEM PRESSURE RELEASE VALVE. FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Install the special tool to the fuel system pressure relief valve.
6. NOTE:
When relieving the fuel system pressure, catch any displaced fuel in a suitable container.
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7. Remove the special tool from the fuel system pressure relief valve.
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All vehicles
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Fuel System
Fuel System
Fuel is stored in the fuel tank mounted across the vehicle behind the passenger compartment bulkhead. Fuel is
drawn by the fuel pump from the tank and then supplied to the rail via a filter. Fuel injectors, controlled by the
ECM are installed in the fuel rail on each side of the intake manifold. The amount of fuel injected into the engine is
controlled by the ECM. A cross-over pipe connects the the fuel rail together at the front of the manifold. A test
valve in the rail allows the fuel rail to be pressurized and de-pressurized during the servicing and troubleshooting
procedures. A pressure regulator on the rear of the fuel rail controls the pressure in the fuel rail. A return line
directs excess fuel from the pressure regulator back to the fuel tank.
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Fuel Tank
The steel fuel tank is located inside the trunk and mounted across the vehicle behind the passenger compartment
bulkhead.
On the coupe model the tank is held in position by locating pins at at the front and retaining straps fitted to
body-mounted brackets; on the convertible model it is held in position by the closing panel and locating pins at the
front of the tank.
The fuel tank has an integral non-adjustable filler pipe and breather.
Fuel is drawn by the fuel pump from the fuel tank and supplied via the fuel lines and 70 micron filter to the fuel
rails.
The fuel lines run from front-to-rear down the vehicle's left-hand-side and consist of two assembly clusters, front
and rear, jointed near the fuel-filter position.
The fuel pumps run constantly and excess fuel is returned to the fuel tank. The amount of fuel being injected into
the engine is controlled by the engine management system.
The fuel filler cap with bayonet-type fixing is located beneath a remote-release spring-latched lid on the side of the
rear panel tonneau on the left-hand-side of the vehicle. This is attached to a non-adjustable fuel pipe and breather
integral with the fuel tank.
Check Valve
On vehicles with on-board refueling vapor recovery (ORVR) a check valve is located inside the fuel tank.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Purge Valve
The purge valve is mounted in the left-hand front wheel arch and is controlled by the engine control module
(ECM). It is linked to the evaporative emission canister system located in the left-hand front wheel arch.
Fuel Lines
The fuel lines run from front-to-rear down the vehicle's left side and consist of two assembly clusters front and
rear, which are jointed near the fuel filter position.
All fuel lines are serviceable; the removal of the front cluster requires no major disassembly but rear cluster
removal requires the lowering of the rear suspension assembly. A variety of quick fit connectors are used
throughout the fuel system, including the fuel tank to underfloor pipe connections above the rear axle.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Fuel Pump
The fuel pump which is located inside the fuel tank, is energized by an ECM controlled relay. Fuel is drawn by this
pump and supplied to the fuel injectors via the fuel line, filter and fuel rails.
Vehicles with supercharger are fitted with an additional fuel pump to compensate for the increase in fuel demand.
The sender unit for the fuel gauge is fitted into the back of the fuel tank and can be serviced without removing the
tank. The fuel tank must be drained before removing the fuel gauge sender unit.
Fuel Valves
Any excess fuel flowing through the system is returned to the fuel tank via a diaphragm-operated fuel regulator
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Excess fuel is directed back to the fuel tank via a return line.
A test valve is fitted to the fuel injection supply manifold. This valve allows the fuel rail to be pressurized and
depressurized during servicing and troubleshooting.
Two bracket-and-strap assemblies secure the tank in position on the coupe model only.
A steel closing panel on the convertible version is fitted across the full width of the vehicle, bolted to the body
behind the fuel tank with access to the fuel-gauge sender in the rear of the tank.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Fuel Cut-Off Inertia Switch
The inertia switch, when operated, disables the ignition system and fuel pump, releases any locked doors and
switches off unnecessary electrical systems.
The inertia switch is located next to the fuse box at the left-hand end of the fascia.
To reset the switch after it has been activated, the rubber cap on the top of the switch is pressed down.
On vehicles with a convertible top an earth strap is fitted from the left-hand rear flange of the fuel tank to the
left-hand wheelarch.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Fuel Pump Relay
Location
Operation
The fuel pump relay, under control of the ECM, switches power to the fuel pump motor.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Monitoring Procedure
With the ignition on, the drive to the main fuel pump relay is examined. If the state of the drive is not as expected,
then a main fuel relay failure judgement is made. The DTC is stored if failure is detected on two successive
ignition cycles.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Depressurize the fuel system, refer to <<19.50.02>>.
2. Drain the fuel tank using a suitable manually operated (NOT electrically operated) suction pump / tanker.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
5. CAUTION:
Use two spanners to make sure no strain is placed on the pipes.
NOTE:
Position a suitable container below the filter to collect the fuel.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Installation
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Removal
1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Remove battery. Refer to operation <<86.15.01>>.
2. NOTE:
If On-board Refueling Vapor Recovery (ORVR) system is fitted, refer to General Procedures Section
<<310-00>>.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Installation
1. NOTE:
Install new seal.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Removal WARNING:
PLACE THE VEHICLE IN A QUARANTINED AREA AND ARRANGE 'NO SMOKING/PETROL FUMES'
SIGNS ABOUT THE VEHICLE.
WARNING:
BEFORE ANY WORK IS CARRIED OUT ON THE FUEL SYSTEM, GROUND THE VEHICLE TO EARTH
AND MAINTAIN THE GROUND CONNECTION UNTIL THE WORK IS COMPLETE.
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING
ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS
PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED
OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
AFTER CARRYING OUT REPAIRS, THE FUEL SYSTEM MUST BE CHECKED VISUALLY FOR LEAKS.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES
AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF TAKEN INTERNALLY DO NOT INDUCE VOMITING, SEEK IMMEDIATE MEDICAL ATTENTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
IF FUEL CONTACTS THE EYES, FLUSH THE EYES WITH COLD WATER OR EYEWASH SOLUTION AND
SEEK MEDICAL ATTENTION.
WARNING:
WASH HANDS THOROUGHLY AFTER HANDLING, AS PROLONGED CONTACT MAY CAUSE
IRRITATION. SHOULD IRRITATION DEVELOP, SEEK MEDICAL ATTENTION.
WARNING:
DO NOT CARRY OR OPERATE CELLULAR PHONES WHEN WORKING ON OR NEAR ANY FUEL
RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
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Installation
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1999 XK RANGE - Fuel Tank and Lines - 310-01
3. CAUTION:
Make sure the fuel pump is correctly located before the retaining bolt is fully tightened. Failure to
follow these instructions may result in damage to the vehicle.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Installation
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1999 XK RANGE - Fuel Tank and Lines - 310-01
Removal
1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION
<<100-00>> (UNDER THE HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Release the fuel filler flap from inside vehicle.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
6. Remove the paintwork protection covers and close the engine compartment.
7. Drain the fuel tank using a suitably manually operated (NOT electrically operated) suction pump / tanker.
9. Remove the front liner from the luggage compartment. Refer to operation <<76.19.31>>.
10. Remove the side liner, left hand. Refer to operation <<76.19.22>>.
11. Remove the side liner, right hand. Refer to operation 76.19.23.
12. Convertible / Soft Top vehicles only - remove the fuel tank closing panel.
Remove the seven bolts; three from the top edge and two from each lower bracket to body.
Remove the closing panel.
13. Remove the fuel gauge tank sender unit. Refer to operation <<88.25.32>>.
14. Drain the remaining fuel from the tank, through the sender aperture, using the equipment described
previously.
15. Install the fuel gauge tank sender unit. Refer to operation <<88.25.32>>.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
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1999 XK RANGE - Fuel Tank and Lines - 310-01
18. Disconnect the drain hose from the filler neck body aperture.
Release and reposition the securing clip.
Disconnect the drain hose.
19. Disconnect the electrical connector from the fuel filler flap solenoid.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
21. Remove the straps which secure the harness to the filler neck breather pipe.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
22. Disconnect the ground lead from the fuel tank flange.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
25. Disconnect the filler neck gaiter drain hose from below the luggage compartment floor.
Release the hose from the clip on the luggage compartment floor.
Reposition the hose through the grommet into the luggage compartment.
26. From under the vehicle, identify the fuel feed and return tank / pipe connections which are located above
and slightly to the rear of the axle assembly.
1. Identify the fuel feed pipe.
2. Identify the fuel return pipe.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
27. Disconnect the fuel feed and return pipes from the fuel tank.
Install special tool 310-054 around the pipe as shown. Press the tool in between the fuel pipe and tank
connector to release the quick-fit tangs. While holding the tool firmly in place, pull out the fuel pipe.
Repeat for the second pipe.
Plug the tank outlet connectors and the fuel pipes.
29. CAUTION:
Whilst removing the fuel tank, take care not to damage the left side of the vehicle body with the
filler neck.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
30. If installing a new, complete tank assembly - remove the insulation padsfrom the top of the tank.
Use a sharp knife to very carefully remove the pads.
31. If installing a new, complete tank assembly - remove the seal (fuel tank to body) from the fuel line stub
pipes at the base of the tank.
Installation
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1999 XK RANGE - Fuel Tank and Lines - 310-01
1. If removed previously, install the seal (fuel tank to body) to the fuel line stub pipes at the base of the tank.
Apply adhesive to the tank face of the seal before installation to the stub pipes.
2. If removed previously, install the insulation pads to the top of the tank.
Apply adhesive to the pads, carefully align and locate them onto the tank.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
3. CAUTION:
Whilst installing the fuel tank, take care not to damage the left side of the vehicle body with the
filler neck.
4. Route the filler neck gaiter drain hose through the luggage compartment floor.
Reposition the hose through the grommet aperture in the luggage compartment. Install the grommet.
Reposition the hose retaining clip to the side of the luggage compartment.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
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1999 XK RANGE - Fuel Tank and Lines - 310-01
8. Install new straps which secure the harness to the filler neck breather pipe.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
10. Connect the drain hose to the filler neck body aperture.
Connect the drain hose.
Reposition the securing clip.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
12. NOTE:
Reposition the gaiter through the body aperture.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
14. NOTE:
Remove the blanking plugs from the tank outlet connectors and the fuel pipes.
Connect the fuel feed and return pipes to the fuel tank.
1. Install the fuel feed pipe to the Quick Fit Connector. Ensure that the pipe is fully locked in place.
2. Repeat for the return pipe. Ensure that the pipe is fully locked in place.
15. Install the filler neck drain tube into the clip.
18. Convertible / Soft Top vehicles only - install the fuel tank closing panel.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
19. Install the left hand side liner to the luggage compartment. Refer to operation <<76.19.22>>.
20. Install the right hand side liner. Refer to operation 76.19.23.
22. Install the battery and battery cover. Refer to operation <<86.15.01>>.
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1999 XK RANGE - Fuel Tank and Lines - 310-01
7. Slacken and remove fuel tank closing panel securing bolts and carefully withdraw panel from trunk.
Installation
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1999 XK RANGE - Fuel Tank and Lines - 310-01
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1999 XK RANGE - Fuel Tank and Lines - 310-01
1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
Installation
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1999 XK RANGE - Acceleration Control - 310-02
1. Load the Approved Jaguar Diagnostic System with power train data logger.
3. With 'Disable Network Integrity Test - YES/ NO' displayed on the screen select YES.
4. With new menu displayed on the screen, select ' Engine Management'.
6. On data logger select PPS11 and PPS2 (Pedal demand sensors 1 and 2).
7. On Sedan models only, remove the bulkhead covers on both sides and the engine compartment rear
cover.
8. Cut, remove and discard the ratchet strap which retains the throttle cable to the abutment bracket.
9. Ensure there is no tension on the throttle cable by releasing the throttle cable adjustment nut from the
abutment bracket.
10. Record the voltages for both sensors, PPS11 and PPS2.
11. Partially insert the throttle cable adjustment nut into the abutment bracket.
12. Recheck the voltages for both sensors, PPS11 and PPS2.
13. Where the voltages at step 12 are higher than the voltages taken at step 10, continue to step 15 below.
14. Where the voltages at step 12 are the same as the voltages taken at step 10, continue to step 16 below.
15. Rotate the adjustment nut clockwise (as viewed from the front of the vehicle) until the same voltages are
indicated as in step 10. Continue to turn through a part revolution until the sides of the nut are vertical. Turn
through a further 90 degrees, then fully insert the nut into the abutment bracket.
16. Rotate the adjustment nut anti-clockwise (as viewed from the front of the vehicle) until the indicated
voltage starts to increase. Then rotate the nut clockwise through a part revolution until the sides are vertical.
Turn through a further 90 degrees, then fully insert the nut into the abutment bracket.
17. Fit a new ratchet strap to secure the throttle cable adjusting nut to the abutment bracket.
18. Operate the throttle pedal through 20 full cycles to settle the cable. Check the voltages now shown,
remain the same as in steps 15 and 16.
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1999 XK RANGE - Acceleration Control - 310-02
19. Check and where necessary adjust the kickdown switch. For additional information, refer to
<<307-05A>><<307-05B>> .
20. On Sedan models only, refit the engine compartment rear cover and the bulkhead covers on both sides.
21. Switch the ignition OFF and disconnect the Approved Jaguar Diagnostic System.
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1999 XK RANGE - Acceleration Control - 310-02
4. Disconnect the throttle cable from the electronic throttle assembly quadrant.
1. Rotate the throttle quadrant to release the cable.
2. Disconnect the throttle cable from the electronic throttle assembly quadrant.
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1999 XK RANGE - Acceleration Control - 310-02
6. Release the grommet from the plenum chamber closing plate and route the cable/grommet through the
aperture.
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1999 XK RANGE - Acceleration Control - 310-02
12. From under the hood, remove the cable from the vehicle.
Installation
1. Installation is the reverse of the removal procedure.
Adjust the throttle cable, refer to 19.20.08.
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1999 XK RANGE - Speed Control - 310-03
Speed Control
The Vehicle Speed Control system offers the driver relaxed vehicle cruising by enabling a pre-set constant vehicle
speed to be maintained without driver operation of the accelerator pedal.
Vehicle Speed Control is activated by an ON/OFF master switch adjacent to the 'Sport' mode switch in the 'J' gate
surround. An integral red light illuminates when the system is activated.
A steering wheel mounted four button control pad provides for driver increase (+) or decrease (-) of set vehicle
speed, suspension of system operation with set speed memorised (CANCEL) and resumption of operation at
memorised vehicle speed (RESUME). The selected vehicle speed is displayed in the message centre. The
vehicle speed control system will not operate below 26km/h (16mph).
The set vehicle speed can be increased or decreased in 2km/h (1mph) increments by briefly pressing the (+) or (-)
control button up to a maximum of five times. Alternatively, the (+) or (-) button can be pressed and held until the
required vehicle speed is displayed in the message centre.
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1999 XK RANGE - Speed Control - 310-03
Speed Control
Principles of operation
The speed control system is activated by an ON/OFF master switch in the J-gate surround, which has an integral
LED to indicate status.
The steering wheel switches allow the driver to set the speed, increase or decrease the selected speed, cancel
and resume the facility without his/her hand ever leaving the steering wheel
The vehicle speed can be increased and decreased in increments of 2 kmh (1 mph) by briefly pressing the + or
-buttons up to a maximum of five times.
Alternatively, the + or - button can be held until the desired speed is reached.
The selected speed (by whichever method) will be displayed in the message center.
The system will not function at speeds below 26 kmh (16 mph), and can be cancelled from the master switch, the
steering wheel switches, and by depressing the brake pedal. The system can be overridden by accelerating as
normal.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. If the cause is not visually evident, verify the symptom, check for DTCs and follow the routines in this
section.
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1999 XK RANGE - Speed Control - 310-03
Diagnostic Trouble Code (DTC) index
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1999 XK RANGE - Speed Control - 310-03
P1571 Brake switch Brake switch to ECM circuit open circuit, For brake switch circuit
malfunction short circuit to ground, high resistance tests,
Goto <<F>>
Brake switch ignition switched ground
.
circuit open circuit
Brake switch failure
Brake cancel switch to ECM circuit open
circuit, short circuit to ground, high
resistance
Brake cancel switch to speed control
switch circuit open circuit, short circuit to
ground, high resistance
Brake cancel switch ignition switched
power supply open circuit
Brake cancel switch failure
Speed control switch failure
Pinpoint tests
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
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1999 XK RANGE - Speed Control - 310-03
5. Measure the resistance between SW02, pin 03 (at the cassette reel side of the connector) and GROUND.
Is either resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<A3>>
1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 03 (SG).
2. Operate the speed control CANCEL switch.
Does the resistance vary by 680 ohms?
-> Yes
Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for
normal operation.
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
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1999 XK RANGE - Speed Control - 310-03
1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 03 (SG).
2. Operate the speed control RESUME switch.
Does the resistance vary by 430 ohms?
-> Yes
Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for
normal operation.
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
1. Check for continuity between SW02, pins 06 (BO) and 03 (SG) with the steering wheel CANCEL switch
operated.
Is the circuit continuous?
-> Yes
Goto <<C3>>
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
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1999 XK RANGE - Speed Control - 310-03
1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel switches inactive.
Is the circuit continuous?
-> Yes
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
-> No
Goto <<C5>>
1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel CANCEL switch
operated.
Is the circuit continuous?
-> Yes
Goto <<C6>>
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
1. Check for continuity between SW02, pins 06 (BO) and 04 (SR) with the steering wheel CANCEL switch
operated.
Is the circuit continuous?
-> Yes
Goto <<C7>>
-> No
INSTALL a new cruise control switchpack. CLEAR the DTC. TEST the system for normal operation.
C7 : CHECK THE STEERING WHEEL CASSETTE REEL FOR CONTINUITY (CIRCUIT #1)
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1999 XK RANGE - Speed Control - 310-03
2. Measure the resistance between SW01, pin 06 and SW02, pin 06 through the cassette reel.
Is the cassette reel continuous?
-> Yes
Goto <<C8>>
-> No
INSTALL a new steering wheel cassette. CLEAR the DTC. TEST the system for normal operation.
1. Measure the resistance between SW01, pin 03 and SW02, pin 03 through the cassette reel.
Is the cassette reel continuous?
-> Yes
Goto <<C9>>
-> No
INSTALL a new steering wheel cassette. CLEAR the DTC. TEST the system for normal operation.
C10 : CHECK THE ECM TO CASSETTE REEL CIRCUIT FOR CONTINUITY (CIRCUIT 2)
1. Measure the resistance between EM11, pin 05 (SG) and SW01, pin 03 (SG).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
system for normal operation.
-> No
Contact dealer technical support for advice on possible ECM failure.
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
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1999 XK RANGE - Speed Control - 310-03
1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 04 (SR).
2. Operate the speed control DECEL/SET- switch.
Does the resistance vary by 680 ohms?
-> Yes
Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for
normal operation.
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
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1999 XK RANGE - Speed Control - 310-03
1. Measure the resistance between SW02, pin 06 (BO) and SW02, pin 04 (SR).
2. Operate the cruise control ACCEL/SET+ switch.
Does the resistance vary by 430 ohms?
-> Yes
Recheck DTCs. No short found. Possible intermittent fault. CLEAR the DTC. TEST the system for
normal operation.
-> No
INSTALL a new speed control switchpack. CLEAR the DTC. TEST the system for normal operation.
WARNING:
WHERE TESTS INVOLVE THE REMOVAL OF THE STEERING WHEEL, AND/OR DISCONNECTION OF
AIR BAG CONNECTORS, THE PROCEDURE FOR DISARMING AIR BAGS MUST BE FOLLOWED,
<<501-20A>><<501-20B>>
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1999 XK RANGE - Speed Control - 310-03
F2 : CHECK THE BRAKE SWITCH TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
1. Reconnect the battery negative terminal.
2. Turn the ignition switch to the ON position.
3. Measure the voltage between AC24, pin 01 (US) and GROUND.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<F3>>
F4 : CHECK THE BRAKE SWITCH IGNITION SWITCHED GROUND CIRCUIT FOR HIGH
RESISTANCE
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1999 XK RANGE - Speed Control - 310-03
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
-> No
Goto <<F5>>
F6 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR HIGH RESISTANCE
F7 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR SHORT TO HIGH VOLTAGE
F8 : CHECK THE BRAKE CANCEL SWITCH TO ECM CIRCUIT FOR SHORT TO GROUND
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1999 XK RANGE - Speed Control - 310-03
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
the system for normal operation.
-> No
Goto <<F9>>
F9 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT
FOR HIGH RESISTANCE
F10 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT
FOR SHORT TO HIGH VOLTAGE
F11 : CHECK THE BRAKE CANCEL SWITCH TO CRUISE CONTROL SWITCH TO ECM CIRCUIT
FOR SHORT TO GROUND
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1999 XK RANGE - Speed Control - 310-03
F12 : CHECK THE BRAKE CANCEL SWITCH IGNITION SWITCHED POWER SUPPLY
13 2012-07-20
1999 XK RANGE - Climate Control System - General Information - 412-00
Feature Requirement
Recovery rate 0,014 - 0,062 m3 / min. (1,36 kg in 20 minutes)
Cleaning capability 15 ppm moisture; 4000 ppm oil; 330 ppm non-condensable gases in air
Oil separator With hermetic compressor and automatic oil return
Moisture indicator Sight-glass type, sensitive to 15 ppm minimum
Vacuum pump Two-stage 0,07 - 0,127 m3 / min.
Filter Replaceable, with moisture indicator
Charge Selectable charge weight and automatic delivery
Hoses Dedicated HFC 134A port connections
Charge pressure Heating element to increase pressure
Unit Specification
Refrigerant HFC 134A
Compressor lubricant Polyalkyleneglycol (PAG)
Capacities
Unit Specification
Refrigerant charge weight 650 +/- 50 g
Compressor lubricant capacity 160 - 200 ml
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1999 XK RANGE - Climate Control System - General Information - 412-00
1. Attach the center (service) hose to a vacuum pump and start the pump. Open fully both high and low valves
and allow the vacuum to remove air and moisture from the manifold set for at least five minutes. CAUTION:
It is imperative that the vacuum pump is not subjected to a positive pressure of any degree.
Therefore the pump must be fitted with an isolation valve at the center (service hose) connection
and this valve must be closed before the pump is switched off. This operation replaces the 'purge'
procedure used on previous systems. Observe the manufacturer's recommendation with regard to
vacuum pump oil changes.
Turn the vacuum pump off and isolate it from the center service hose but do not open the hose to atmosphere.
CAUTION:
Only use hoses with connectors which are dedicated to HFC 134A charge ports.
1. Attachment of the hose quick release connectors to the high and low side system ports is straightforward,
provided that the high and low valves are closed and the system is NOT operational. WARNING:
UNDER NO CIRCUMSTANCES SHOULD THE CONNECTIONS BE MADE WITH THE SYSTEM IN
OPERATION OR THE VALVES OPEN. SHOULD THE VALVES BE OPEN AND A VACUUM PUMP OR
REFRIGERANT CONTAINER ATTACHED, AN EXPLOSION COULD OCCUR AS A RESULT OF HIGH
PRESSURE REFRIGERANT BEING FORCED BACK INTO THE VACUUM PUMP OR CONTAINER.
Assessment of system operating efficiency and fault classification may be achieved by using the facilities on
your Recovery / Recharging / Recycling station, follow the manufacturer's instructions implicitly and observe all
safety considerations.
1. Accurate test gauge data will only be attained if the system temperatures and pressures are stabilized.
Ensure that equipment and hoses cannot come into contact with engine moving parts or sources of heat.
It is recommended that a free standing air mover is placed in front of the vehicle to provide air flow through
the condenser / cooling system.
Start the engine, allow it to attain normal working temperature and set at fast idle (typically 1200 to 1500
rpm).
Select full air conditioning performance.
With all temperatures and pressures stable, or displaying symptoms of faults; begin relevant test
procedures.
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Recover / Reclaim
1. CAUTION:
Read the procedures and instructions supplied by the manufacturer of the air conditioning service
center before commencing any process requiring the handling of refrigerant. In addition to the
manufacturer's information, observe all safety precautions and advice detailed in this section.
5. Remove vehicle charge port protective caps and connect equipment pressure hoses to vehicle.
1. BLUE hose = low pressure.
2. RED hose = high pressure.
Evacuation
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Charging
3. Disconnect hoses from vehicle and replace charge port protective caps.
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1. The 'manifold gauge set' is a most important tool for tracing faults and system efficiency assessment. The
relationship between HIGH and LOW pressures and their correlation to AMBIENT and EVAPORATOR
temperatures must be compared to determine system status (see Pressure / Temperature graphs).Because of
the heavy reliance upon this piece of equipment for service diagnosis, ensure that the gauges are calibrated
regularly and the equipment is treated with care.
2.
Parts List
Item Description
1 LOW side service hose - BLUE
2 LOW side hand valve - BLUE
3 LOW pressure compound gauge _ BLUE
4 HIGH pressure gauge _ RED
5 HIGH side hand valve - RED
6 HIGH side service hose - RED
7 System service hose - Neutral color, commonly YELLOW
Manifold.
1. The manifold is designed to control refrigerant flow. When connected into the system, pressure is registered
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on both gauges at all times. During system tests both the high and low side hand valves should be closed (rotate
clockwise to seat the valves). The hand valves isolate the low and the high sides from the center (service) hose.
1. This compound gauge, is designed to register positive and negative pressure and may be typically calibrated
- Full Scale Deflection, 0 to 10 bar (0 to 150 lbf / in2) pressure in a clockwise direction; 0 to 1000 mbar (0 to 30
in Hg) FSD negative pressure in a counter clockwise direction.
1. This pressure gauge may be typically calibrated from 0 to 30 bar (0 to 500 lbf / in2) FSD in a clockwise
direction. Depending on the manufacturer, this gauge may also be of the compound type.
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Refrigerant Adding
CAUTION:
If oil was drawn out during the recovery process, the correct amount may be added directly from the
recovery, recycle and recharge station (if so equipped) prior to the charging process. It must be stressed
that the need to protect compressor oil from moisture is vital, observe the procedures in HANDLING
LUBRICATING OIL and those concerning excessive engine speed.
1. In order that the air conditioning system may operate efficiently it must contain a full refrigerant charge. The
indications of some system defects, and the results of certain tests, will show that a low charge is the most
probable cause of the fault. In such cases the charge should be recovered from the system, the weight noted,
and the correct amount added.Should refrigerant be added in liquid form, the engine speed must not exceed
2000 rpm for a period of two minutes after first running the compressor. If the engine speed is excessive,
compressor damage may occur due to the lubricating oil and the liquid refrigerant being initially forced around
the system as a 'slug', thus taking oil away from the compressor. These marginal lubrication conditions in the
compressor will cease as the refrigerant becomes gaseous.Never attempt to estimate the amount of refrigerant
in a system. Always recover and recharge with the correct charge weight; this is the only accurate method.
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CAUTION:
Always decant fresh oil from a sealed container and do not leave oil exposed to the atmosphere. PAG oil is
very hygroscopic (absorbs water) and will rapidly attract atmospheric moisture. PAG oil must NEVER be
mixed with mineral based oils. Do not re-use oil following a recovery cycle, dispose of it safely.
1. The amount of oil drawn out during a recovery procedure will be dependent on the state of the system and
the rate of recovery. The quantity will be approximately 30 to 40 ml.; this may vary, and the figure is given only
for guidance.The oil separator vessel in the recovery equipment must be clean and empty at the start of the
process, so that the quantity of oil which is drawn out may be accurately measured.NOTE:
The equipment manufacturer's instructions must be followed when adding oil directly into an original, or new
unit, owing to rectification work to the existing compressor, or the need to fit a new compressor.
Oil may be added to the system either via the recovery, recycle and recharge station or by using a proprietary
oil injector. Alternatively, if the compressor has been removed from the vehicle, the oil may be added directly to
the compressor.
Original Compressor
1. From an existing compressor, drain the oil into a measuring cylinder and record the amount. Flush the unit out
with fresh oil and drain thoroughly. Replenish the compressor with the same amount of oil that was originally
drained out and immediately plug all orifices ready for refitting to the vehicle.
New Compressor
1. Drain and discard the transit lubricating oil from the new compressor before it is be fitted.To avoid over-filling
the system, an allowance must be made for the quantity of oil found in the original compressor and the quantity
deposited in the recovery equipment oil separator from the charge recovery operation.Typical example:
Drained from original compressor - 50 ml.
Recovered from oil separator - 40 ml.
Quantity to be put in new compressor - 50 + 40 = 90 ml.
2. The difference between the combined total quantity of recovered and drained oil and the nominal capacity of
the system (180 ml.), is due to the quantity of oil remaining in components such as the condenser, receiver drier
or evaporator. This oil is not normally recoverable.The same procedure may be followed if a problem has
occurred due to oil leakage, as the amount of oil lost is generally small. If the recovery process has not been
necessary, because refrigerant has also been lost, then only the quantity drained from the original compressor
needs to be replaced.
System Components
1. Should a major component such as condenser, receiver drier or evaporator be renewed, then an adjustment
to the system oil content must be made. This may be carried out in the same way as the examples for the
compressor, except for the fact that trapped oil within any of these components cannot normally be recovered.
An extra quantity of oil should be added, in addition to that recovered from the recovery station separator, as
follows:
Condenser - Add 40 ml.
Evaporator - Add 40 ml.
Receiver drier - No addition.
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WARNING:
USE EXTREME CARE AND OBSERVE ALL SAFETY PRECAUTIONS RELATED TO THE USE OF
REFRIGERANTS. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
CAUTION:
The A/C refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do
so puts workshop bulk refrigerant at risk of contamination. If the vehicle A/C refrigerant is contaminated,
refer the customer to return to the repair facility that carried out the last A/C repair. If the customer wishes to
pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C
refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. To prevent possible
personal injury, for all equipment, follow the equipment manufacturer's procedures and instructions.
NOTE:
Jaguar Cars Ltd. supports the efficient usage, recovery and recycling of the refrigerant used in passenger car air
conditioners. Jaguar Cars Ltd. recommends the use of UL-approved recovery/recycling equipment during any A/C
system repair and recharge procedure which requires that the system be evacuated.
1. Use UL-approved recovery/recycling equipment to evacuate and recover the A/C system.
Follow the equipment manufacturer's procedures and instructions for use of equipment.
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CAUTION:
Observe all relevant safety requirements. Wear suitable eye and skin protection Do not mix HFC 134A and
CFC 12 refrigerants. Do not vent refrigerant directly to atmosphere and always use Jaguar approved
recovery, recycle and recharge equipment. Note the amount of recovered refrigerant; it will indicate the state
of the system.
Working Practices
Be aware of, and comply with all health and safety requirements, whether they be legislative or common sense. This
applies to conditions set both for the operator and workshop.
Before commencing any repair or service procedure, disconnect the vehicle battery ground lead and protect the
vehicle, where appropriate, from dirt or damage.
Recovery, recycle and recharge equipment must meet, or exceed, the requirements detailed in the Specification
sub-section.
Handling Refrigerant
Wear eye protection at all times. Use gloves and keep all skin covered that may come into contact with refrigerant.
Should refrigerant come into contact with eyes or skin, wash the affected area with cool water and seek medical
advice; do not attempt to treat the condition yourself.
Avoid breathing refrigerant vapor; it may cause irritation to the respiratory system.
CAUTION:
Never use high pressure compressed air to flush out a system. Under certain circumstances a combination
of HFC 134A refrigerant, compressed air and a source of combustion (welding and brazing operations in the
vicinity), may result in an explosion and the release of potentially toxic compounds.
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HFC 134A and CFC 12 refrigerants must never come into contact with each other. They will form an inseparable
mixture which can only be disposed of by incineration.
Do not vent refrigerant directly to atmosphere; always use Jaguar approved recovery equipment. Never depress the
charge or discharge port valves to check for the presence of refrigerant.
HFC 134A refrigerant is fully recycleable and it may be 'cleaned' by the recovery equipment and therefore re-used
following removal from a system.
WARNING:
NEVER USE A CFC 12 ANALYZER OR NAKED FLAME TYPE.
Leak tests should be carried out with a UV spot lamp or an electronic analyzer which is dedicated to HFC 134A
refrigerant.
Avoid breathing lubricant mist; it can cause irritation to the respiratory system.
Always use fresh oil from a sealed container and do not leave oil exposed to the atmosphere for any reason other
than to fill or empty a system. PAG oil is very hygroscopic (absorbs water) and will rapidly become contaminated by
atmospheric moisture.
PAG oil is NOT compatible with previously used mineral based oils and must NEVER be mixed. Do not re-use oil when
it has been separated from refrigerant, following a recovery cycle. Dispose of used oil safely.
System Maintenance
Plug pipes and units immediately after disconnection and do not remove the plugs until immediately before making the
connection. Do not leave the system open to atmosphere.
The receiver drier must be renewed if the compressor has failed or if it is suspected that debris may be present in the
system.
It is not always necessary to renew the receiver drier if the correct procedures have been followed. However, if a
component or part of the system is left dismantled for more than five minutes, it may be advisable to renew the
receiver drier. This guidance is based on UK average humidity levels; locations with lower humidity levels will be less
critical to moisture contamination. It must be stressed however that there is not a safe period for work to be carried
out in.
Do not use any replacement parts supplied without transit plugs and seals - return them to the supplier.
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Diagnostic equipment for pressure, mass and volume should be calibrated regularly and certified by a third party
organization.
Use extreme care when handling and securing aluminum fittings; always use a backing spanner and take special care
when handling the evaporator.
Use only the correct or recommended tools for the job and apply the manufacturer's torque specifications.
The 'Normal' condition is that which is relevant to the prevailing ambient temperature.
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(To obtain lbf / in2 from bar, multiply the figure by 14.5)
Probable causes of faults may be found by comparing actual system pressures, registered on your manifold gauge
set or recovery / recharge / recycle station, and the relevant pressure to temperature relationship graph. The following
chart shows the interpretation that may be made by this difference.
NOTE:
The A/CCM will disengage the compressor clutch should the evaporator temperature fall to 0°C.
NOTE:
Graphs are typical for HFC 134A
The 'Normal' condition is that which is relevant to the prevailing evaporator temperature.
This table should be used in conjunction with the graphical representations of 'High side' pressure / ambient
temperature and 'Low side' pressure / evaporator temperature.
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Leak Test
Faults associated with low refrigerant charge weight and low pressure may be caused by leakage. Leaks traced to
mechanical connections may be caused by torque relaxation or joint face contamination. Evidence of oil around such
areas is an indicator of leakage.
Models that have fluorescent tracer dye incorporated into the refrigeration system can be checked for non-apparent
leaks by scanning with a high intensity ultraviolet lamp. The location of leaks can be pinpointed by the bright yellow
glow of the tracer dye.
CAUTION:
Observe ALL safety precautions associated with ultraviolet equipment.
Should a leak be traced to a joint, check that the fixing is secured to the correct tightening torque before taking any
other action.
When examining the system for leaks, check the compressor shaft seal and evaporator.
The process of charge recovery will depend on the basic characteristics of your chosen recovery / recycle / recharge
equipment, therefore, follow the manufacturer's instructions carefully.
Remember that compressor oil may be drawn out during this process, take note of the quantity recovered so that it
may be replaced.
This process, the removal of unwanted air and moisture, is critical to the correct operation of the air conditioning
system.
Moisture in the system can be highly destructive and may cause internal blockages due to freezing; water suspended
in the lubricating oil will damage the compressor. Once the system has been dismantled, or the refrigerant charge
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Specific procedures will vary depending on the individual characteristics of the recovery / recycle / recharge
equipment, and must be carried out exactly in accordance with the manufacturer's instructions. However, it is
recommended that initially only the high-side valve be opened at the start of the procedure. After a short time a small
depression should be seen on the low-side, at which point the low-side valve may be opened and the evacuation
process completed. If a vacuum is not registered on the low-side, it may indicate that the expansion valve is
permanently closed or that the system is blocked. This simple check may save time and effort when the system is
recharged.
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Introduction
It is very important to positively identify the area of concern before starting a rectification procedure. A little time spent
with your customer to identify the conditions under which a problem occurs will be beneficial. See below for example:
Condition(s):
No defrost
Possible Source(s):
No airflow to windshield
Action(s) to take:
Check blowers and flaps
Possible Source(s):
No function in defrost mode
Action(s) to take:
Check A/CCM
Possible Source(s):
Mode selection not available
Action(s) to take:
Check control panel communication
Possible Source(s):
Airflow OK but no heat
Action(s) to take:
Check water pump and valve
Relevant criteria are: Weather conditions, ambient temperature, intermittent or continuous fault, airflow fault,
temperature control fault, distribution fault and air inlet problem.
Functional Check
This simple 'first line check' will allow you to ascertain whether the system is operating within its design parameters,
without recourse to PDU.
2. Presss AUTO to display selected temperature and illuminate AUTO and A/C state lamps.
3. Rotate FAN to increase or decrease lower speed, verify bar graph representation.
4. Select A/C to toggle on or off. (The compressor may be inhibited by the ECM should either the engine
temperature NOT be normal or the ambient be < 2° C).
5. Select RECIRC , state lamp should be lit and the recirculation flaps open.
6. Select distribution buttons in turn, verify correct air distribution and relevant state lamp.
8. Cycle TEMPERATURE to ' HI ' and ' LO ' to verify demanded variations and display operation. Note that
extremes will provide max heat or cold independent of in-car temperature.
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10. Select F (where fitted) and R - noting exterior mirror; verify timer and operation (glass may be warm to the
touch)
11. Initiate system 'Self Test' to display stored faults should any of the above not perform as stated.
System symptoms
There are five basic symptoms associated with air conditioning fault diagnosis.
Symptom #1
Condition(s):
No cooling
Possible Source(s):
Compressor seized
Compressor seal failure
Compressor valve or piston damage
Action(s) to take:
Renew compressor
Possible Source(s):
Compressor clutch / circuit faulty
Action(s) to take:
Refer to PDU
Possible Source(s):
Drive belt slack / broken
Action(s) to take:
Adjust or renew
Possible Source(s):
Blower motor / circuit faulty
Pressure switch / circuit fault
Action(s) to take:
Refer to PDU
Possible Source(s):
Total loss of refrigerant caused by broken pipe or joint
Action(s) to take:
Repair / renew. Check code 23
Possible Source(s):
Partial loss of refrigerant caused by leaking joint or pipe
Action(s) to take:
Repair / renew, check fault code #23
Possible Source(s):
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Condenser damage
Action(s) to take:
Renew, check fault code #23
Possible Source(s):
Blocked receiver / drier filter
Action(s) to take:
Renew receiver / drier
Possible Source(s):
Evaporator sensor / circuit faulty
Action(s) to take:
Refer to PDU, check fault code #13
Possible Source(s):
Blocked pollen filter (if fitted)
Action(s) to take:
Clean or renew
Symptom #2
Condition(s):NOTE:
Should a leak or low refrigerant be established as the cause of INSUFFICIENT COOLING, follow the procedures
Recovery / Recycle / Recharge, this section, and observe all refrigerant and oil handling instructions.
Insufficient cooling
Possible Source(s):
Compressor clutch slipping
Action(s) to take:
Renew clutch assembly
Possible Source(s):
Flaps or vents closed / seized
Action(s) to take:
Check fault codes #41 to 46
Possible Source(s):
Blower circuit fault
Action(s) to take:
Refer to PDU
Possible Source(s):
Blocked condenser matrix / fins
Action(s) to take:
Check high / low side pressures / renew. Check / clean fins
Possible Source(s):
Blocked evaporator matrix
Action(s) to take:
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Possible Source(s):
Blocked pollen filter (if fitted)
Action(s) to take:
Clean or renew
Possible Source(s):
Evaporator temperature sensor faulty
Action(s) to take:
Refer to PDU
Possible Source(s):
Partial loss of refrigerant caused by leaking joint or pipe
Action(s) to take:
Repair / renew
Possible Source(s):
Blocked expansion valve
Action(s) to take:
Check high / low side pressures / renew
Possible Source(s):
Expansion valve fault
Action(s) to take:
Check system pressure differential
Possible Source(s):
Collapsed air conditioning hose hose
Action(s) to take:
Check high / low side pressures / renew
Possible Source(s):
Moisture or air in the system
Action(s) to take:
Check system pressures
Possible Source(s):
Low refrigerant charge
Action(s) to take:
Initiate recovery procedure, check fault code #23
Possible Source(s):
Coolant flow valve open
Action(s) to take:
Check operation
Symptom #3
Condition(s):
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Intermittent cooling
Possible Source(s):
Compressor clutch slipping
Action(s) to take:
Renew clutch assembly
Possible Source(s):
Compressor clutch circuit faulty
Blower(s) circuit faulty
Action(s) to take:
Refer to PDU
Possible Source(s):
Motorized in-car aspirator faulty
Action(s) to take:
Refer to PDU, check fault code #11
Possible Source(s):
Evaporator temperature sensor faulty
Action(s) to take:
Refer to PDU, check fault code #13
Possible Source(s):
Blocked condenser matrix / fins
Action(s) to take:
Check high / low side pressures / renew. Check / clean fins
Possible Source(s):
Blocked evaporator matrix
Action(s) to take:
Check high / low side pressures / renew
Symptom #4
Condition(s):
Noisy system
Possible Source(s):
Loose or damaged compressor drive belt
Action(s) to take:
Adjust or renew
Possible Source(s):
Loose compressor mountings
Action(s) to take:
Check for damage, tighten to specification if OK
Possible Source(s):
Compressor oil level low
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Action(s) to take:
Look for evidence of leakage and rectify as required
Possible Source(s):
Compressor internal damage
Action(s) to take:
Check for debris, renew compressor and receiver drier
Possible Source(s):
Blower motor noise
Action(s) to take:
Renew motor (assuming no fan interference)
Possible Source(s):
Excessive refrigerant charge
Action(s) to take:
Check for vibration or 'thumping' in high pressure line; may be witnessed by high pressure on
both HIGH and LOW sides. Recover / recharge
Possible Source(s):
Low refrigerant charge
Action(s) to take:
Check for 'hissing' at expansion valve; may be witnessed by low HIGH side pressure.
Recover / recharge
Possible Source(s):
Moisture or air in the system
Action(s) to take:
Check system pressures
Possible Source(s):
Heater circuit air-lock
Action(s) to take:
Refer section 303-03 for fill / bleed procedure
Possible Source(s):
Suction pipe touching bank 1 (A) cylinder head (rubber isolator missing)
Action(s) to take:
Check the pipe cluster for correct fitting
Symptom #5
Condition(s):NOTE:
Electrical faults may be more rapidly traced using PDU
Insufficient heating
Possible Source(s):
Coolant flow valve stuck 'closed'
Coolant flow valve stuck 'open' allowing recirculation of coolant at engine idle
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Action(s) to take:
Renew valve
Possible Source(s):
Motorized in-car aspirator seized
Action(s) to take:
Renew aspirator
Possible Source(s):
Cool air bypass damper stuck open
Action(s) to take:
Renew, check fault code #43
Possible Source(s):
Blocked air inlet / pollen filter
Action(s) to take:
Check / clean / renew
Possible Source(s):
Blower speed low
Action(s) to take:
Check performance range
Possible Source(s):
Low coolant level
Action(s) to take:
Adjust as required (verify and correct reason for loss)
Possible Source(s):
Engine thermostat faulty
Action(s) to take:
Check engine running temperature
Possible Source(s):
Heater water pump seized
Action(s) to take:
Check operation
Possible Source(s):
Heater matrix blocked
Action(s) to take:
Renew matrix
Possible Source(s):
Heater circuit air-lock
Action(s) to take:
Refer section 303-03 for fill / bleed procedure
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Air Distribution
Outside air enters the plenum via two inlets in the lower finisher at the base of the windshield.
If the air conditioning system is operating in FRESH mode (not recirculation mode), then air is drawn through an air
particle filter (where fitted) and into the air conditioning unit via the blower interconnecting ducts in the LH and RH
blower assemblies. Air is cooled and dehumidified as it passes through the evaporator and is then 'reheated' to the
required temperature as it passes through the heater matrix.
In RECIRCULATION mode, the air in the passenger compartment is drawn into the air conditioning unit via the
recirculation air inlets on the blower assemblies.
In FRESH mode, air flows from the cabin into the trunk via extraction slots in the rear parcel shelf at the base of the
backlight on the Coupe and the hood containment panel on Convertible. The air is exhausted from the vehicle through
extraction vent assemblies (incorporating one way flaps) whose outlets are above the rear mufflers.
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Foot / defrost mode.
Face mode.
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Defrost mode.
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Air Particle Filter (Rain deflector removed for clarity)
The air particle filter system (where fitted) is located in the 'wet' plenum below the windshield finisher.
The filter element is retained by clips which are moulded onto the filter housing. Please note that the filter must be
fitted with the light, flocked surface, towards the engine.
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Parts List
Item Description
1 Air outlet - EOD vent
2 Servomotor - center fascia vent
3 Servomotor - windshield
4 Air outlet - fascia center
5 Air outlet - windshield
The upper air distribution box ADB, is fixed to the defrost duct and facia assembly, and seals by contact pressure to
the outlet (top) of the air conditioning unit. The ADB incorporates two servo motor operated flaps which regulate
airflow to:
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Internal Components and Air Flow
Parts List
Item Description
1 Air inlet - from RH blower (LH opposite, not shown)
2 Air outlet - fascia center vent
3 Air outlet - defrost
4 Air outlet - EOD 1LH and 1RH
5 Air outlet - footwell
6 Flap - cool air bypass
7 Evaporator
8 Matrix - heater
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Using a thin plastic lever, carefully remove fascia centre veneer panel from fascia. Refer to <<76.47.06>>
4. Accessing through glove box aperture, disconnect fascia centre vent harness multiplug.
5. Exercising care to avoid damaging surfaces, use a thin plastic lever to release centre vent dowels from fascia.
6. Positioning vent for access, move vent lead and multiplug clear of fascia harness and remove vent from fascia.
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Installation
1. Position centre vent at fascia and route harness multiplug to fascia location.
3. Accessing through glovebox aperture, connect centre vent nultiplug to fascia harness.
4. Fit and fully seat centre vent veneer panel. Refer to <<76.47.06>>.
6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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4. Release two tangs securing the top of the filter element and tilt the top of the element forward.
5. Release the two lower securing tangs, lightly press the accelerator cable support clear and remove the filter
element.
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Installation
1. CAUTION:
The air particle filter element must be installed with the white flock side facing forwards. If the
element supplied will not fit in this position it must be changed for the correct part.
Positioning lower securing tangs and accelerator cable support to achieve clearance, install element lower edge
in the housing
2. Lift the upper securing tangs, press the top of the filter element rearwards and fully seat it in the housing.
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Schematic Diagram
Parts List
Item Description
1 Heater matrix
2 Firewall
3 Non return valve
4 Water pump
5 Water valve
6 Return to engine
7 Feed from engine
8 Non return valve (heater bypass)
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Heater System Components
Parts List
Item Description
1 Hose - heater (from engine)
2 Assembly pump - water
3 Assembly valve - water
4* Hose - water valve to water pump
5 Hose - water pump to heater (feed)
6* Assembly hose - heater to water valve (return)
7 Valve - non return
NOTE:
* These hoses are flattened at the bends by design and NOT by incorrect installation.
The heater circuit 'scavenges' coolant from the engine cooling system by means of an electric water pump. The water
pump has a protection circuit to inhibit operation when the coolant temperature is <16°C; this is to prevent possible
damage to the impeller due to the presence of coolant borne ice particles. Coolant is drawn from the engine system
through the water valve inlet port into the heater matrix. The coolant passes through the bottom section of the heater
matrix from left to right filling the end tank of the matrix before returning through the top half of the matrix and through
the outlet ports of the water valve and back into the engine cooling system.
Non return valves are located in the heater bypass hose and the hose between heater outlet and water valve. These
valves are required to prevent coolant flowing in the wrong direction at low engine speeds and restrict convected flow
through the heater after the engine is switched off.
When the exterior ambient temperature is > 3° C the refrigeration system automatically operates cooling and
dehumidifying incoming air before it is re-heated by the heater matrix.
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Water Valve Assembly
Location
The water valve assembly is located above the water pump, in the engine compartment and is secured to the firewall
by a bracket. The valve operates by means of an electrical solenoid which oscillates the valve stem between the inlet
and outlet ports.
A heatshield protects the water valve from exhaust system radiated heat.
When in automatic mode, the water valve is controlled by the following inputs to the A/CCM:
Maximum heating demand will cause the water valve to be fully open (not energised) to allow maximum coolant flow
through the heater matrix.
At Maximum cooling, the water valve will be fully closed (energised) to prevent hot (engine temperature) coolant
entering the heater circuit; the pump however will continue to circulate coolant through both the heater matrix and
water valve bypass.
Under engine stall conditions, when ignition is ON, the water valve will be open.
Located in the same area as the water valve, the water pump continually circulates coolant through the heater matrix
except when the conditions below apply:
The flow indicator arrow embossed on the valve body MUST point towards the coolant header tank.
CAUTION:
Coolant flow will be compromised if either valve is fitted incorrectly. Observe the correct direction.
A second non-return valve is located in the heater outlet to water valve hose. This valve prevents hot coolant from
flowing into the heater with the engine switched off. The flow indicator arrow MUST point towards the water valve.
The heater feed and return hoses are connected to the engine feed and return hoses by 'Quick-Fit' connection unions.
The feed hose has a Norma R20 connector and the return hose a Norma push and seal connector. The coolant
system bleed joints have Cobra clamps. All remaining hose connections have spring band hose clamps.
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The engine feed hose is connected to the engine bypass housing and the engine return hose is connected to the
engine water pump.
Clamp Identification
Parts List
Item Description
1 Cobra
2 Spring band
3 Quick-fit
4 Norma push and seal 'R' type
5 Norma push and seal 15
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5. Remove fascia support bracket to bulkhead securing bolts (from between air duct and fascia harness).
6. Disconnect cool air bypass servo motor connector and heater matrix pipes.
Disconnect connector.
Remove screws which secure retaining brackets.
NOTE:
Position suitable cloth to absorb coolant leakage before disconnecting pipes.
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Displace and reposition fascia support bracket to permit removal of heater matrix.
Remove heater matrix.
Installation
1. NOTE:
Fit new O-ring seals.
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1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
5. From under the hood: Disconnect air conditioning pipes at the evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.
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Installation
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9. Install brace.
Reposition and align brace to heater / cooler unit.
Install brace to transmission tunnel securing bolts.
Install brace to bulkhead securing bolt (where fitted).
Install steering column upper mounting bracket / brace to firewall securing bolt.
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15. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
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Air Conditioning
Introduction
Component Location
Parts List
Item Description
1 Fascia panel with integral ducting
2 Heater / cooler assembly
3 A/CCM
4 Blower LH and RH
5 Plenum
6 Control panel
7 Solar sensor (LHD shown)
8 Assembly valve - water
9 Assembly pump - water
10 Temperature sensor - external
11 Compressor
12 Pressure switch - 4 level
13 Motorized in-car aspirator (LHD shown)
14 Receiver drier
15 Condenser
The climate control system features fully automatic control of temperature, blower speed (airflow) and air distribution
to maintain optimum comfort under most driving conditions.
Manual controls are provided to allow the operator to over-ride automatic operation.
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System Features
Sensors
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Major Components
Item Description
1 Compressor assembly
2 Condenser
3 Evaporator and heater matrix (internal)
4 Receiver drier
5 4-level pressure switch
6 Expansion valve (internal)
7 High-side charge port
8 Low-side charge port
9 Suction muffler
10 Discharge hose
11 Discharge pipe
12 Suction hose
13 Suction pipe
14 Liquid line
15 Jumper hose (condenser hose)
Compressor
Features
Receiver drier
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Vertically mounted on the right-hand side of the engine compartment next to the engine coolant radiator.
Fitted with the high-side charge port.
Condenser
Multi-pass fin-over-tube type, mounted in front of the engine cooling pack and directly to the radiator.
Expansion Valve
Parts List
Item Description
1 Valve body
2 Pressure spring
3 Diaphragm
4 Capillary tube
5 Temperature sensing bulb
6 Valve inlet
7 Valve outlet
8 Equalizer pipe
The expansion valve is located inside the heater / air conditioning unit and comprises of a diaphragm, connected by a
capillary tube to a temperature sensing bulb, which regulates the valve according to temperature variations at the
evaporator outlet pipe. This component is NOT serviceable. See 'Refrigeration Cycle'
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Parts List
Item Description
1 Air inlet - LH (RH opposite, not shown)
2 Servomotor - cool air bypass
3 Servomotor - footwell outlet
4 Air outlet - footwell
5 Air outlet - ADB (with foam seal)
The air conditioning unit houses the evaporator, heater matrix and their temperature sensors. The unit also
incorporates two servo motor operated air distribution flaps which regulate airflow to the front footwells and the
quantity of airflow through the cool air bypass (air which by-passes heater matrix) up to the upper air distribution box
(ADB).
When the front footwell flap is open, air is ducted to the footwell area via the lower air distribution duct (LADD) and
front footwell duct. The LADD is clipped to the bottom of the air conditioning unit case and the front foot ducts clipped
onto the outlets of the LADD.
Condensate (water) which forms on the evaporator fins is drained out of the unit case through two drains, located
either side of the unit underneath the evaporator. The liquid is routed to the vehicle exterior via flexible tubes which are
located behind the firewall heatshield.
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Refrigeration Cycle
Item Description
1 Compressor
2 Condenser
3 Receiver drier
4 Expansion valve
5 Evaporator
6 4-level pressure switch
The Compressor draws low pressure, low temperature, refrigerant from the evaporator and, by compression, raises
the refrigerant temperature and pressure. High pressure, hot, vaporized refrigerant enters the condenser, where it is
cooled by the flow of ambient air. A change of state occurs as the refrigerant cools in the condenser and it becomes a
reduced temperature, high pressure, liquid.
From the condenser, the liquid passes into the receiver drier which has three functions:
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As heat is absorbed by the refrigerant, it once again changes state, into a vapor, and returns to the compressor for
the cycle to be repeated.
An automatic safety valve is incorporated in the compressor, which will operate if the system pressure rises above 41
bar. The valve will reseat when the pressure drops below 27,6 bar.
The terms 'high' and 'low' pressure (or side) refer to the pressure differential between the compressor and expansion
valve ports. This differential is critical to system fault diagnosis and efficiency checks.
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Air Conditioning
Refer to section <<412-00>>.
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1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
4. Remove front end accessory drive belt; refer to <<12.10.40>> or (SC) 12.10.40.
5. NOTE:
A commercially available brake pipe clamp is recommended. Do not over tighten.
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7. NOTE:
Position drain tin to collect the fluid when union nut is released.
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10. NOTE:
Reposition compressor after releasing the fixings to allow removal.
Remove compressor.
Remove bolts.
11. NOTE:
This step is not necessary in the case of refrigerant loss.
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Installation
2. Install compressor.
Tighten fixings.
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6. Lower ramp.
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8. Install front end accessory drive belt; refer to <<12.10.40>> or (SC) 12.10.40.
10. Reconnect battery ground cable (IMPORTANT, see SRO <<86.15.15>> for further information).
12. Check / bleed / top up power steering fluid reservoir; refer to <<211-02>>.
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1. NOTE:
It is not necessary to remove the fan cowl in order to access the condenser.
Installation
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Installation
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1. Disconnect battery ground cable (IMPORTANT, see SRO <<86.15.19>> for further information).
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Installation
1. NOTE:
Install new O-rings and lubricate with clean compressor oil.
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Control Components
System Controls
The climate control system is controlled by :
1. Manual input from the operator, via the center console located control panel.
Communication between the control panel and the A/CCM is via a serial data communications link.
The climate control system can be switched ON by pressing one of the following :
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Ref #11 AUTO (resumes the system on at the previous temperature setting).
Ref #12 DEF (resumes the system on at the previous temperature setting).
All buttons with an integral LED state lamp conform to the following operating logic.
When the state lamp is lit the relevant function is operational. From this condition, pressing the button will de-activate
the function, confirmed by the LED being de-energized and the presence of a single audible 'beep'. A single 'beep' will
accompany the state lamp to confirm function re-selection.
Pressing this knob activates the system ON at the last setting or switches the system OFF. Rotate the knob
clockwise to increase and anti-clockwise to decrease fan speed and thus airflow.
With the system OFF, ram air is available by the selected air distribution mode (indicated by state lamp). Air flow will
NOT occur unless a manual air distribution mode is selected, this air being unconditioned and flow dependent upon
vehicle speed.
NOTE:
The blowers are inhibited until the engine coolant temperature is > 35°C, unless DEFROST is selected.
Closes the outside air intakes of the blower assemblies and recirculates air within the vehicle.
Timed Recirculation. Pressing the button for less than 1.5 seconds lights up the LED (confirmed by a single
bleep). This provides recirculation of interior air for a period of approximately 5 minutes. Pressing the button
within five minutes returns the system to fresh air intake mode.
Continuous Recirculation. Pressing and holding the button for more than 1.5 seconds lights up the LED
(confirmed by two beeps). This provides continuous recirculation of interior air. Pressing the button returns the
system to fresh air intake mode.
NOTE:
Avoid using manual air recirculation for prolonged periods in cold weather, this may result in interior misting of
glass.
Rotating the fan speed control knob (to vary fan speed) will display a proportional number of horizontal bars on the
LCD. There are total of eleven manual fan speeds available.
5. Temperature Display
Indicator of internal demand temperature or external ambient temperature. The external ambient is updated every 4
seconds when the road speed > 25 km / h.
6. Scale
7. External temperature
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8. Automatic
Symbol indicates when the control of, temperature, fan speed and air distribution are all in Auto mode.
9. External
Quick Display. Pressing the button for <1.5 seconds (confirmed by a single bleep) will display the external
temperature for 4 seconds.
Continuous Display. Pressing and holding the button for >1.5 seconds (confirmed by two beeps) displays the
external ambient temperature continuously, the value of which will be updated every 4 seconds given that
vehicle road speed is > 25 km/h. Pressing the button again for <1.5 seconds resets to the previous display.
NOTE:
Continuous external temperature display will be cancelled when the ignition is switched OFF but not during engine
cranking.
10. A/C
This push-on / push-off button will either select or deselect (as indicated by the state lamp) the refrigeration system.
The refrigeration system is automatically engaged when the Auto button is pressed.
NOTE:
Interior misting of screens may be reduced by continuous operation of the refrigeration system.
11. Auto
When selected and the state lamp lit, A/C mode will be operational and control of vent outlet temperature, fans speed
and air distribution will be automatic.
AUTO mode will disengage should manual air distribution or defrost buttons be operated or the manual fan speed
knob be rotated.
NOTE:
Automatic temperature control is constantly maintained irrespective of selected manual overrides.
12. Defrost
Push-on push-off button, which when engaged will direct all air to the front and side glass at maximum fan speed. The
heated windshield (if fitted) will also be energized for a timed cycle of 6,5 minutes, but may be cancelled by pressing
the HEATED WINDSHIELD (F) button. Pressing 'DEF' again will return to the last setting with automatic temperature
control being maintained.
Directing warm and humid air onto a cold screen can produce interior misting of screens. Operating the climate control
system without the refrigeration system operating will exacerbate this problem.
NOTE:
Directing cold air onto the screen in warm humid conditions can produce external condensation.
Pressing the heated windshield button (where fitted) will energize the electrically heated windshield elements for a
timed cycle of 6,5 minutes; pressing the button again will cancel the request. Should the engine stall or the ignition be
turned OFF, the timer will be cleared and the function cancelled.
NOTE:
The heated windshield may be activated with the climate control system OFF but the engine must be running.
In very cold ambient temperatures, icing of the interior of the glass is possible when the climate control system is
operating in AUTO mode; to reduce this possibility the A/CCM provides automatic operation of the heated windshield.
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With the following conditions met, the heated windshield will automatically energize but the state lamp will NOT be lit.
Pressing the heated backlight button will simultaneously energize the heater elements for timed cycles of;
If the engine is stalled, or the ignition switched OFF, the backlight and door mirror timers will be cleared, resulting in
both functions being switched off.
NOTE:
Both the backlight and door mirrors may be activated with the climate control system OFF, but the engine must
be running.
Pressing this button (BLUE symbol) decreases the interior temperature setting in 1° increments. Should the button be
pressed when the setting temperature is below the lower automatic control temperature limit, the display will indicate
'LO'.
Pressing this button (RED symbol) will raise the temperature setting in 1° increments Should the button be pressed
when the setting temperature is above the upper automatic control temperature limit, the display will indicate 'HI'.
°C °F
LO LO
17 61
62
18 63
64
19 65
66
20 67
68
21 69
70
22 71
72
23 73
74
24 75
76
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25 77
78
26 79
80
27 81
82
28 83
84
29 85
86
30 87
88
31 89
90
HI HI
LO demands the maximum COOLING performance from the system with the blowers operating automatically at
maximum speed.
HI demands the maximum HEATING performance from the system with the blowers operating automatically at
maximum speed.
Pressing and holding either temperature selection button continuously changes the setting temperature by steps of 1°,
every 0.4 seconds.
NOTE:
The interior temperature does not change when the temperature scale is changed between Celsius and
Fahrenheit, however the temperature display will change to the nearest equivalent number.
Examples:
Pressing this button will direct all airflow to the center and side face vents only; pressing again will return the system
to automatic control mode.
NOTE:
When in AUTO mode and in a hot climate, a bleed of cold air is delivered to foot level. This bleed automatically
shuts off when the interior temperature has cooled sufficiently.
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18. Bi-Level
This push-on / push-off button will direct air to the center and side face vents and the front footwells. Pressing the
button (off) will return the system to automatic control mode.
19. Foot
This push-on / push-off button will direct the majority of airflow to the front footwells with a small bleed of air to the
front and side screens. Pressing the button (off) will return the system to automatic control mode.
20. Demist
Pressing this button will direct air to the front and side screens and the front footwells. Pressing the button (off) will
return the system to automatic control mode.
Parts List
Item Description
1 Temperature differential control
2 Airflow control
3 Air direction control
The center vent assembly incorporates the Temperature Differential control thumbwheel. This control provides
adjustment of the outlet air temperature from the center and end of dash vents (EOD), relative to the foot duct air
temperature. The air temperature from the face vents air will increase when the thumbwheel is rotated upwards and
decrease when rotated downwards.
NOTE:
The face level air temperature is always cooler than the foot air temperature and the temperature differential
control ONLY operates when the system is in AUTO or manual Bi-Level mode.
Only the center face air vent assembly incorporates the three listed controls; the EOD vents, not shown, only feature
items 2 and 3.
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Automatic Operation
Initial setting
Should a new A/CCM be fitted, it will 'power-up' in the OFF mode; switching ON will result in the following settings:
Feature Status
Setting temperature 24°C or 75°F
LH and RH blower assembly recirculation / fresh flap Fresh mode
Control mode Automatic 'AUTO' displayed
Blower Auto
Compressor output A/C ON
Heated windshield and mirrors OFF
Water valve Auto temperature control
After initial start up the system operating conditions will be stored in the A/CCM to the conditions which prevailed prior
to ignition OFF.
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Location
The A/CCM is located on the right hand side of the air conditioning unit and controls all system functions.
The temperature within the passenger compartment is continually compared with the temperature selected on the
control panel LCD. The A/CCM receives data input signals and compares these with signals from the system
temperature sensors and feedback devices. Based on this information the A/CCM adjusts the air outlet temperature,
airflow and distribution from the air conditioning system into the passenger compartment.
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Identification
Inputs / Outputs
1. Engine speed:
Input from the heater matrix temperature sensor used to control water valve and thus vent temperatures.
Used to monitor the temperature of coolant at the heater matrix to assist the control of air outlet temperature.
Used to inhibit the blowers when heating is selected and the engine coolant temperature is below 30°C.
Is used to provide progressive increase in blower speed up to 60°C.
To inhibit the water valve and pump when the coolant temperature is = < 10°C
4. Compressor ON signal:
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Solar Sensor
The solar sensor is mounted on the top surface of the fascia between the driver's defrost grille and speaker grille.
The sensor is a photo-diode which is calibrated to measure direct sunlight. It provides an output signal to the A/CCM
which automatically reduces air temperature and increases fan speed (airflow volume) to compensate for solar
heating.
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Evaporator Sensor
The sensor is positioned next to the evaporator fins and measures air temperature after it has passed through the
evaporator. The sensor inputs a signal to the A/CCM which controls the compressor (see table) when the refrigeration
system is operating.
The sensor's connector is located on the LH side of the air conditioning unit, in front of the main power connector.
The A/CCM disengages the compressor clutch when the temperature of the air off the evaporator is 2° C or less. This
is to prevent the moisture which may collect between the cooling fins of the evaporator from freezing and thus
restricting airflow.
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Heater Matrix Temperature Sensor
The heater matrix temperature sensor is a thermistor which changes its electrical resistance in response to changes in
air temperature converting a temperature rating to an electrical signal.
The sensor connector is located on the RH SIDE of the air conditioning unit. The sensor bead is located inside the unit
down-stream from the heater matrix and measures the 'post-heater' air temperature, before the air is distributed to
the cabin The sensor provides a signal to the A/CCM which adjusts the duty ratio of the water valve to provide the
required air temperature from the heater.
The sensor is a thermistor which changes its electrical resistance in response to changes in air temperature,
converting a temperature rating to an electrical signal.
The ambient temperature sensor measures exterior air temperature and is mounted on the RH horn bracket which is
located on the front bumper beam.
The signal from the ambient sensor allows the A/CCM to compensate for the ambient conditions and to display the
information on the control panel - updated every four (4) seconds.
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Sensor response is 'damped' by the A/CCM and therefore does not appear to react to temperature changes as
quickly as the other sensors. This feature prevents the effects of sudden changes in air outlet temperatures due to
factors such as:
Recirculating air from the engine cooling pack at low vehicle speeds
Sudden changes in ambient temperature
The effects of water splash
Cabin air is drawn through a grille (located near the steering column on the knee bolster) over a thermistor. Remotely
mounted from the thermistor is the motorised aspirator with a rubber hose which connects both components.
The electrical resistance of the thermistor changes in response to variations in air temperature and converts this
temperature rating into an electrical signal; the signal is used by the A/CCM to adjust the temperature, airflow and air
distribution from the air conditioning unit.
This signal is supplied to the A/CCM from the instrument cluster, the input being required to:
Provide blower inhibit control , to avoid the system in heating mode delivering cold air when the coolant
temperature is below 35C unless DEFROST is selected.
To progressively increase the fan speed up to maximum blower speed during warm up control.
To assist in the control of the outlet temperature.
To avoid possible pump or valve damage caused by ice particles in the coolant.
Compressor ON Signal.
This signal monitors the compressor relay to confirm the compressor operating state and so provide relevant fault
information.
Flap position, which directs the flow of air through the system, is controlled by servo motors; these may be driven in
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either a clockwise or anti-clockwise direction by signals from the A/CCM. Motor, thus flap position, is monitored via a
feedback potentiometer which is situated within the motor housing.
The A/CCM controls the speed of two blower motors which deliver airflow to the air conditioning unit. The blower
motors are regulated by power transistor modules which provide a linear variation of blower speed.
NOTE:
Blower motors are inhibited when the engine coolant temperature is below 35C and heating is demanded, unless
DEFROST is selected.
Control Components
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The control panel provides operator interface with the climate control system.
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Control Panel Inputs / Outputs
A/CCM Connections
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System Self-test
The control panel has a self-diagnosis feature, and is capable of displaying and clearing stored fault codes.
Climate control is an integrated system, therefore it is recommended that the PDU is used for fault diagnosis. The
fault codes displayed with the control panel self-diagnosis feature are not as comprehensive as those of the PDU. The
PDU will display the relevant fault code, fault code description and information of the system peripherals at the time
the fault occurred.
Error information is stored in the A/CCM up to a maximum of 5 faults. Should a sensor fault occur there will be an
audible beep and the message Er will be displayed on the control panel display for 5 seconds after ignition on. Please
note that this will happen only once in any ignition switch cycle. The error source may be accessed by the following
procedure
Step Result
#1 Simultaneously hold AUTO and RECIRC - Display element check
Switch ignition to ON
#2 Press AUTO Display of stored fault (NUMERIC) code. If ZERO appears,
there are no stored codes
#3 Press FACE Scroll through stored faults (maximum of 5)
#4 Simultaneously press FACE and R Clear stored fault codes (may need to be repeated for each
fault)
#5 Press RECIRC (Press FAN to skip actuator Initiate actuator check (Actuator codes 20 through 27 * )
check)
#6 Press FAN Exit error check mode
NOTE:
* Actuator codes do NOT equate to system fault codes.
NOTE:
Only codes 11, 15 and 21 (see Fault Code Listing) will cause audible beep and 'Er' display.
NOTE:
If '0' is displayed, there are no stored fault codes, wait 30 seconds to allow system self-test.
The control panel display will flash repeatedly indicating a list of two digit numbers (see table for code
analysis).
Should a code be displayed accompanied by an audible beep, the fault is current and therefore still present
within the system. A code displayed without an accompanying 'beep' indicates a fault had previously occurred
but is not present within the system.
NOTE:
It is advisable to check all areas indicated with cleared fault codes. Such faults may re-occur if intermittent
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1999 XK RANGE - Control Components - 412-04
To delete stored and cleared fault codes press 'R' and 'FACE' buttons simultaneously.
After investigating and correcting all stored faults, press the 'Push Off' button to restore normal operation
with default panel settings, ie AUTO at 24°C.
Condition(s):NOTE:
Reference fault code #23*: In ambient temperatures below 0°C, this code may be logged because the low
ambient causes a temporary low gas pressure.
NOTE:
Where the ambient temperature rises above 40°C, with the engine close to overheating, electrical feed to the
compressor clutch may be cut and code #23 registered.
Action(s) to take:
Wait 30 seconds for system self-check.
Action(s) to take:
Panel fault codes are not stored for motorized in-car aspirator motor failure.
Action(s) to take:
After rectification, disconnect the vehicle battery for 10 seconds to reset the system.
Action(s) to take:
Refer to PDU
Action(s) to take:
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1999 XK RANGE - Control Components - 412-04
Refer to PDU
Action(s) to take:
Refer to PDU
21 Solar sensor
Possible Source(s):
Sensor open /short circuit
Action(s) to take:
Refer to PDU
Action(s) to take:
Adjust items as required
Action(s) to take:
Refer to PDU
Action(s) to take:
Rectify as required and recharge system
Action(s) to take:
Refer to PDU
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1999 XK RANGE - Control Components - 412-04
In certain circumstances the servo motor may over-travel and cause further logged faults. This may be
cured, following fault rectification, by cycling the ignition ON-OFF-ON 3 times
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
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1999 XK RANGE - Control Components - 412-04
Possible Source(s):
Harness / connector fault
Servo motor seized or sticking
Flap seized or sticking
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
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1999 XK RANGE - Control Components - 412-04
Action(s) to take:
Refer to PDU
Action(s) to take:
Refer to PDU
Associated Faults
Other conditions which may exist but will NOT log fault codes:
Condition(s):
No heat
Possible Source(s):
Airlock in system.
Action(s) to take:
Refer section 303-03 for fill / bleed procedure
Possible Source(s):
Heater water pump inoperative
Coolant flow valve stuck closed
Action(s) to take:
Check operation and circuit
Possible Source(s):
Faulty engine coolant thermostat
Action(s) to take:
Renew as required
Action(s) to take:
Renew as required
Poor airflow
Possible Source(s):
Blower motors - incorrect operation
Action(s) to take:
Check operation and circuit
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1999 XK RANGE - Control Components - 412-04
The panel communication check verifies the inputs and outputs from the control panel to the A/CCM.
Step Result
#1 Simultaneously hold FACE Panel communication with FACE, Bi-LEVEL, FOOT, DEMIST, DEFROST and
and FAN - Switch ignition to RECIRC lines checked - State lamps will illuminate if all is OK. Unlit state lamp
ON indicates a continuity fault for that specific link
#2 Press ON Exit check mode
The system self test procedure drives all the actuator motors, to check their operation. If an actuator is operating
incorrectly or operating outside of its limits then a fault code will be present.
Before commencing with the actuator check procedure, ensure the car is operating under normal conditions.
2. Press and hold the RECIRC and AUTO buttons simultaneously, switch ignition ON and run the engine.
3. All the control panel LEDs and all LCD segments will flash on and off. Any function LED indicator which does
not flash on / off suggests a fault condition within that area of the panel or, with the LED.
Any LCD element which fails to flash on / off indicates a fault within the display element or panel.
4. Press AUTO
7. Press the FAN button to restore normal operation with default panel settings, ie AUTO @ 24°C.
NOTE:
* The water valve operates on a 6 second pulse, ie 3 seconds ON, 3 seconds OFF.
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1999 XK RANGE - Control Components - 412-04
Outlet
Blower Centre Foot Cool air Fresh / Water
Code Level vent Defrost by-pass Recirc. Compressor valve
20 0 open closed closed closed fresh OFF closed
21 1 open closed closed closed fresh OFF closed
22 10 open closed closed open half A/C ON closed
open
23 17 bleed half closed half half A/C ON 6s pulse
open open open *
24 17 bleed half closed closed recirc. A/C ON 6s pulse
open *
25 23 closed open bleed closed recirc. A/C ON open
26 23 closed half half closed recirc. A/C ON open
open open
27 31 closed closed open closed open A/C ON open
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1999 XK RANGE - Control Components - 412-04
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1999 XK RANGE - Control Components - 412-04
Installation
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1999 XK RANGE - Control Components - 412-04
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Remove radio console securing screws and position console for access.
5. Disconnect air conditioning control module harness multiplug and cut and remove securing tiestrap.
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1999 XK RANGE - Control Components - 412-04
6. Remove remaining switch control module central securing screw and withdraw module from vehicle.
Installation
1. Position air conditioning switch control module on radio console and install module securing screws.
7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Control Components - 412-04
Installation
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1999 XK RANGE - Control Components - 412-04
Installation
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1999 XK RANGE - Control Components - 412-04
Installation
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1999 XK RANGE - Control Components - 412-04
Installation
1 2012-07-21
1999 XK RANGE - Instrument Cluster and Panel Illumination - 413-00
1 2012-07-21
1999 XK RANGE - Instrument Cluster and Panel Illumination - 413-00
2. Position housing for access, rotate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation
2. Install bulb holder in housing and rotate 1/4 turn clockwise to fully engage.
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1999 XK RANGE - Instrument Cluster and Panel Illumination - 413-00
2. Position housing for access, rotate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation
2. Install bulb holder in housing and rotate 1/4 turn clockwise to fully engage.
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1999 XK RANGE - Instrument Cluster and Panel Illumination - 413-00
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Rotate appropriate bulb holder 1/4 turn counter-clockwise, withdraw holder and remove bulb.
Installation
2. Install bulb and holder in module and rotate 1/4 turn clockwise to fully engage.
5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Cluster - 413-01
Instrument Cluster
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1999 XK RANGE - Instrument Cluster - 413-01
Item Description
1 Variable Power Steering
2 Coolant Level
3 Fuel Level
4 Oil Pressure
5 Lamp Dimmer
6 Driver's Switchpack (Trip Computer)
7 Generator (Charge Warning Lamp)
8 Catalyst Overheat
9 Instrument Cluster
10 Climate Control (Signal to Module)
11 ICE Head Unit
12 Airbag Circuit Integrity
13 Adaptive Damping
14 Body Processor Module
The Instrument Cluster comprises a Major Cluster and a Minor Cluster, as well as being a primary Electronic Control
Module.
The Minor Cluster indicates engine oil pressure and battery state of charge. The Major Cluster provides indications for
the speedometer, tachometer, coolant temperature, fuel level, driver information (Message Centre) and warning
lamps.
- acts as a protocol converter (software language translator - the languages used on each network are very similar,
but neither can be directly interpreted by the opposite system) for communication between all modules on both the
CAN and SCP multiplexed networks. The Instrument Cluster is the only module on the vehicle which communicates
between the two networks.
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1999 XK RANGE - Instrument Cluster - 413-01
Major Cluster
Item Description
1 Low Fuel Level
2 Exhaust System Temperature *
3 Engine Coolant High Temperature
4 Direction Indicator Right Hand
5 Side / Parking Lamps
6 Handbrake ON / Low Brake Fluid Level
7 Main Beam
8 Airbag / Airbag System Fault
9 High Priority Text Message Displayed
10 Message Centre (Text Messages)
11 Low Priority Text Message Displayed
12 Seat Belt Not Fastened (Driver's)
13 ABS Integrity
14 EMS Fault
15 Direction Indicator Left Hand
All gauges look like conventional analogue gauges, but each pointer is driven by a stepper motor to provide more
accurate indication.
The message centre is used to warn the driver, using text messages; for warnings not covered by conventional
warning lamps, to indicate that the Automatic Stability Control is operating and for other shared warnings. Two
warning lamps, Red and Amber, are located above the Message centre to attract the driver's attention when a text
warning message has been displayed.
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1999 XK RANGE - Instrument Cluster - 413-01
Instrument Cluster
The complexity of the electronics involved with the Instrument Cluster and the two multiplexed communication
networks which are connected to it, preclude the use of workshop general electrical test equipment. Therefore,
reference should be made to the PDU User Guide for detailed instructions on testing the Instrument Cluster and
associated circuits.
The PDU systematically tests and analyses all functions of the Instrument Cluster, the various systems controlled by it
and individual sensors which are attached to each separate system.
Where a fault involving a remote sensor e.g. water temperature sensor, is indicated, some basic diagnostic methods
may be necessary to confirm that connections are good and that wiring is not damaged, before replacing the
component.
Diagnostics using the PDU is via the CAN network, accessed at the diagnostic connector on the car.
Replaceable Parts
The only replaceable parts are, General Illumination Bulbs, Direction Indicator Warning Bulbs and Main Beam Warning
Bulb, which are all of the conventional filament type. Other warning lamps are LEDs and are not replaceable.
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1999 XK RANGE - Instrument Cluster - 413-01
1. Turn ignition key to position 'II', adjust steering column to lowest and fully extended position and turn ignition
key to 'O'.
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
7. Using a thin plastic lever, remove major gauge module veneer panel.
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1999 XK RANGE - Instrument Cluster - 413-01
Installation
7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
8. Turn ignition key to position 'II', return steering column to original position and turn ignition key to 'O'.
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1999 XK RANGE - Instrument Cluster - 413-01
1. Turn ignition key to position 'II', adjust steering column to lowest and fully extended position and turn ignition
key to 'O'.
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
Installation
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1999 XK RANGE - Instrument Cluster - 413-01
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Instrument Cluster - 413-01
Installation
4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Cluster - 413-01
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1999 XK RANGE - Instrument Cluster - 413-01
3. Withdraw lens assembly from gauge module and remove clock setting stalks.
Installation
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1999 XK RANGE - Horn - 413-06
Horn
The horns are operated by the Body Processor Module (BPM), as described below.
The switch, located on the steering wheel pad, signals the BPM to sound the horn. The BPM horn-output connection
responds by providing an earth path for the horn relay coil. The relay contacts are subsequently closed and the horns
sound.
The horn operating relay is located in the under bonnet fusebox at the left hand side of the engine compartment.
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1999 XK RANGE - Horn - 413-06
Horn
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed
communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should
be made to the PDU User Guide for detailed instructions on testing the horn circuit.
The PDU systematically tests and analyses all functions of the horn, the horn relay, the body processor module and
the operating switch.
Where a fault involving the horn, relay or switch is indicated by the PDU, some basic diagnostic methods may be
necessary to confirm that connections are good and that wiring is not damaged, before replacing the component.
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1999 XK RANGE - Horn - 413-06
Horn 86.30.02
Removal
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. RH horn only. Release ambient air temperature sensor from horn mounting bracket tang .
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1999 XK RANGE - Horn - 413-06
Installation
2. RH horn only. Install ambient temperature sensor on horn mounting bracket tang.
4. Raise front of vehicle, remove stands and lower vehicle onto wheels.
5. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Clock - 413-07
Clock
The analogue clock is in the center of three instruments, located on the minor instrument cluster.
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1999 XK RANGE - Clock - 413-07
Clock
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed
communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should
be made to the PDU User Guide for detailed instructions on testing the clock circuit.
The PDU systematically tests and analyses the clock and the electrucal connections to it.
Where a fault involving the clock is indicated by the PDU, some basic diagnostic methods may be necessary to
confirm that connections are good and that wiring is not damaged, before replacing the minor instrument cluster.
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1999 XK RANGE - Information and Message Center - 413-08
Item Description
1 Driver's Information / Message Center
2 Amber Warning Lamp
3 Red Warning Lamp
4 Major Instrument Cluster
5 Speedometer
The Driver's Information Center has a liquid crystal display and is located at the lower area of the Major Instrument
Cluster.
The message centre is used to warn the driver, using text messages, for warnings not covered by conventional
warning lamps, to indicate that the Automatic Stability Control is operating and for other shared warnings.
The amber and red warning lamps attract the driver's attention when a new message has been displayed. The
importance of the message dictates which lamp is swithed on. The lamps are also used together for some warnings
and for some non-text warnings - refer to the Driver's Handbook for variations in local markets.
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1999 XK RANGE - Information and Message Center - 413-08
The complexity of the electronics involved with the speedometer and instrument cluster, of which the Message Center
is a part, and the two multiplexed communication networks which are connected to it preclude the use of workshop
general electrical test equipment. Therefore, reference should be made to the PDU User Guide for detailed
instructions on testing the speedometer and odometer.
The PDU systematically tests and analyses all functions and the various systems affected by it.
Where a fault is indicated, some basic diagnostic methods may be necessary to confirm that connections are good
and that wiring is not damaged, before replacing a component.
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1999 XK RANGE - Charging System - General Information - 414-00
Charging System
Details of the Charging System can be found in sections <<414-01>> and <<414-02>>.
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
Battery Connect
1. NOTE:
Whether one, or both, cables are disconnected, a minimum of 30 seconds MUST elapse between
disconnection of the FIRST cable and reconnection of the LAST cable. A clean final connection must be
made; do not allow temporary contact.
3. Enter the radio security code. If necessary, refer to the Sound System Handbook.
4. Cycle (both) door drop glass up and down to establish the upper and lower datum points.
Switch the ignition ON .
Lower the glass to the stop and hold the switch in the DOWN position for a further five seconds.
Raise the glass fully and hold the switch in the UP position for a further five seconds.
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
The negative (Ground) lead is connected to the vehicle body. The positive lead is connected to a high power
protection module; from here power is connected to the starter motor and distributed to other systems on the vehicle.
The high power protection module comprises three fuses, each of 250A capacity. Two fuses are connected in parallel
to provide protection for the starter circuit. The third one provides high level protection for fusebox supply circuits .
PDU is unable to diagnose the overall condition of the battery - only that it is present and supplying battery voltage to
the system.
To test the battery, follow the test procedure described in Section <<414-02>> Generator and Regulator of this
Manual.
Although these tests will not actually test the battery, they will confirm that the generator, regulator and connecting
cables are working correctly and that consequently, the battery may be at fault. Alternatively, the tests may indicate
that the fault lies in the generator, regulator or wiring and not in the battery.
Battery
Item Description
1 Battery
2 Positive Lead
3 Battery Hold-Down Clamp
4 Negative (Ground) Lead
5 High Power Protection Module (Fuses)
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
Battery 86.15.01
Removal
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the cover
from the battery.
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
Installation
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the battery
cover.
Installation
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the battery
cover.
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
Installation
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1999 XK RANGE - Battery, Mounting and Cables - 414-01
1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
2. Remove the luggage compartment floor panel (when standard size spare wheel is supplied) and the cover
from the battery.
Installation
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1999 XK RANGE - Generator and Regulator - 414-02
Generator
Item Description
1 Generator
2 Bolt - Mounting Upper
3 Bolt - Mounting Lower
4 Voltage Regulator (Internal component)
5 Drive Belt - Multi-Ribbed
Features
Manufacturer - Denso
Type - L3B-HE
Drive Ratio - 3.04:1
Output - 120amps @ 5000 rpm (generator speed) at 25° C
The generator is fitted at the front right hand side of the engine, to a separate mounting bracket, which in turn is
bolted to the cylinder block. Two bolts secure the generator to the mounting bracket; one is reached from above and
one from below the vehicle.
The voltage regulator is integral with the generator body. Battery charging capability has been optimised for charging
a battery which is located remotely, in the luggage compartment. The design of the generator and regulator has been
finely matched, to generate charging current with very low ripple. This provides the best electrical refinement to the
system.
The generator is driven by a single, multi-ribbed belt which also drives all other front-end accessories.
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1999 XK RANGE - Generator and Regulator - 414-02
No special service tools are required to remove the generator from the vehicle.
Belt tension is achieved by an automatic tensioner; neither the belt nor the tensioner require service apart from
checking the belt wear indicators at each normal service interval.
Item Description
1 Generator
2 Suppression Module
3 Starter Motor
4 Battery
5 Power Cable to Rear Fuse Box
6 High Power Protection Module
7 Power Cable to Front Fuse Boxes
The output from the generator 'B+' main terminal passes to the battery via the main terminal on the starter motor and
then the power cable to the high power protection module located in the luggage compartment. From this module, a
short main power cable supplies the battery positive terminal.
The return circuit is through the vehicle body and supplementary ground cables.
The high power protection module comprises four fuses, each rated at 250amps.
Battery output uses the same power cable as the charging circuit, to the high power protection module and to the
starter motor main terminal. Two similar cables, but not such a high rating, supply battery power from the high power
protection module to the fuse box in the luggage compartment and to the fuse boxes at the front of the vehicle.
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1999 XK RANGE - Generator and Regulator - 414-02
The interference suppression module (where fitted) connects to the generator main terminal 'B+' and a ground stud on
the rear face of the generator.
Item Description
1 Generator Assembly
2 Voltage Regulator
3 Main Terminal 'B+'
4 Ignition Supply Terminal 'IG' to Rotor
5 Output Terminal L to Charge Lamp
6 Rotor
7 Stator
8 Rectifier Pack
As with most vehicle ac generators, there is only minimal residual magnetism in the field (rotor) windings. To
compensate for this and to achieve high current output at low engine speed, the field is excited by battery voltage
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1999 XK RANGE - Generator and Regulator - 414-02
To control the level of field excitation and ultimately, generator output, the voltage supplied to the field (rotor) is
controlled by the voltage regulator.
The voltage regulator senses (at the 'B' terminal) battery terminal voltage, which within limits is proportional to the
state of charge of the battery. The regulator then adjusts the supplied voltage between the 'IG' terminal and the
regulator 'F' terminal (a continuously variable process) to maintain the 'B+' output at a constant level.
If the field were not controlled, the 'B+' output would rise to a level which could damage bulbs and ECMs. The
regulator compares the output voltage to an internal voltage reference circuit to achieve the controlled output of the
generator.
Suppression Module
Although the output from the generator is finely controlled and relatively smooth, it is still a pulsed DC output at a
varying frequency proportional to engine speed.
The suppression module damps out any ripple which may be sensed on the main output of the generator. This
prevents possible interference via the power supply, affecting the radio reception or, where fitted, the telephone.
The module is located on the right hand side of the engine compartment adjacent to the generator. It is secured to a
mounting bracket by three bolts. The mounting bracket is bolted to the inner panel, just above the chassis leg. The
illustration shows the suppression module viewed from below the vehicle.
A fuse is fitted internally to the suppression module to protect the generator output in the event of a short circuit within
the suppression module.
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1999 XK RANGE - Generator and Regulator - 414-02
Drive Belt Automatic Tensioner
Item Description
1 New Belt - Minimum Length
2 New Belt - Maximum Length
3 Replace the Belt
Belt tension is achieved by an automatic tensioner; neither the belt nor the tensioner require service apart from
checking the belt wear indicators at each normal service interval.
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1999 XK RANGE - Generator and Regulator - 414-02
Generator
When diagnosing the charging circuit, the PDU indicates only whether the generator is charging or not charging. The
reason for this is that the PDU cannot handle the potential full charging current and that the voltage control circuits are
located within the generator assembly, making them inaccessible by the PDU directly.
It is possible that the battery has failed. In this case, the voltage output at the generator could be correct, but the
voltage at the battery terminals, and therefore the rest of the vehicle system, will be adversely affected by the faulty
battery.
The same result is given by the PDU if the battery is faulty (generator not faulty), wiring fault (damaged or severe
corrosion at the terminals) or if the generator is at fault.
Mechanical Electrical
Visually check the condition of the drive belt Connections on the rear face of the generator
are fully located?
Check that the belt wear indicator, located on the automatic belt
tensioner, is within the limit marks
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1999 XK RANGE - Generator and Regulator - 414-02
Ensure that all electrical loads are switched OFF and that the engine is cool.
Whilst the engine is idling, disconnect the battery negative terminal and, using a digital multimeter (DMM), measure the
voltage between the terminal on the battery negative cable and the battery positive terminal. If the generator is
working, the measured voltage should be within the range 13V to 15V.
This indicates the system voltage without the battery in circuit. If the generator is inoperative, the engine will stall when
the ground lead is disconnected.
Repeat the test, using the ground bolt, as indicated (shown dotted on the illustration). There should be hardly any
detectable difference in the voltage reading (due to minimal current flow); if there is a detectable difference, clean the
cable terminal and the adjacent area of the body.
Reconnect the battery or fit a new battery if it was established that the battery was at fault (Refer to <<414-01>>).
If the cooling fans operate during the above test, the large demand of current will overload the generator and cause
the engine to stall.
If the battery is in a low state of charge the voltage will rise momentarily when the battery is disconnected. However,
the maximum that the voltage can increase to with this new generator is 25V and then only for a maximum time of 200
mS.
A substitute battery may be fitted for the tests. This battery must be a known good example and must have been
off-charge for at least twelve hours, with a terminal voltage of approximately 12.8V.
Ensure that all electrical loads are switched OFF and that the engine is cool.
Measure the voltage across the battery terminals. It should have dropped a little due to the large start current and
then risen to a value of between 13V and 15V.
If the above test (whichever one used) indicates that the generator is not working then the connections on the rear
face of the generator should be checked. If there is a faulty connection, then the generator will not perform correctly
no matter how fast it is driven.
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1999 XK RANGE - Generator and Regulator - 414-02
Item Description
1 Multi-Plug Connector
2 B+ Main Output Terminal
3 Ground Stud for Suppression Module
4 Heatsink for Voltage Regulator
CAUTION:
The engine must not be running when multiplugs are connected or disconnected.
Check that the IG terminal is clean and making good contact; if this connection is faulty, the generator will never
function correctly.
Disconnect the multi-plug at the rear of the generator With the engine not running and with the ignition switched on,
use a DMM to check for battery voltage between the centre pin on the multi-plug connector and a good vehicle
ground. If the measured voltage is correct, switch off the ignition and reconnect the multi-plug.
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1999 XK RANGE - Generator and Regulator - 414-02
Multiplug Connector
Item Description
1 Not Connected
2 IG - Ignition Supply to Generator
3 WL - Output to Charge Warning Lamp
If no voltage or low voltage is indicated, check for continuity of the harness between the multi-plug and Fuse 5 (10A) in
the Engine Compartment Fusebox - Left Hand Side. Repair any damage to the harness if necessary. It should be
noted that if Fuse 5 has blown, the starter motor will not operate and the Engine Control Module will not receive an
ignition supply. Consequently, the engine will not start, even with a slave battery.
Start the engine and test for correct charge or voltage level; check as described previously. If not charging and the
generator is being driven ie. no belt slipping - renew the generator.
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1999 XK RANGE - Generator and Regulator - 414-02
Generator 86.10.02
Removal
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Remove the air cleaner assembly (including fit body paintwork protection sheets to the adjacent working
area); refer to <<303-12>>.
4. Remove the fan and motor assembly from behind the radiator; refer to 303-03.
Check that the belt wear indicator is within the limit marks.
Raise the vehicle on a ramp; refer to <<100-02>>
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1999 XK RANGE - Generator and Regulator - 414-02
5. Remove the air intake ducting from the generator. The ducting comprises two sections; each is retained by
two screws and a clip.
6. Remove the drive belt from the generator and accessory drive,
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner
idler pulley, to turn the adjuster assembly to the left against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner slowly and remove the spanner.
Disconnect the belt from the other pulleys, as necessary, to move it clear of the generator.
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1999 XK RANGE - Generator and Regulator - 414-02
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9. Remove the upper securing bolt and withdraw the generator from the mounting bracket.
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11. Change the position of the generator and remove it upwards between the engine and the radiator.
Installation
1. Move the spacing bush rearwards slightly in the generator mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a tubular spacer or socket spanner, fit a nut and
tighten the assembly to move the bush slightly. Remove the nut, bolt and spacer.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
4. Remove the nut from the main terminal and remove the insulator.
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6. Remove the two remaining nuts which secure the rear cover and remove the cover.
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9. Remove the screws, two long and one short, from the regulator.
Remove the regulator.
Installation
1. Check that the rubber gasket for the brush holder is correctly located.
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2. Check that the new regulator is of the same type and is not damaged.
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8. Install the screw to secure the ground tag and install the three nuts to secure the rear cover.
Tighten the four fixings.
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1999 XK RANGE - Audio Unit - 415-01
Audio System
Base or premium specification audio systems are available and switches on the steering wheel provide for remote
operation in each case. The radio and electrically operated aerial are also common to both systems
An identical audio unit is installed in both systems. On initial installation this is matched to the appropriate system by
selecting the STD or PRM switch position on the underside of the unit chassis.
Telephone controls incorporated in the audio unit facilitate installation of a GSM hands-free telephone system available
as an option.
As in the base system, the audio unit incorporates integral message display and 'Phone Ready' controls, and a CD
autochanger is installed in the trunk. The premium audio system also includes an amplifier unit installed in the trunk a
sub-woofer speaker on the rear parcel shelf (a sub-woofer in each rear quarter on convertible models), two mid-range
speakers in each door, a mid-range speaker in each rear quarter and a tweeter at each side of the facia.
An optional integrated navigation system supplied with the vehicle, or as a service fit accessory, interfaces with either
of the above systems to provide control of voice guidance volume. All other navigation system functions are controlled
from a separate display/controls panel installed in the facia above the audio unit.
1999 XK RANGE - Audio Unit - 415-01
Audio System
The PDU is unable to diagnose radio head faults; there are no self-diagnostics associated with the radio.
PDU is able to test the speakers and the antenna, along with associated wiring and connections, therefore by a
process of elimination, the radio head can be diagnosed.
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1. Remove battery cover and disconnect ground lead from terminal. Refer to <<86.15.19>>.
5. Remove the six radio console securing screws and partially withdraw the console for access.
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7. Remove radio.
1. Release spring retaining clips, remove radio from console and remove radio from mounting panel.
Installation
1. Slide radio into mounting panel and position at console for access.
2. Connect aerial co-axial lead to radio and stow excess harness and lead lengths in radio mounting aperture.
3. Fully seat radio in console, ensuring that retaining clips are fully seated and harnesses and leads do not
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obstruct.
5. Holding radio console in position, route radio harness multiplugs into center console.
8. Finally position radio console and install the six securing screws.
11. Ensuring harness and leads do not obstruct, push radio fully home.
15. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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5. Remove upper bolts securing amplifier mounting bracket to outer mounting bracket.
6. Remove side bolts securing amplifier mounting bracket to outer mounting bracket.
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7. Withdraw amplifier/mounting bracket assembly from trunk and remove bolts securing amplifier to bracket.
Installation
3. Install upper bolts securing amplifier mounting bracket to outer mounting bracket.
4. Install side bolts securing amplifier mounting bracket to outer mounting bracket.
8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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Capacitor 86.10.33
Removal
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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5. Remove upper bolts securing autochanger mounting bracket to outer mounting bracket.
6. Remove side bolts securing autochanger mounting bracket to outer mounting bracket
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7. Withdraw autochanger/mounting bracket assembly from trunk and remove four bolts securing autochanger to
bracket.
Installation
1. Position autochanger on mounting bracket and fit and install securing bolts.
3. Install upper bolts securing autochanger mounting bracket to outer mounting bracket.
4. Install side bolts securing autochanger mounting bracket to outer mounting bracket.
8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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Antenna
The electrically operated antenna operates automatically when the Ignition switch is set to position 1 or 2, and the
radio is switched on.
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Antenna
The PDU tests whether or not the antenna raises and lowers correctly. Although it is obvious if the antenna is not
operating, the PDU analyses why it is not operating and indicates problems such as a faulty radio head signal output,
faulty wiring, loss of power due to a blown fuse - two fuses in the fascia end fusebox left side and one in the luggage
compartment fusebox.
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Antenna
Removal
Installation
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1. Remove the carpet and trim panels from the luggage compartment. For detailed information see <<501-05>>.
1. Remove the carpet.
2. Remove the front liner.
3. Remove the liner from the right hand side.
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Installation
1. Installation is the reverse of removal. Lubricate the vehicle body grommets with soap solution or rubber
lubricant.
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Speakers
Item Description
1 Base System - 152 mm Triple Cone
1 Base System - 152 mm Triple cone
3 Premium System - Mirror Panel Tweeter
4 Premium System - 200 mm Sub Woofer
5 Premium System - Amplifier
6 Premium System - CD Autochanger
Both coupe and convertible with the standard entertainment system use a common speaker configuration.
Vehicles with the premium entertainment system have a different configuration for each model.
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Speaker Location - Convertible
Item Description
1 Base System - 152 mm Triple Cone
2 Base System - 152 mm Triple Cone
1 Premium System - 152 mm Mid / Bass
2 Premium System - Enclosure with 152 mm Long Throw Sub-Woofer and 64 mm Mid Range
3 Premium System - Mirror Panel Tweeter
4 Premium System - Fascia 64 mm Mid Range
5 Premium System - Amplifier
6 Premium System - CD Autochanger
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Speakers
PDU can test whether or not each speaker operates correctly and analyses why it is not operating.
It indicates problems such as a faulty radio head output power signal, faulty power amplifier (where fitted), faulty
wiring, loss of power due to a blown fuse.
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1. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
1. Installation is the reverse of removal, noting that the battery must be reconnected in accordance with
<<414-01>>.
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1. Using a wide flat blade, carefully ease the speaker / grille assembly from the fascia. Disconnect the speaker
multi-plug.
Installation
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1. Using a wide flat blade, carefully ease the speaker / grille assembly from the fascia. Disconnect the speaker
multi-plug.
Installation
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1. Remove the rear quarter armrest / speaker cover for access; refer to <<501-05>>.
Installation
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3. On convertible model only, remove rear quarter casing capping. refer to <<76.13.73>>.
6. Release security aerial retaining clip from speaker assembly and position aerial clear.
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Installation
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1. Using rear passenger entry knob, fold seat back fully forward.
Installation
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2. Carefully lift front edge of speaker cover to release front and side clips from rear parcel shelf.
3. Move speaker cover forward to release rear clips from parcel shelf.
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Installation
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3. Position speaker cover on parcel shelf and engage rear clips in slots.
4. Lower front edge of speaker cover and engage side and front clips in parcel shelf.
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2. Carefully lift front edge of speaker cover to release front and side clips from rear parcel shelf.
3. Move speaker cover forward to release rear clips from parcel shelf.
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Installation
1. Position speaker cover on parcel shelf and engage rear clips in slots.
2. Lower front edge of speaker cover and engage side and front clips in parcel shelf.
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Bulbs
Torques
Component Nm
Rear Lamp Assembly to Body 3
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Exterior Lighting
Front Lamps
Item Description
1 Headlamp Assembly
2 Power Wash Jet Assembly
3 Fog Lamp
4 Side Marker / Reflex
5 Repeater Lamp
Each headlamp assembly incorporates a main beam lamp, a dipped beam lamp, a direction indicator lamp and a side
lamp. Access for bulb replacement is from the engine compartment except for the dipped beam bulb, which is
accessible through a panel in the wheelarch liner.
The fog lamps are located in recesses in the front bumper and secured by three screws. Access for bulb replacement
is through the opening panel in the wheelarch liner. The lamps are not interchangeable, side to side, because of the
orientation of the fixing holes.
The side marker lamps (where fitted) incorporate a reflector and are secured by a spring clip at each end of the lamp
unit. Access for bulb replacement is through the opening panel in the wheelarch liner. In markets where they are not
specified, a reflector is fitted.
The repeater lamps (where fitted) are secured by a spring clip at each end of the lamp unit. In markets where they
are not specified, a leaping Jaguar badge is fitted.
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Rear Lamps
Item Description
1 Side Marker / Reflex
2 Rear Lamp Assembly
3 License Plate Lamps
4 High Mounted Stop Lamp
Side marker lamps, incorporating reflectors, are secured by a spring clip at each end of the lamp. Access for bulb
replacement is from beneath the rear of the vehicle. Not connected for all markets.
Each rear lamp assembly incorporates a stop lamp, a tail lamp, a fog lamp, a reversing lamp and a direction indicator
lamp. Access for bulb replacement is from the luggage compartment.
The license plate lamps are located on a trim finisher panel, secured to the lid by four nuts. Each bulb is accessible
after removing the relevant lens.
A High Mounted Stop Lamp (not fitted to all markets) is fitted inside the rear screen on coupe models (as shown
above) and externally, on the luggage compartment lid, on convertible models. These lamps operates using sixteen
LEDs instead of conventional bulbs. Individual LEDs cannot be replaced; the complete lamp unit must be renewed if
one LED is inoperative.
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Exterior Lighting
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed
communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should
be made to the PDU User Guide for detailed instructions on testing the exterior lamps and circuits.
The PDU systematically tests and analyses the lamp assemblies, the bulbs and the electrical connections to them. It
should be noted that the lamps are not wired directly to the switches. Each switch provides a signal to the Body
Processor which interprets the signal as a request to switch on a specific lamp.
The Body Processor places the instruction onto the SCP Network. The module which is closest to the specific lamp,
for example, the Security and Locking Module will translate the request which is currently on the network and switch
on the rear fog lamps (also controls the reverse lamps). The remaining rear lamps and front lamps are controlled
directly by the Body Processor (it has a sufficient number of high power output stages to drive the lamps / relays
compared to other modules). The door hazard lamps are controlled locally by the relevant Door Module.
Where a fault involving a lamp is indicated by the PDU, some basic diagnostic methods may be necessary to confirm
that connections are good and that wiring is not damaged, before replacing the components.
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2. Remove and discard the BPP switch wiring harness retaining strap.
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Installation
2. CAUTION:
Make sure the brake pedal is held clear of the BPP switch ratchet mechanism during installation.
Failure to follow this instruction may result in incorrect adjustment of the BPP switch.
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4. CAUTION:
Make sure the brake pedal is fully raised. Failure to follow this instruction may result in incorrect
adjustment of the BPP switch.
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3. Remove the fog lamp from the vehicle (working through the access panel aperture).
1. Disconnect the electrical connector from the bulb holder.
2. Remove the three bolts which secure the lamp assembly.
3. Remove the lamp from the housing, rearwards through the access panel aperture.
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Installation
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3. CAUTION:
The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is
important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned
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Remove the fog lamp bulb from the vehicle (working through the access panel aperture).
1. Disconnect the bulb holder (quarter-turn) from the lamp.
2. Remove the bulb from the holder.
Installation
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Installation
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Installation
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2. Release headlamp access panel inner retaining tangs and remove panel.
3. Rotate direction indicator lamp bulb holder 1/4 turn clockwise to release it from headlamp assembly.
4. Rotate bulb 1/4 turn to release and remove bulb from holder.
Installation
1. Install direction indicator lamp bulb in bulb holder and rotate 1/4 turn to fully engage.
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2. Install bulb holder to headlamp and rotate 1/4 turn counterclockwise to seat and fully engage.
4. Install headlamp access panel ensuring that seal is in position and retaining tangs are correctly engaged.
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Installation
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Installation
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3. Release lens to headlamp assembly lower and side retaining tangs and remove lens from assembly
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4. Rotate direction indicator bulb holder 1/4 turn clockwise and remove from headlamp lens.
5. Rotate parking/side lamp bulb holder 1/4 turn counter-clockwise and remove from headlamp lens.
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Installation
5. Install lens to headlamp assembly ensuring that retaining tangs are correctly engaged.
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2. Slacken power steering reservoir mounting bracket securing nuts, remove nuts together with rubber washers
and position reservoir for access.
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4. Rotate actuator 1/4 turn, tilt forward end downward and withdraw assembly from headlamp.
Installation
2. Align actuator with headlamp and rotate it 1/4 turn to engage and fully seat.
4. Position power steering reservoir, install rubber washers and securing nuts .
5. Carry out headlamp beam alignment to the appropriate alignment equipment instructions
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4. Rotate actuator 1/4 turn, tilt forward end downward and withdraw assembly from headlamp.
Installation
2. Align actuator with headlamp and rotate it 1/4 turn to engage and fully seat.
5. Carry out headlamp beam alignment to the appropriate alignment equipment instructions
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3. CAUTION:
The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is
important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned
with methylated spirit before fitting.
Remove the main beam bulb / bulb holder assembly from the vehicle (working through the access cap aperture).
1. Rotate the bulb holder anti-clockwise by approximately a quarter-turn to release it from the lamp.
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4. Remove the bulb / bulb holder assembly from the vehicle harness.
Installation
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1. With trunk lid fully open, remove and discard fasteners securing liner to forward edge of lid.
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3. Remove the three blanking plugs from forward underside of trunk lid.
5. Routing harness through aperture, remove stop lamp from trunk lid.
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6. Release retaining tangs and remove top cover from stop lamp.
Installation
1. Install top cover on stop lamp ensuring retaining tangs are fully seated.
2. Routing harness through aperture, position stop lamp assembly on trunk lid.
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2. Remove the rearward fasteners (six, fir tree type) from the luggage compartment lid trim pad. Reposition the
trim pad for access.
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Installation
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2. Remove the rearward fasteners (six, fir tree type) from the luggage compartment lid trim pad. Reposition the
trim pad for access.
Installation
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4. CAUTION:
The bulb will be damaged if touched by bare hands or contaminated with oil or grease. It is
important to use clean gloves or cloth when handling a bulb. A contaminated bulb may be cleaned
with methylated spirit before fitting.
Remove the bulb from the harness plug (working through the access panel aperture).
1. Remove the bulb from the harness plug.
Installation
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Installation
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Installation
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Installation
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Installation
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3. Remove the bulb from the vehicle (working through the access cap aperture).
1. Rotate the bulb holder (quarter-turn) and harness plug to remove the assembly from the lamp.
Pull the bulb from the bulb holder assembly.
Installation
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Installation
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Installation
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Installation
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Bulbs
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Interior Lighting
Item Description
1 Footwell Lamps
2 Glovebox Lamp
3 Door Guard / Puddle Lamps
4 Luggage Compartment Lamps
5 Roof Rear Lamp (Coupe Only)
6 Roof Console Map / Courtesy Lamps
7 Sun Visor Vanity Mirror Lamps
Two footwell lamps are fitted, one at each end of the fascia lower rail. They are not fitted with manual switches and
operate only when either or both doors are opened.
The glovebox lamp operates whenever the glovebox lid is opened. The lamp comprises a combined switch and bulb
holder assembly, and a white lens.
A lamp is fitted to the rear lower corner of each door. Each has a double lens; red to project rearwards to warn
oncoming traffic that the door is open and white to project down onto the ground. They are not fitted with manual
switches and operate only when either or both doors are opened.
A lamp is fitted to each rear corner of the luggage compartment, adjacent to the rear lamp assemblies. They are
operated automatically whenever the luggage compartment lid is opened; the switch is incorporated within the latch
mechanism.
The roof rear lamp is fitted to the coupe only. It is not fitted with a manual switch and operates only when either or
both doors are opened.
The two lamps located in the roof console, function as map reading lamps and as courtesy lamps. Individual switches
control each lamp manually and the door switches control the lamps automatically to provide the courtesy lamp function
The vanity mirror lamps, two on each sun visor, operate automatically when the mirror flap is opened. The lamps will
operate only when the sun visor spindle is engaged in the stowage
1 clip.
1999 XK RANGE - Interior Lighting - 417-02
Interior Lighting
The complexity of the electronics involved with the various Electronic Control Modules and the two multiplexed
communication networks, preclude the use of workshop general electrical test equipment. Therefore, reference should
be made to the PDU User Guide for detailed instructions on testing the interior lamps and circuits.
The PDU systematically tests and analyses the lamp assemblies, the bulbs and the electrical connections to them. It
should be noted that the lamps are not wired directly to the switches. Each manual switch provides a signal to the
Body Processor which interprets the signal as a request to switch on a specific lamp.
The lamps are controlled directly by the Body Processor (it has a sufficient number of high power output stages to
drive the lamps / relays compared to other modules) except for the door mounted hazard / puddle lamps.
The door hazard / puddle lamps are controlled locally by the relevant Door Module.
The Body Processor Module receives messages on the SCP network from the door modules relating to door ajar /
closed / locked status, sensed by the door courtesy switch(es).
Where a fault involving a lamp is indicated by the PDU, some basic diagnostic methods may be necessary to confirm
that connections are good and that wiring is not damaged, before replacing the components.
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Installation
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1. Using a small flat-bladed screwdriver, release guard lamp lens retaining tang and withdraw lens from door.
2. Rotate bulb 1/4 turn and remove bulb from guard lamp.
Installation
2. Install lens on guard lamp, ensuring that securing tang is correctly engaged
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
5. Disconnect switch module harness multiplug, release module end locaters and lightly press module out of
console.
6. Rotate bulb holder 1/4 turn counter-clockwise and remove from module.
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Installation
2. Install bulb and holder in module and rotate 1/4 turn clockwise to fully seat.
3. Install switch module in console ensuring that end locaters are fully seated.
8. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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2. Turn the lamp through 90° to allow the connector to pass through the aperture, tilt it slightly and fully remove it.
Installation
1. Installation is the reverse of removal. Install the new lamp so that the face marked 'REAR' is towards the rear
of the vehicle; failure to do this will make the lamp very difficult to remove.
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2. Turn the lamp through 90° to allow the connector to pass through the aperture, tilt it slightly and fully remove it.
Installation
1. Installation is the reverse of removal. Install the new lamp so that the face marked 'REAR' is towards the rear
of the vehicle; failure to do this will make the lamp very difficult to remove.
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Installation
4. Release light/switch assembly retaining tangs and partially withdraw assembly from glovebox exterior.
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5. Position light/switch assembly for access, disconnect harness spade connectors and remove assembly from
glovebox aperture.
Installation
1. Position light/switch assembly at glovebox aperture and connect harness spade connectors.
2. Install light/switch assembly in aperture, ensuring that retaining tangs are fully seated.
4. Check that harness leads are not in contact with the bulb glass.
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Installation
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2. Using a thin plastic lever, carefully release lamp retaining tangs from trunk rear finisher.
Installation
2. Install and fully seat lamp assembly on trunk rear finisher ensuring that retaining tangs correctly engage.
1. Carefully prise the lamp from the luggage compartment trim panel.
Installation
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Installation
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Installation
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1. Move sun visor to downward position and turn mirror cover upwards.
2. Using a small screwdriver or similar thin blade, carefully release illumination lens lower tangs and remove both
lenses from mirror assembly.
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3. Using a small screwdriver or similar thin blade, carefully release side tangs and remove mirror assembly from
base.
Installation
1. Ensure that bulbs, bulb holders and switch contactors are correctly positioned and seated.
2. Position mirror assembly on base and press firmly at each side to fully engage tangs.
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1. Rotate the sun visor down and open the vanity mirror flap.
Installation
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The complexity of the electronics involved with the Body Processor and the two multiplexed communication networks
which are associated with it, preclude the use of workshop general electrical test equipment. Therefore, reference
should be made to the PDU User Guide for detailed instructions on testing the Daytime Running Function.
The Daytime Running function is exactly the same as for the normal operation of the side lamps (or dipped beam,
where specified) in as much as the body processor drives the same lamps from the same outputs.
The body processor has been programmed to respond to an alternative set of conditions in order to operate the
lamps, instead of waiting for a signal from the normal light switch.
The conditions which have to be set are; ignition switch set to position II or III and sidelight switch set to OFF. The
sidelights, side marker lamps (if fitted and enabled), tail lights and number plate lights will all be switched ON.
The PDU systematically tests and analyses all functions of the daytime running lamps.
Where a fault is indicated, some basic diagnostic methods may be necessary to confirm that connections are good
and that wiring is not damaged, before replacing a component.
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Communications Network
Fuse-boxes
Parts List
Item Description
1 Engine Compartment
2 Engine Management - RHD Only
3 Engine Management - LHD Only
4 Fascia End - Right Hand Side
5 Luggage Compartment
6 High Power Protection module
7 Fascia End - Left Hand Side
There are six fusebox assemblies per vehicle, five of which have conventional, replaceable fuses. The High Power
Protection Module does not have conventional fuses.
Two Engine Management fuse-boxes are shown. Only one is fitted (LHD or RHD) to any vehicle, on the opposite side
to the pedal box.
The High Power Protection Module comprises three 250amp fusible links to protect the starting circuit (two connected
in parallel) and the battery positive supply to the other fuse-boxes.
The J1962 socket is located on the fascia, adjacent to the 'A' pillar on the driver side.
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Communications Network
Principles of Operation
There are three module communication networks connected to the Data Link Connector (DLC), Controller Area
Network, (CAN), Standard Corporate Protocol (SCP), and International Standards Organisation (ISO). CAN and
SCP are unshielded twisted pair cable; data bus + and data bus -, while ISO is a single wire system. (The exceptions
to this are the Adaptive Damping Control Module (ADCM), the Engine Control Module (ECM), and the Air Conditioning
Control Module, (A/CCM) which have two wires). The networks can be connected to the Jaguar approved diagnostic
system or scan tool by the DLC.
The SCP communication network remains operational even with the severing of one of the bus wires. Communications
will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+), or if some, but not all,
termination resistors are lost.
The ISO network, however, will not function if the circuit is damaged.
Modules may log DTCs if power supply or ground is interrupted. Supply and ground tests are in this section under the
DTC number flagged, or by module name in the pinpoint tests.
Some faults may occur without logging a network DTC. If this is the case, refer to the wiring diagrams to determine
which network includes the faulty circuit, and follow the pinpoint test indicated in the DTC index.
The instrument cluster (IC) is connected to the CAN and SCP communication networks, and forms a 'gateway'
between the networks. The networks share information, allowing sensors to serve more than one network.
2. Confirm which, if any, warning lights and/or messages were displayed on the instrument cluster.
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.
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Visual Inspection Chart
Electrical
General
Fuses (see table)
Wiring harness
Correct engagement of electrical connectors
Loose or corroded connections
Controller Area Network (CAN)
Instrument cluster (IC)
J-Gate (gear shift) illumination module (GSI)
Engine control module (ECM)
Transmission control module (TCM)
ABS/Traction control module (ABS/TCCM)
Vehicle speed interface module (VSIM)
Standard Corporate Protocol (SCP)
Instrument cluster (IC)
Body processor module (BPM)
Security and locking control module (SLCM)
Passenger door control module (PDCM)
Driver door control module (DDCM)
Passenger seat control module (PSCM)
Driver seat control module (DSCM)
International Standards Organisation (ISO)
Restraints control module (RCM)
Adaptive damping control module (ADCM)
Engine control module (ECM)
Key transponder module (KTM)
Air conditioning control module (A/CCM)
Body processor module (BPM)
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Fuse Identification Chart
4. 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
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exception to this is P1260, which will only clear following an ignition OFF, wait one minute, ignition ON cycle after
rectification.)
5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan
tool to retrieve the fault codes before proceeding to the DTC index chart, or the symptom chart if no DTCs are
set.
CAUTION:
Diagnosis by substitution from a donor vehicle is NOT acceptable. Each vehicle is configured to it's own VID
block, and substitution of control modules may not only not confirm a fault, but may cause faults in the
vehicle being tested and/or the donor vehicle.
CAUTION:
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
CAUTION:
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part
number 3548-1358-00.
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:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
6. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step
7. If the cause is not visually evident, verify the symptom and refer to the DTC index.
NOTE:
Use this table to identify DTCs associated with the message centre display, then refer to the DTC index for
possible sources and actions.
NOTE:
For definitions of Default Modes, see the foot of this table.
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LIMP-HOME MODE
Power limitation
Vehicle speed limited to 74.5 mph (120 kph)
Reverse throttle progression enabled *
Cruise (speed) control Inhibited
REVERSE THROTTLE PROGRESSION
Power limitation
Vehicle speed limited to 74.5 mph (120 kph)
Reverse throttle progression enabled
Cruise (speed) control Inhibited
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Power Supply/Ground test index
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TCM supply or GROUND failure TCM permanent supply fault For TCM circuit tests,
Goto <<M>>
TCM ignition switched supply
.
fault
TCM GROUND fault
ABS/TCCM supply or GROUND failure ABS/TCCM permanent supply For ABS/TCCM circuit
fault tests,
Goto <<N>>
ABS/TCCM ignition switched
.
supply fault
ABS/TCCM GROUND fault
GSI module supply or GROUND failure GSI module ignition switched For GSI module circuit
supply fault tests,
Goto <<O>>
GSI module GROUND fault
.
Data Link Connector (DLC) supply or GROUND DLC permanent supply fault For DLC circuit tests,
failure Goto <<P>>
DLC ignition switched supply
.
fault
DLC ignition switched
GROUND fault
DLC logic GROUND fault
Vehicle speed interface module (VSIM) supply or VSIM ignition switched supply For VSIM circuit tests,
GROUND failure fault Goto <<Q>>
.
VSIM GROUND fault
Pinpoint tests
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
1. Measure the voltage between FC14, pin 104 (NW) and GROUND.
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1. Measure the resistance between FC14, pin 15, (WU) and GROUND.
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. This circuit includes the ignition switch. For additional information, refer
to the wiring diagrams. Test the system for normal operation.
-> No
Goto <<A6>>
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REPAIR the high resistance circuit. This circuit includes the ignition switch. For additional information, refer
to the wiring diagrams. Test the system for normal operation.
-> No
CONTACT dealer technical support for advice on possible BPM failure.
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
1. Measure the resistance between BT40, pins 13, 14 and 15 (BK) and GROUND.
Is any resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
CONTACT dealer technical support for advice on possible SLCM failure.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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-> Yes
REPAIR the circuit between the RCM and battery. This circuit includes the luggage compartment fuse box,
(fuse 05) and the ignition switch. For additional information, refer to the wiring diagrams. Test the system for
normal operation.
-> No
Goto <<H5>>
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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additional information, refer to the wiring diagrams. Test the system for normal operation.
-> No
Goto <<L2>>
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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-> Yes
REPAIR the circuit between the ECM and battery. This circuit includes the engine compartment fuse box
(fuse 16). For additional information, refer to the wiring diagrams. Test the system for normal operation.
-> No
Goto <<N3>>
NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
1. Measure the voltage between the DLC, pin 16 (NW) and GROUND.
Is the voltage less than 10 volts?
-> Yes
REPAIR the circuit between the DLC and battery. This circuit includes the driver side fuse box (fuse 13). For
additional information, refer to the wiring diagrams. Test the system for normal operation.
-> No
Goto <<P2>>
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NOTE:
Before beginning any power supply tests, make sure the vehicle battery is fully charged and in good condition.
NOTE:
Turn the ignition switch to the OFF position after testing.
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NOTE:
A tolerance of +/- 10% should be used when testing the network.
NOTE:
For vehicles without adaptive speed control, bypass the tests for vehicle speed interface module and adaptive
speed control module.
1. Measure the resistance between LF37, pin 15 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R4>>
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1. Measure the resistance between LF61, pin 11 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R6>>
R6 : CHECK THE CAN + CIRCUIT BETWEEN THE ASCCM (WHERE FITTED) AND THE ABS/TCCM
FOR CONTINUITY
1. Measure the resistance between LF37, pin 05 (Y) and LF61, pin 13 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R7>>
R7 : CHECK THE CAN - CIRCUIT BETWEEN THE ASCCM (WHERE FITTED) AND THE ABS/TCCM
FOR CONTINUITY
1. Measure the resistance between LF37, pin 15 (G) and LF61, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R8>>
R8 : CHECK THE CAN + CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR
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CONTINUITY
R9 : CHECK THE CAN - CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR
CONTINUITY
1. Measure the resistance between EM74, pin 16 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R10>>
R11 : CHECK THE CAN + CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR
CONTINUITY
R12 : CHECK THE CAN - CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR
CONTINUITY
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1. Measure the resistance between FC25, pin 24 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R13>>
R13 : CHECK THE CAN + CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI
MODULE FOR CONTINUITY
1. Disconnect the GSI module electrical connector, FC88.
2. Measure the resistance between FC88, pin 09 (Y) and FC25, pin 11 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R14>>
R14 : CHECK THE CAN - CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI
MODULE FOR CONTINUITY
1. Measure the resistance between FC88, pin 08 (G) and FC25, pin 23 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R15>>
R15 : CHECK THE CAN + CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
R16 : CHECK THE CAN - CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Measure the resistance between EM10, pin 27 (G) and FC88, pin 03 (G).
Is the resistance greater than 5 ohms?
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-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R17>>
R17 : CHECK THE CAN + CIRCUIT BETWEEN THE ECM AND THE ABS/TCCM FOR CONTINUITY
R18 : CHECK THE CAN - CIRCUIT BETWEEN THE ECM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between LF37, pin 15 (G) and EM10, pin 25 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
NO circuit fault found in network. Recheck DTCs.
R19 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE DLC AND THE INSTRUMENT
CLUSTER FOR SHORT CIRCUIT TO EACH OTHER
R20 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE INSTRUMENT CLUSTER AND THE GSI
MODULE FOR SHORT CIRCUIT TO EACH OTHER
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REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R21>>
R21 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ECM FOR
SHORT CIRCUIT TO EACH OTHER
1. Disconnect the ECM electrical connector, EM83.
2. Measure the resistance between EM83, pins 25 (Y) and 16 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R22>>
R22 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE TCM FOR SHORT
CIRCUIT TO EACH OTHER
R23 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE ASCCM (WHERE
FITTED) FOR SHORT CIRCUIT TO EACH OTHER
R24 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ASCCM (WHERE FITTED) AND THE
ABS/TCCM FOR SHORT CIRCUIT TO EACH OTHER
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-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<R25>>
R25 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ASCBCM
(WHERE FITTED) FOR SHORT CIRCUIT TO EACH OTHER
NOTE:
A tolerance of +/- 10% should be used when testing the network.
NOTE:
For vehicles without adaptive speed control, bypass the tests for vehicle speed interface module and adaptive
speed control module.
S2 : CHECK THE CAN + CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR
CONTINUITY
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S3 : CHECK THE CAN - CIRCUIT BETWEEN THE VSIM (WHERE FITTED) AND THE DLC FOR
CONTINUITY
1. Measure the resistance between EM74, pin 16 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
NO circuit fault found in network. Recheck DTCs.
S5 : CHECK THE CAN + CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR
CONTINUITY
S6 : CHECK THE CAN - CIRCUIT BETWEEN THE DLC AND THE INSTRUMENT CLUSTER FOR
CONTINUITY
1. Measure the resistance between FC25, pin 24 (G) and DLC, pin 14 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<S7>>
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S7 : CHECK THE CAN + CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE
FOR CONTINUITY
S8 : CHECK THE CAN - CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE GSI MODULE
FOR CONTINUITY
1. Measure the resistance between FC88, pin 08 (G) and FC25, pin 23 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<S9>>
S9 : CHECK THE CAN + CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
S10 : CHECK THE CAN - CIRCUIT BETWEEN THE GSI MODULE AND THE ECM FOR CONTINUITY
1. Measure the resistance between EM83, pin 16 (G) and FC88, pin 03 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<S11>>
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S11 : CHECK THE CAN + CIRCUIT BETWEEN THE ECM AND THE TCM FOR CONTINUITY
S12 : CHECK THE CAN - CIRCUIT BETWEEN THE ECM AND THE TCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 85 (G) and EM83, pin 15 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<S13>>
S13 : CHECK THE CAN + CIRCUIT BETWEEN THE TCM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 83 (Y) and LF37, pin 05 (Y).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
Goto <<S14>>
S14 : CHECK THE CAN - CIRCUIT BETWEEN THE ASCCM AND THE ABS/TCCM FOR CONTINUITY
1. Measure the resistance between EM07, pin 82 (G) and LF37, pin 15 (G).
Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Test the system
for normal operation.
-> No
NO continuity fault found in CAN circuit. CHECK DTCs for possible module fault.
S15 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE DLC AND THE INSTRUMENT CLUSTER
FOR SHORT CIRCUIT TO EACH OTHER
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S16 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE INSTRUMENT CLUSTER AND THE GSI
MODULE FOR SHORT CIRCUIT TO EACH OTHER
S17 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE GSI MODULE AND THE ECM FOR
SHORT CIRCUIT TO EACH OTHER
S18 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE TCM FOR SHORT
CIRCUIT TO EACH OTHER
S19 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE TCM AND THE ABS/TCCM FOR SHORT
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S20 : CHECK THE CAN + AND - CIRCUITS BETWEEN THE ECM AND THE VSIM (WHERE FITTED)
FOR SHORT CIRCUIT TO EACH OTHER
1. Measure the resistance between pins 06 (Y) and 16 (NW) of the DLC.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<T2>>
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1. Measure the resistance between pins 14 (G) and 16 (NW) of the DLC.
Is the resistance less than 10,000 ohms?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<T7>>
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T10 : CHECK THE CAN - FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
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1. Measure the resistance between pins 02 (Y) and 05 (BK) of the DLC.
Is the resistance between 90 and 150 ohms?
-> Yes
TERMINATION is correct. Check for DTCs indicating a module or circuit fault. Refer to the DTC index.
-> No
Goto <<U2>>
U2 : CHECK THE SCP NETWORK + AND - FOR SHORT CIRCUIT TO EACH OTHER
1. Measure the resistance between pins 02 (Y) and 05 (BK) of the DLC.
Is the resistance less than 90 ohms?
-> Yes
A short circuit to each other in the SCP network will mean the disconnection of the modules and tracing the
short by traditional methods.
-> No
Goto <<U3>>
1. Measure the voltage between pins 02 (Y) and 16 (NW) of the DLC.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<U4>>
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1. Measure the voltage between pins 10 (U) and 16 (NW) of the DLC.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<U9>>
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2. Measure the voltage between pins 10 (U) and 09 (WU) of the DLC.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<U10>>
U11 : CHECK THE SCP - FOR SHORT CIRCUIT TO ACCESSORY SWITCHED GROUND
U12 : CHECK THE SCP - FOR SHORT CIRCUIT TO IGNITION SWITCHED GROUND
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1. Measure the voltage between pins 07 (O) and 16 (NW) of the DLC.
Is the voltage greater than 3 volts?
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Test the system for normal
operation.
-> No
Goto <<V2>>
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V7 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO IGNITION POSITIVE
V9 : CHECK THE SERIAL INPUT CIRCUIT FOR SHORT CIRCUIT TO ACCESSORY SWITCHED
GROUND
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V10 : CHECK THE BIDIRECTIONAL CIRCUIT FOR SHORT CIRCUIT TO IGNITION SWITCHED
GROUND
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
4. Remove the glovebox assembly, for access to the connectors. Refer to Section <<501-12>>.
5. From behind the fuse-box (in the glovebox area) disconnect the harness multi-plug.
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Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
5. From behind the fuse-box (in the underscuttle area) disconnect the harness multi-plug.
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Installation
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Navigation System
Description
A fully integrated navigation system installed as an option, employs visual displays and voice commands to provide
various types of route guidance information to the driver. Using signals from the global positioning satellite (GPS)
system together with terrestrial map data, vehicle road speed and yaw rate, the system calculates the position of the
vehicle to an accuracy of a few metres.
Following receipt of information on the desired destination and selected route, the system provides both visual and/or
voice instructions as progress is made along that route. In the event of deviation from the original route, the navigation
system determines vehicle position and revises the route accordingly.
Operation
With a DVD for the appropriate region or country loaded into the DVD reader, information on the destination is fed into
the system using the screen menus and panel controls to make selections and input text as directed. Addresses can
be entered or selections made from the DVD database list of 'Points of Interest'. Other types of destination such as
road intersections, recent destinations, map cursor positions or local points of interest within a specified radius can
also be requested. In addition to DVD stored data, 'memory point' map locations for subsequent selection as route
destinations or 'landmarks' can be created. The route initially specified can also be split into sections, or modified to
include or avert selected roads or highways.
Screen Guidance
Map View displays the appropriate map area with the route highlighted and the vehicle icon arrowed. The
map automatically scrolls to maintain the vehicle icon on screen.
Arrow View is a diagrammatic display providing a detailed view of the junction approached and the direction
to be taken together with distance information.
With Hybrid View selected, the map and highlighted route are displayed until, on approaching the next junction
or manoeuvre point, Arrow View appears.
Voice Guidance
Synthesised Voice Guidance provides audible instructions for the junction or manoeuvre point approached (e.g. 'Turn
Left') and a pushbutton on the control panel enables these instructions to be repeated. Voice Guidance instructions
are broadcast through the ICE system and can be adjusted using the MODE and volume controls on the
radio/cassette panel. The balance between Voice Guidance and ICE volume can also be varied.
Clock
A digital clock displays 12 hour format time in the lower left hand corner of the screen when the navigation system is
switched on. No adjustment is provided as the correct time is automatically maintained from GPS satellite signals.
Time zone and Summer Time settings are selectable from a screen menu and must be adjusted to suit vehicle location
and time of year.
System Components
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The integral display and controls panel is installed in the central facia area otherwise occupied by the clock and minor
gauge module. The panel is secured by four screws and finished by a clip-in veneer panel.
The navigation system DVD reader provides data storage, processing and system control and incorporates a
gyrometer for measurement of vehicle yaw rate. Maps and associated data for the relevant country or region are
received from digital versatile disks (DVD) loaded into the reader. The navigation DVD reader is located between the
CD autochanger and the power amplifier (premium audio only) in the trunk.
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The navigation system vehicle speed module receives wheel speed signals fed to the CAN data bus by the
ABS/traction control module. The vehicle speed module is secured by velcro to the underside of the engine
compartment coolbox cover.
The global positioning system (GPS) antenna is connected to the DVD reader by a co-axial cable, the inner conductor
of which carries a 5Vdc power supply. The antenna is secured to the rear parcel shelf (coupe) or the convertible top
stowage compartment by a self-adhesive coating on the base.
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1. Remove trim from rear parcel shelf/convertible top compartment. Refer to <<76.67.06>> (coupe only).
3. Using a thin blade, carefully release antenna base from parcel shelf panel/convertible top compartment.
4. Clean antenna mounting area of parcel shelf panel/convertible top compartment ensuring that any residual
adhesive is removed.
5. If original antenna is to be re-used, remove adhesive pad and clean any residual adhesive from base.
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Installation
1. Remove paper backing from one side of adhesive pad and press firmly onto antenna base.
2. Position antenna at parcel shelf panel/convertible top compartment and connect flying lead connector.
3. Remove paper backing from adhesive pad and press base firmly into position on parcel shelf/convertible top
compartment.
4. Install rear parcel shelf/convertible top compartment trim. Refer to <<76.67.06>> (coupe only).
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1. Remove battery cover and disconnect ground lead from battery terminal. Refer to <<86.15.19>>
3. Disconnect three connectors from side of amplifier unit (premium audio only).
4. Remove four bolts securing audio/DVD reader module stack to mounting frame.
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5. Carefully withdraw audio/DVD reader module stack and disconnect four connectors from rear of DVD reader
module
7. Remove four DVD reader module to mounting bracket screws and withdraw module from bracket.
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Installation
2. Position audio/DVD reader module stack at mounting bracket and connect DVD reader harness connectors.
3. Ensure that amplifier and CD autochanger harnesses will not obstruct stack installation.
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7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
3. Commencing at bottom, use a thin plastic blade to release four centre veneer clips.
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5. Remove Panel.
Partially withdraw panel for access.
Depressing tangs, disconnect harness connectors.
Remove panel from facia
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Installation
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3. Position and fully seat veneer panel ensuring all securing clips are engaged.
5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.15>>.
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Installation
1. Install Module.
Connect harness connector to module.
Position module on underside of coolbox lid and firmly seat module on velcro pad.
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4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Remove the trim pad from the door; refer to Section <<501-05>>.
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8. If necessary remove the foam gasket from the module; note that a new gasket must be fitted when installing
a new module.
Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
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1. Switch ON the ignition. Move the passenger seat fully rearwards. Switch OFF the ignition. Whilst the door(s)
is still open and the window down, disconnect the battery ground cable.
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Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
3. Remove the trim pad from the door; refer to Section <<501-05>>.
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8. If necessary remove the foam gasket from the module; note that a new gasket must be fitted when installing
a new module.
Installation
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1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors
remain open until after the battery has been disconnected.
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Installation
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1999 XK RANGE - Body System - General Information - 501-00
Body
The convertible body style is a cut-down version of the coupe with tubular internal sill reinforcements and additional
structure to suit.
Front
The hood is hinged at the front and supported by two non-locking gas struts when open. Hood release is by a lever
located at the LHS 'A' post.
The front bumper beam is in a GMT material or aluminum for N. American markets, and covered in polyurethane. N.
American models also have energy absorbing strut mountings. Valance reinforcement is provided for front fender
mounting.
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The front fenders are common parts to both coupe and convertible. A chrome-plated splitter vane with twin
polyurethane overriders is installed in the front air intake of normally aspirated vehicles. On supercharged vehicles
(XKR), a chromed mesh grill is installed in the front air intake.
The front fenders carry Jaguar badges and direction indicator repeaters. A single front towing eye stored in the trunk,
screws in to either the left- or right-hand side of the lower cross member.
Center
The full width injection moulded fascia matches the 'A' posts and windshield valance assembly. Faced with a walnut
burr veneer, it houses instrument panels appropriate to the market, and air conditioning vents
The toeboard supports the steering column and air conditioning unit casing.
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Convertible and Coupe Bodyshells
For added rigidity, convertibles have internal sill reinforcing tubes and a tubular brace is installed between each BC
post and the rear seat squab panel.
'A' post inners support the windshield and body side assemblies. The coupe body sides are one-piece assemblies
each incorporating part of the outer sill, 'A' and 'B' posts and cantrail reinforcement and are joined to the rear tonneau.
The convertible has cropped coupe monosides with the outer wheel arches bonded to the tonneau. Both treadplates
are bright finish with the car designation, Jaguar XK8, inscription added. To accommodate the folded top, the
convertible rear seats are of a dedicated design and are not interchangeable with the coupe seats.
A one-piece soft tonneau cover, color keyed to the vehicle interior and secured by two Tenax fasteners, two velcro
pads and two press studs, is retained by the trunk lid when in place. It is stowed in a bag on the front face of the trunk.
The coupe rear parcel shelf is trimmed in headlining cloth. It has provision for air extraction and has child seat
anchorage points. For some markets, the rear parcel shelf also incorporates a high mounted stop light cover. Acoustic
cloth covered speakers, courtesy lamps, integral armrests and stowage trays are incorporated in the coupe
one-piece, moulded rear quarter casing.
The convertible rear quarter casing is similar to the coupe but does not have armrests fitted. The body has two-piece,
LHS and RHS, carpets joined at the center console. Single color moulded carpets are fitted to the trunk. The coupe
roof is trimmed in a one-piece moulded 6 mm thick cloth headlining supported by four body tangs, sun visor fixings at
the front, and the rear quarter casings at the rear.
The header console incorporates two courtesy lamps and switched map lights. The convertible has a padded
serviceable headlining and header console. On some market versions, garage door opener switches are also fitted in
the header console.
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Rear
Internal and External Trunk Lid Releases
A welded double loop rear towing eye is installed on the right hand rear corner of the luggage floor.
The trunk lid which is dedicated either to the coupe or the convertible, consists of inner and outer panels clinched
together to minimise welding requirements. For some markets, warning triangle stowage is provided in the trunk lid
liner. The trunk is opened from the car interior via a switch mounted in the driver side underscuttle. This switch is only
operational when the valet mode is inactive, security disarmed (vehicle is unlocked) and the vehicle is stationary.
A key operated lock situated on the RHS of the trunk rear panel, provides emergency external access to the trunk.
Non-locking gas struts support the trunk lid when open.
The fuel filler flap which incorporates a magnetic filler cap retainer, is unlocked via an illuminated switch in the driver's
underscuttle. The filler flap can only be opened when the engine is not running, security is disarmed and the car is
either unlocked or the key is in the ignition switch. A petrol/water drain is provided in the filler recess.
Convertible Top
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The fully lined and padded convertible top is fitted to an aluminum frame with steel linkages, providing good structural
strength with light weight. The top folds down to a low stack height in the body opening of the rear quarter and has a
semi-rigid cover. The top is power latched and has a green tinted, heated, glass backlight incorporating a security
antenna. The convertible top operating pump is located on the right-hand side of the trunk.
To operate the top, the switch must be held depressed with the ignition switch in either position I or II. When the top
starts to move, an audible warning sounds for 0.7 seconds. Latching and unlatching is automatic. Operation of the
convertible top is inhibited at vehicle speeds in excess of 16 km/h (10 mph). If the vehicle exceeds this speed when
the top is moving to the lowered position, it will continue to the fully down position. Should the vehicle exceed this
speed when the top is being raised, further movement will be inhibited until the speed is reduced. Ensure that all
passengers, personnel and equipment are clear of top before raising or lowering it.
Raising and lowering of the convertible top is controlled from the SCP network via the Security and Locking Module
(SLM) and the Body Processor Module (BPM).
In the event of latch failure when raising the top, a visual warning is illuminated on the instrument panel. A center pull
down feature facilitates manual latching of the top in emergency circumstances. Provision is also made for manual
raising of the top should loss of electrics occur.
Doors
Doors are common to both coupe and convertible, with a frameless glass system, dual door-mounted seals and
demountable hinges with separate multi-stage check arms. The door casings and top rolls are UEV trimmed with cloth
center pads. Leather center pads are fitted for some markets. Combined armrests/door pockets are trimmed in
leather and have burr walnut veneer insets.
The colour-keyed exterior door handles each have an integrated switch for glass drop on opening. Additionally, the
driver's door handle has an integrated key barrel. The cheater is formed by the door mirror base and a black injection
moulded inner cheater. The cheater seal is integral with the secondary door seal. Tweeters are fitted in the inner
cheater as part of the premium in-car entertainment option. Each door has a combined rearguard/puddle lamp
mounted in the door pocket casing.
Both the driver and passenger door incorporate Door Control Modules (DDM and PDM) which are connected to the
SCP network and control the raising and lowering of the window glass, locking and security, puddle lamp and door
mirror movement and heating functions. A drive-away door locking function incorporated in the DDM and PDM
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software is activated when the transmission is taken out of Park or Neutral position.
Adjustment of driver and passenger door mirrors including memory functions is controlled by the driver door
switchpack through each door module. Door mirror heating is controlled via the rear windshield heating switch on the
air conditioning control panel. Electrochromic mirrors available as an option are automatically heated at very low
ambient temperatures. A mirror fold back function enabling the door mirrors to fold back against the body/glass when
parking the car, is featured for some markets.
Dipping of the passenger door mirror when reverse gear is selected is also featured on some vehicles/markets.
Dipping is either 7 degrees in a downward direction, bottom of travel or 5 seconds dependent upon which condition is
satisfied first. When the gear selector is moved from reverse the door mirror will return to the original position.
Glass
The windshield, which is common to the coupe and convertible, is in 5 mm laminated glass with a black obscuration
band and has a rear-view mirror direct-mounted. The windshield finisher is a one-piece, single color unit with seal. The
backlight is 4 mm tempered glass, green tinted and heated. The windshield, backlights and quarter lights, except for
the convertible model, are direct glazed to body.
The windshield and coupe backlight are supplied as assemblies complete with trim which is secured to the glass by
clips and is fully demountable when the assembly is bonded to the vehicle.
The convertible backlight and outer seal are conventionally glazed to the inner seal, which is stitched and bonded to
the top. On both models, the heated backlight remains 'on' for 21 minutes after being switched on unless the driver
switches it off before the time delay expires. Some backlights are fitted with a security antenna. A fine wire heated
windshield offered as an option on some markets, is controlled from the air conditioning panel.
The door glass on both models is a frameless system with 5 mm green tempered glass. The door glass is operated
electrically and raised and lowered by a scissor mechanism.
Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or
lowered, closing when either the door is shut or the top is fully raised and latched in position. The door glass can be
closed via the remote control unit. Operation is internally controlled from switchpacks located in the driver and
passenger arm rests via the driver and passenger door modules. The switchpacks are illuminated when the sidelights
are on.
One-touch up operation causes the glass to fully close unless an object is detected or if the glass is already within 45
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mm of top of travel when the door is opened. On detection of an object, the glass will drop fully open or to 200 mm
below the obstruction. All drop-glass operates with the ignition switch in either position I or II and for 30 seconds after
ignition is switched off or the associated door is opened.
The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit direct glazed to the tonneau. The rear
quarters of the convertible are 5 mm, tempered, semi-flush, green tinted units with a drum and wire lowering and
raising system which provides full glass drop when the top is lowered.
Control is incorporated in the convertible top switch. With the convertible top up, the rear quarter glass is raised by
pressing and releasing the front of the switch and lowered by pressing and releasing the rear of the switch (one touch
down).
The rear quarter glass is automatically powered to the bottom position when the top is lowered and further operation
is inhibited until the top is raised and latched.
When lowering the rear quarter glass at vehicle speeds up to 16 km/h (10 mph), failure to release the switch on
operation of the audible alarm will result in lowering of the top.
The rear quarter glass is operated automatically up or down respectively when raising or lowering the convertible top.
When the top is raised, with the door glass at the top of its travel, the glass will be powered down 12 mm and the
rear quarters will be powered to the bottom of their travel. When the top is fully raised all glass will be powered up to
close to form a seal with the top.
If the front glass has been either fully or partially lowered manually, the rear quarters only will be powered up. If the
power supply to the driver or passenger module is disconnected (battery disconnected, module unplugged or fuse
removed), then the system must re-learn the characteristics. The last known glass position is regarded as top of
travel by one touch operation until re-learning has taken place. One touch down, manual up and down control and the
automatic lowering of the glass for door opening are unaffected.
To re-learn the positioning characteristics, the associated door must be closed (door ajar switch inactive). The glass
must then be driven fully down and held stalled at the bottom of its travel for a minimum of one second. The glass is
finally driven to the fully up position and held stalled for a minimum of one second. The re-learning procedure must also
be accomplished to regain the automatic closing sequence.
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Wipers/Washers
The windshield wiper motor, with integral microswitch for overload protection, is mounted in the plenum below the
windshield and is handed for market requirements. The vehicle has a conventional twin wiper arm system with
synthetic rubber blades and wiper arm mounted windshield wash jets. Jets are designed to resist freezing, eliminating
the need for heated nozzles. Wiper modes are 2-speed, flick wipe and six settings of intermittent wipe.
Screen wash tubing is supplied assembled in the wiper arm and is fitted to a connector which is part of the plenum
cover assembly. The wipers park on the windshield. The washer fluid reservoir is located in the cavity formed by the
front bumper, LH front valance and the front wing liner. The reservoir has a fluid capacity of 7 liters of liquid and is
fitted with a low level sensor. When screenwash is selected, the wipers complete three cycles followed by a 4 second
delay and a further cycle to clear residual fluid from the screen until either the switch is released or the ignition is
moved from position II.
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Some markets and options have a headlamp telescopic power wash mounted below each lamp glass. These washers
will operate in conjunction with the screen-washers, when the headlights are on dip or main beam, or daylight running
is enabled, the washer fluid does not indicate low level, and the ignition switch is in position II.
When wash/wipe is selected and held, the headlamp wash pump is activated and sprays for 800 ms, waits 6 seconds
and then sprays again. This spray is repeated after each six second interval until the switch is released or 20 seconds
has elapsed. When the switch is released, further power wash cycles will be inhibited for the next 5 wash/wipe
operations to conserve wash fluid.
All power wash fittings are snap fit, cover to jet, jet to headlamp, jet to hose. The wash/wipe system is operated from
switches on the steering column via the Body Processor Module (BPM), part of the SCP network.
Seats
The driver and passenger seat control modules (DSM and PSM) which control seat and squab movement, and seat
heating where fitted, are mounted on brackets below the seat frames and are connected to the SCP network.
Seat movement control switch assemblies fitted in the outboard side of both the driver and front passenger seats, are
color keyed to the seats. These switches, through the seat control modules, operate motors for fore and aft, recline
and raise and lower movements of the seat. On some markets/options, another motor operates the lumbar
adjustment pump which is also controlled by a switch mounted in the seat. Only one of the slide, recline or height
motor outputs can be driven at any one time under manual control. Additionally, some markets/options have
passenger seat height adjustment, seat and squab heaters and driver's seat position memory.
On cars fitted with driver seat memory, each motor is fitted with feedback potentiometers. The illuminated on/off
switches for seat heating where fitted as options or standard fit in cold climate territories, are mounted in the center
console. Rear passenger access/egress is made easier by a lever mounted on the upper outside of driver and
passenger seats allowing the seat squabs to fold forward. Each front seat has a rear map pocket.
The rear seats are wire-framed units trimmed to match the front seats and specifically tailored to fit either the coupe
or the convertible. No adjustment of the rear seats is provided. Provision is made for the fitting of child seats where
legally required.
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Body Structure
Produced in coupe and convertible styles complete with doors, hood and trunk lid, the body comprises almost 200
components. For service requirements, each body shell is available less doors, front fenders, hood and trunk lid. The
convertible body is a cut-down version of the coupe, incorporating tubular internal sill reinforcements and associated
structures.
To fully satisfy requirements for a minimum of six years corrosion resistance, more than 70% by weight of steel
panels are zinc coated on both sides (ref. illustration above) and all panel joints below the roof line have zinc
protection between them prior to welding together. Close tolerance apertures together with water tight joints and
seals ensure low interior noise levels and general travel refinement. For additional torsional strength and anti-flutter
properties at key points, metal to metal adhesives or interweld seals are applied to mating surfaces before welding.
Whilst during manufacture, bodyshell aperture gaps are set to dedicated panels, these components are available as
service items.
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1999 XK RANGE - Front End Body Panels - 501-02
Torques
Component Nm
Nut and bolt front cruciform brace - normally aspirated 20 - 26
Bolt front cruciform brace - supercharged 41 - 54
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1999 XK RANGE - Front End Body Panels - 501-02
The front body structure is designed to satisfy bumper impact requirements and primarily comprises the front bumper
assembly which is fully described in Section <<501-19>>.
The front fenders which are common to coupe and convertible models, are each bolted to the front valance, front
bumper casing and 'A' post. Removal and installation of the fenders is detailed in the Body and Paint Repair manual.
Description and removal and installation instructions for the hood are included in Section <<501-03>>.
A GMT undertray fitted to assist air flow through the cooling pack, is secured to the bottom of the bumper casing and
the body front cross-member. A small GMT air deflector fitted to the undertray at each wheelarch improves air flow in
the front wheel area.
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1999 XK RANGE - Front End Body Panels - 501-02
Plenum Cover and Front Seals
Protective GMT liners fitted in the wheelarches each incorporate a readily detachable panel for access to the
headlamp assembly. An injection moulded plenum cover, painted Dorchester grey on all vehicles and secured to the
bodywork by screws and plastic fasteners, incorporates windshield and fender seals, and screenwash connectors.
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Installation
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Installation
1. Position plenum cover for access and connect drain hoses and screenwasher tubes.
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1999 XK RANGE - Front End Body Panels - 501-02
3. Fit but do not tighten the retaining screws and plastic fasteners.
4. Commencing in the center, tighten the retaining screws and plastic fasteners.
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4. NOTE:
Driver side water deflector is captive to throttle cable.
Slacken and remove bolts securing plenum chamber water deflectors to BIW and remove passenger side
deflector from vehicle.
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5. Rotate throttle quadrant to fully open position and disconnect throttle inner cable nipple from quadrant.
6. Cut through and discard tie strap securing throttle cable and adjuster to abutment bracket and lift cable and
adjuster clear of bracket.
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8. Pass throttle cable through driver side water deflector and remove deflector.
9. NOTE:
This step is not applicable to N/A vehicles from 1999 Model Year onwards.
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10. Slacken and remove plenum chamber closing panel to BIW securing nuts and remove panel from vehicle.
11. Remove nuts securing ignition amplifiers to closing panel and remove amplifiers from panel.
Installation
1. Position ignition amplifiers on closing plate and fit and tighten securing nuts.
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2. Fit closing plate to BIW ensuring that lower clips locate correctly on body flange.
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1999 XK RANGE - Front End Body Panels - 501-02
4. NOTE:
This step is not applicable to N/A vehicles from 1999 Model Year onwards.
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1999 XK RANGE - Front End Body Panels - 501-02
7. Position throttle quadrant to fully open position and fit throttle cable inner to quadrant ensuring that nipple fully
seats in slot.
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1999 XK RANGE - Front End Body Panels - 501-02
8. Release throttle quadrant and fit and fully seat throttle cable adjuster in abutment bracket.
10. Using new tie strap, secure throttle cable adjuster in abutment bracket.
11. Position plenum water deflectors and fit and tighten securing bolts.
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1999 XK RANGE - Front End Body Panels - 501-02
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Installation
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3. Slacken and remove four bolts securing front cruciform assembly to BIW.
Installation
3. Position undertray on vehicle and secure with new plastic rivets. Refer to 76.22.28.
4. Raise front of vehicle, remove stands and lower vehicle onto wheels.
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1999 XK RANGE - Front End Body Panels - 501-02
4. Slacken and remove two lower bolts securing front cruciform brace to BIW.
5. Supporting front cruciform brace, slacken and remove two bolts and nuts securing brace to upper support
brackets.
6. Exercising care to avoid damaging radiator and condenser, lift front cruciform brace from vehicle.
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1999 XK RANGE - Front End Body Panels - 501-02
Installation
1. Carefully lower cruciform brace into position between radiator and condenser.
5. Position undertray on vehicle and secure with new plastic rivets. Refer to 76.22.28.
7. Raise front of vehicle, remove stands and lower vehicle onto wheels.
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1999 XK RANGE - Front End Body Panels - 501-02
Installation
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3. Remove and discard scrivets securing undertray to bumper cover and wheelarch liners.
4. Remove and discard screws securing undertray to lower crossmember and remove undertray.
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1999 XK RANGE - Front End Body Panels - 501-02
Installation
1. Fit undertray.
Position undertray on vehicle and secure to lower cross-member with screws.
2. Secure undertray to bumper cover and wheelarch liners using new scrivets.
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1999 XK RANGE - Body Closures - 501-03
1. Supporting trunk lid in the open position, disconnect support struts from lid.
4. Open trunk lid, adjust position on hinges as necessary and tighten one securing bolt on each side.
7. Fit support struts to trunk lid pivots ensuring that retaining clips are fully seated.
Body Closures
Doors
Door Seal
The doors, which are common to coupe and convertible models and have a frameless glass system, each comprise
inner and outer panels, clinched and bonded together to form a door assembly. Both panels incorporate extensions
spot welded together to form a cheater assembly and a PVC sealant is applied in cosmetic bead form to all clinch
joints. Both the door assembly and separate outer panel are available as service items.
A dual, joint-less EPDM sponge seal is installed on each door together with a water shedder and separate vacuum
formed speaker cup.Upper and lower door hinges and multi-stage check arms require no lubrication throughout vehicle
life
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1999 XK RANGE - Body Closures - 501-03
Hood
Common to coupe and convertible models, the hood assembly consists of one piece inner and outer panels, clinched
and bonded together, with cosmetic bead PVC sealant applied to all clinch joints.
Hinge assemblies, hinge reinforcements, gas strut brackets and a hood lock striker are attached to the inner panel
which also accommodates a hood liner. The hinge assemblies are of double link design to permit minimum clearance
between the hood leading edge and the top of the bumper casing.
The hood seats on EPDM sponge bulb seals on the BIW front cross member and four flanges on the secondary
bulkhead, and on a transverse seal bonded to the plenum cover.
Trunk Lid
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Dedicated either to the coupe or convertible, the trunk lid comprises one piece inner and outer panels clinched and
bonded together, with cosmetic bead PVC sealant applied to all clinch joints.Hinge reinforcements and a lock striker
mounting reinforcement are attached to the lid inner panel and combined hinge and gas strut mounting assemblies are
secured by bolts to the inner panel and the tonneau/trunk flange at each side.
The trunk lid seats on a single joint, EPDM sponge, single profile bulb seal, mounted on the trunk flange.
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1999 XK RANGE - Body Closures - 501-03
1. Remove the treadplate finisher and place face uppermost on sheet of clean dry polythene.
2. Slacken and remove treadplate securing screws and remove treadplate.
3. Remove front of welt from aperture flange.
NOTE:
The rear welt section is integral with the seal and must not be separated from it.
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3. Remove seal complete with rear draught welt section from door aperture.
Installation
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1999 XK RANGE - Body Closures - 501-03
6. Using clip removal tool, remove seal fixings from door inner face and lock face.
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1999 XK RANGE - Body Closures - 501-03
7. Ensuring that door paintwork is not damaged, cut through sealant between cheater seal and cheater frame.
9. Carefully pull seal upwards to clear cheater frame and remove seal from door.
10. Clean any residual sealant and butyl strip from cheater frame.
11. If original seal is to be re-fitted, carefully remove residual butyl strip from seal interior.
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1999 XK RANGE - Body Closures - 501-03
Installation
4. Fit and fully seat seal fixings to upper door lock face.
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1999 XK RANGE - Body Closures - 501-03
8. Fit door waist rail finisher, aligning rear end with edge of door and maintaining a 4mm gap at other end.
9. Fit door inner waist rail seal ensuring that it is fully forward and contacting the front guide leg.
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1999 XK RANGE - Body Closures - 501-03
6. If fitted pass fuel filler flap emergency release cord through slot and remove LH liner from trunk. Refer to
<<76.10.25>>.
7. Supporting fuel filler flap, slacken and remove securing nuts and remove filler flap from vehicle.
Installation
1. Position fuel filler flap on vehicle and fit and tighten securing nuts.
2. Position LH side liner in trunk and if fitted pass emergency release cord through slot. Refer to <<76.10.25>>.
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Hood 76.16.01
Removal
4. With assistance, supporting hood, release support strut upper retaining clips and remove struts from hood
pivots.
5. Fully supporting hood to prevent paintwork damage, remove securing bolts and remove hood from vehicle.
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1999 XK RANGE - Body Closures - 501-03
6. Slacken and remove expander screws from hood insulation pad retainers.
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1999 XK RANGE - Body Closures - 501-03
9. Slacken and remove bolts securing striker/buffer assemblies to hood and remove assemblies.
Installation
2. Position both hood striker/buffer assemblies and fit but do not tighten securing bolts.
3. Position insulation pad on hood and commencing at top, fit and fully seat new plastic retainers.
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1999 XK RANGE - Body Closures - 501-03
5. With assistance, carefully lift hood into position on vehicle and fit but do not tighten securing bolts.
6. Fit and fully seat upper end of each support strut on hood pivot
7. Exercising care to avoid damaging paintwork, close hood and check alignment.
8. Open hood, adjust alignment on hinges as necessary and fully tighten securing bolts.
12. Open hood, fully tighten striker/buffer securing bolts and fully tighten hood securing bolts.
13. Remove masking tape and fender covers and close hood.
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1999 XK RANGE - Body Closures - 501-03
3. Commencing at bottom, remove insulation pad plastic retainers and remove pad from hood.
Installation
1. Position insulation pad on hood and commencing at top, fit and fully seat plastic retainers.
3. Release strut upper retaining clip and remove strut from hood pivot.
4. Release strut lower retaining clip and remove strut from vehicle.
Installation
1. Fit strut onto lower pivot ensuring that retaining clip is fully seated.
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1999 XK RANGE - Body Closures - 501-03
2. Extend strut and fit onto hood pivot ensuring that retaining clip is fully seated.
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1999 XK RANGE - Body Closures - 501-03
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Remove and discard the twenty fasteners securing insulation pad to trunk lid and remove insulation pad.
5. Release rubber grommet from trunk aperture and pass rear harness and multiplug through aperture.
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10. With assistance to prevent trunk lid from moving, slacken and remove bolts securing hinges to trunk lid.
12. Slacken and remove number plate securing screws and remove number plate from mounting bracket.
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1999 XK RANGE - Body Closures - 501-03
13. Drill out rivets securing number plate mounting bracket to trunk lid.
Installation
1. Position number plate mounting bracket on trunk lid and secure with new rivets.
2. Position number plate on mounting bracket and fit and tighten securing screws.
3. With assistance, position trunk lid on vehicle and fit but do not tighten lid to hinge securing bolts.
7. Pass rear harness and multiplug through trunk aperture and rubber grommet and seat grommet in aperture.
10. Position insulation pad on trunk lid underside and secure with twenty new fasteners.
11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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Installation
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2. Release strut upper retaining clip and remove strut from trunk lid pivot.
3. Release strut lower retaining clip, remove strut from trunk pivot and remove strut from trunk.
Installation
1. Fit strut lower end to trunk pivot ensuring that retaining clip fully seats.
2. Extend strut and fit upper end to trunk lid pivot ensuring that retaining clip fully seats.
3. Remove temporary support and check that trunk lid closes satisfactorily.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
Interior Trim
Carpets
The interior carpets which incorporate floor insulation and are molded in two pieces joined at the center line below the
center console, cover the entire floor area and the inner door sills, and are color co-ordinated to the interior trim and
seats. The door sills are additionally fitted with polished tread plates bearing 'Jaguar XK8' inscriptions. While the floor
carpets are common to the convertible and coupe models, an additional section of carpet trims the convertible top
stowage area. The coupe rear parcel shelf is trimmed to match the headlining cloth. The shelf trim is secured to the
rear seat squab by two screws and to the center of the shelf by four speaker or blank plate screws, and is supported
at the rear by two foam blocks.
Fascia
The full width, slush molded, soft feel PVC fascia is faced with maple or walnut burr veneer. In addition to the air
conditioning and central, outer and demisting vents, it accepts instrument packs dedicated to market requirements. A
center switchpack and the ICE head unit are also incorporated in the fascia.
A lockable and illuminated glove box is provided on the passenger side, and fuse panels are installed at each end.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
'A' Posts
Grained UEV post finishers color matched to upper trim, are common to convertible and coupe.
The inner finishers are secured to the pillars by studs and BIW retainers, the upper finishers are molded to the pillar
contours and wiring channels and secured by steel clips inserted into BIW slots. A hood release lever is located in the
LH side inner finisher.
Coupe Roof
The 6 mm thick, molded, single piece cloth roof lining is color keyed to the interior trim and supported by sun-visor
fixings at the front, a concealed fixing behind the central interior lamp and two body tangs at each side. An overhead
console installed centrally at the front of the roof is common to both models and incorporates two courtesy lamps,
switchable map/reading lights and a glass breakage sensor. An additional courtesy lamp is installed centrally in the
roof over the rear seats.
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Convertible Top
The convertible top has a transverse external seam and a fully padded interior incorporating a full length headlining
with backlight surround panel. The heated backlight is bonded in position to achieve a semi-flush finish.
The windshield header seal has been specifically designed to achieve reductions in noise levels and superior
weatherproofing and aerodynamics. A grained UEV head rail finisher is secured in position by the sun visor fixings.
Doors
The doors are common to coupe and convertible and have dual seals and vacuum-formed water shedders with
separate speaker curtains to provide internal insulation. The door casings are trimmed in UEV with cloth or ambla
center pads and integral pockets are attached to the inner panels by plastic studs and retainers and a large dowel.
The top rolls are integral with the door casings and trimmed to match the upper fascia.
A leather trimmed armrest attached to each door casing by plastic fixings, is secured to the door by a screw passed
through a pull cup into a bracket. An inset maple or burr walnut veneer switch pack is held in position by a single
screw and captive nut.
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Rear Quarter Casings
The rear quarter casings are individually styled to suit installation in either the coupe or convertible.
Both styles are trimmed in ambla and incorporate acoustic cloth-covered speakers. Coupe casings are additionally
fitted with ambla trimmed armrests and stowage trays.
Convertible rear quarter casings are secured at the rear by dowels locating in the seat squab panel, and at the front
by spring steel clips locating in the 'B' posts. Coupe rear quarter casings are retained by spring steel clips located in
the cantrails and 'B' posts and a screw passed through each front seat belt escutcheon. A plastic clip in each coupe
rear quarter engages in the parcel shelf.
Trunk
The trunk has a two-height load floor structure in order to accommodate either the full size or space-saver spare
wheel. When the space saver wheel is carried, a removable center floor section is recessed in the spare wheel well.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
For the full size spare wheel, the floor is a one piece full-width removable section. The trunk lid, front and side casings
and floor are lined with molded single color carpet.
The trunk lid is produced in two styles to suit convertible and coupe. For some markets, a warning triangle is located
in the trunk lid lining.
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1. Using a suitable plastic lever, carefully ease trim pad spring clips free from 'A' post.
Installation
2. Lifting aperture seal at 'A' post, position trim pad and press firmly to fully seat spring clips.
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Installation
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Using a thin plastic lever, carefully remove the treadplate finisher and place face uppermost on sheet of
clean dry polythene.
2. Slacken and remove treadplate securing screws and remove treadplate.
3. Remove front of draught welt from aperture flange.
2. Exercising care to avoid damaging surface, pull pad rearwards to release retainer from 'A' post stud. On
driver side it will be necessary to pull and hold hood release rearwards.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
3. Withdraw trim pad front tang from toeboard and remove trim pad.
Installation
1. Position trim pad at 'A post and engage retainer on securing stud. For access at driver side it will be
necessary to pull and hold hood release lever rearwards.
2. Ensuring that tang engages in toeboard carpet slot, push trim pad forward to fully seat retainer on stud.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
2. Remove trim mat from rear of door pocket and slacken and remove the securing screw.
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8. Slacken and remove the door speaker cover securing screws from lower face of trim pad and remove cover
from casing.
9. Slacken and remove four screws securing armrest to door casing and remove armrest from casing.
Installation
2. Position armrest on casing and fit and tighten the four securing screws.
3. Position speaker cover on casing and fit and tighten securing screws.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
4. Position and align puddle lamp assembly on casing and fit and tighten two securing screws.
7. Position casing at door and connect switch pack and puddle lamp multiplugs.
8. Align casing to door and press and fully seat securing studs into door locations.
9. Fit and tighten casing securing screw at front of switch pack location.
10. Align switch pack to casing and fit and tighten securing screw at rear.
11. Fit trim to front of door pocket and fully seat plastic fastener.
12. Fit and tighten casing securing screw to rear of door pocket.
15. Fit and tighten securing screw and fit securing screw cover.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
9. Exercising care, use a thin blade to release footrest tangs and spigots from mounting plate.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
10. Remove footrest mounting plate securing bolts and remove mounting from vehicle.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
12. Release carpet from around kickdown switch and toeboard area.
14. Remove handbrake lever trim and ensure that lever is left in fully upright position. Refer to <<76.13.63>>.
3 2012-07-22
1999 XK RANGE - Interior Trim and Ornamentation - 501-05
15. Withdraw draught welt and release carpet retaining clips from door aperture flange.
17. Lift rear of carpet and pass seat harness and connector through.
19. Lift carpet over handbrake lever, ensuring carpet is free, pull rearwards and remove it from vehicle.
Installation
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
7. Install and fully seat new fastener securing carpet to fascia/console area.
16. Install driver seat and adjust to original position. Refer to 76.70.01.90.
18. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
Headliner 76.64.01
Removal
2. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
3. Remove battery cover and disconnect earth cable from battery terminal. Refer to <<86.15.19>>
12. Withdraw each door aperture seal from flange upper section.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
14. Avoiding damage to fascia, door aperture seals and door casings, lift and turn headlining through 90
degrees, tilt into passenger footwell and remove from vehicle.
Installation
2. Place headlining in vehicle tilted to position with one end in footwell and opposite end at top of door aperture.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
4. Position headlining at roof and reposition door aperture seals to retain it.
15. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
16. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
3. Remove front liner, exercising care when withdrawing ends from behind side liners.
Installation
1. Easing side liners inwards, fit and fully seat trunk front liner.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Remove and discard the eight fir tree fasteners securing trunk rear finisher to rear panel.
4. Position trunk rear finisher for access, disconnect trunk lamp harness multiplugs and remove lamp assemblies.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
Installation
3. Fit and fully seat finisher on trunk rear panel and secure with new fir tree fasteners.
5. Connect ground cable to battery and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
5. If fitted, pass fuel filler flapemergency release cord through slot in LH side liner and withdraw liner from trunk.
Installation
1. Position side liner in trunk and where fitted, pass fuel filler flap emergency release cord through slot .
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
Installation
5. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
Removal WARNING:
FOLLOWING DISCONNECTION OF THE BATTERY, A PERIOD OF AT LEAST ONE MINUTE MUST BE
ALLOWED TO ELAPSE BEFORE ANY WORK IS CARRIED OUT ON AN AIR BAG.
NOTE:
For safety reasons, the veneer panel is an integral part of the air bag deployment door and is not available as a
separate service item.
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Remove passenger air bag complete with deployment door. Refer to <<76.73.37>>.
3. Slacken, remove and discard two bolts securing air bag tether bracket and deployment door to air bag
module.
Installation
1. Position air bag tether bracket and deployment door on air bag module and secure with two new bolts.
3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
11. Withdraw draught welt and release carpet retaining clips from door aperture flange.
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13. Lift rear of carpet and pass seat harness and connector through.
15. Ensuring carpet is free, pull rearwards and remove it from vehicle.
Installation
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13. Install passenger seat and adjust to original position. Refer to 76.70.01.90.
15. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1. Using rear passenger entry knob, fold seat back fully forward.
Installation
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Rear Quarter Panel Armrest and Speaker Grille Vehicles Without: Convertible Top 76.13.71
Removal
1. Using rear passenger entry knob, fold seat back fully forward.
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Installation
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1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
4. On coupe model, detach rear seat belt anchor and remove escutcheon.
Slacken and remove rear seat belt anchor plate securing bolt and retain card washer.
Remove rear seat belt escutcheon from rear quarter casing.
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8. On coupe model rear quarter casing, release clips from locations in the cantrail, 'B' post and rear parcel
shelf, and position casing for access.
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9. On convertible model rear quarter casing, release clips from locations in the 'B' post and two dowels from
seat squab panel, and position casing for access.
10. Pass seat belt anchor plates through rear quarter casing apertures and remove casing from vehicle.
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Installation
1. On coupe model, position rear quarter casing and engage plastic clip in rear parcel shelf.
2. On convertible model position rear quarter casing and engage two dowels in rear seat squab panel.
4. Press home and fully seat the remaining casing clips in body locations.
5. Position and seat front seat belt escutcheon to casing aperture. On coupe model, fit and tighten securing
screw.
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8. On coupe model:
Fit rear seat belt anchor plate.
Fit securing bolt to rear seat belt anchor plate.
Fit card washer to securing bolt.
Position anchor plate over bolt location and engage and fully tighten securing bolt.
Position and seat rear seat belt escutcheon to casing aperture.
Fit coat hanger hook.
9. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and
tighten three screws.
10. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
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Installation
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1. NOTE:
The finisher can be easily damaged, care must therefore be exercised during removal.
Using a thin plastic lever and starting at one end, carefully remove the treadplate finisher and place face
uppermost on sheet of clean dry polythene.
Installation
1. Ensure that draught welt is correctly positioned and fully seated on aperture flange.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
4. Install treadplate finisher, pressing firmly into place. If finisher has been renewed, remove protective film.
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1. Turn sun visor downward, release from retention bezel and pivot outwards.
3. Slacken and remove the two visor securing screws and remove visor from vehicle.
Installation
1. Position sun visor at location and fit and tighten securing screws.
3. Pivot visor inwards, position in retention bezel and return to upward position.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Lower roof console, release bezel multiplug from retaining clip and disconnect multiplug from harness.
3. Turn sun visor downwards, release from retention bezel and pivot outwards.
4. Carefully open flap on retention bezel cover and slacken and remove bezel retaining screw.
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5. Withdraw bezel from location, carefully feeding multiplug through aperture and remove bezel from vehicle.
Installation
1. Position bezel for access and route multiplug through aperture to retaining clip.
4. Connect multiplug to harness and fit and fully seat multiplug on retaining clip.
6. Pivot sun visor inwards, locate in bezel and turn visor to upward position.
7. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Interior Trim and Ornamentation - 501-05
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
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Installation
1. Install veneer panel on switch ensuring retaining clips are fully seated.
4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Exterior Trim and Ornamentation - 501-08
Exterior Trim
Body Front
A chrome splitter vane assembly installed centrally in the bumper casing air intake incorporates polyurethane covers
for the two bumper beam overriders. A Jaguar 'growler' badge is mounted centrally on the upper face of the front
bumper casing.
Body Sides
For certain markets, a Jaguar 'leaper' badge is surface mounted on the rear of each fender in place of side repeater
lamps. Three piece color-keyed body side mouldings are surface mounted to align with the side repeaters or Jaguar
'leaper' badges dependent upon the market. Chrome door handles are fitted for N. American markets.
Door Sills
Extruded, polished aluminum tread plates with 'Jaguar XK8' inscriptions are fitted to the door sills.
Body Rear
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1999 XK RANGE - Exterior Trim and Ornamentation - 501-08
Rear External Trim
Two script badges are surface mounted on the trunk rear panel. A 'Jaguar' badge is fitted on the LH side, and an
'XK8' badge on the RH side has external trunk lock key access between the letters X and K.
GLAZING
Door glass trims and one piece windshield and coupe backlight finishers are in extruded aluminum alloy and painted
Dorchester grey on all cars. Coupe quarter-light trims are secured to the body at waist level by 'T' studs, and at the
top by clips bonded with the glass as an assembly.
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2. Using a hand-held heat gun, appply heat uniformly along moulding length.
3. Applying local heat at one end and using a suitable thin lever to avoid damaging paintwork, progressively
ease moulding away from door panel.
5. Remove any residual adhesive and thoroughly clean area using white spirit.
Installation
1. NOTE:
Optimum adhesion is achieved by warming body panel and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and de-greased.
3. NOTE:
Do not allow moulding to contact the body panel until it is correctly aligned.
4. Aligning with adjacent fender moulding or to match opposite side of vehicle, press new moulding firmly onto
body panel.
6. Allow moulding and door panel to cool , then thoroughly clean both using white spirit.
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2. Exercising care to avoid damaging paintwork, lift and release waist rail moulding from door flange.
Installation
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2. Using a hand-held heat gun, appply heat uniformly along moulding length.
3. Applying local heat at one end and using a suitable thin lever to avoid damaging paintwork, progressively
ease moulding away from fender.
5. Remove any residual adhesive and thoroughly clean area using white spirit.
Installation
1. NOTE:
Optimum adhesion is achieved by warming body panel and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and de-greased.
3. NOTE:
Do not allow moulding to contact the fender until it is correctly aligned.
4. Aligning with adjacent door moulding or to match opposite side of vehicle, press new moulding firmly onto
fender.
6. Allow moulding and fender to cool , then thoroughly clean both using white spirit.
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1. Open hood.
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Installation
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1999 XK RANGE - Exterior Trim and Ornamentation - 501-08
3. From hood underside, check that all louvre tangs are fully seated.
5. Close hood.
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2. Slacken and remove number plate securing screws and remove number plate.
3. Drill out pop rivets securing number plate trim surround to trunk lid.
Installation
1. Position trim surround on trunk lid and secure with new pop rivets.
2. Align number plate with trunk lid and fit and tighten securing screws.
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1. Slacken and remove trunk stowage strap securing screw and remove strap.
2. Release eight fasteners securing the insulating pad to rear of the trunk lid and position pad for access.
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4. Slacken and remove the four trim finisher/number plate lamp assembly securing nuts and remove assembly
from trunk lid.
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5. Remove lenses and bulb holders and discard gaskets from number plate lamps.
Installation
2. Fit and fully seat bulb holders and lenses to number plate lamps.
3. Position trim finisher/number plate lamp assembly on trunk lid and fit and tighten the securing nuts.
5. Re-position insulation pad on trunk lid and fit and fully seat fasteners.
6. Position trunk stowage strap and fit and tighten securing screw.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
5. Using a thin plastic lever, carefully release front number plate from plinth.
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8. Remove three screws securing undertray to lower cross-member and remove undertray.
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12. Remove and discard fastener securing bottom of radiator grill to bumper beam.
13. Remove and discard fasteners securing top of radiator grill to bumper beam.
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Installation
1. Install surround strips on grill and secure with new tie straps.
2. Position grill on bumper beam and secure top with new fasteners.
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7. Install undertray.
Position undertray on vehicle and secure to lower cross-member with three screws.
Secure undertray to bumper cover using new rivets.
10. Raise vehicle, remove stands and lower vehicle onto wheels. Refer to Section <<100-02>>.
11. Position front number plate plinth on overriders, fit and tighten securing screws and fit number plate to plinth.
12. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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3. Exercising care to avoid damaging paintwork, release quarter light finisher from edge securing clips.
Installation
1. Position quarter light finisher on BIW and press firmly to fully seat in securing clips.
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2. Apply wet sealant behind finisher butt joint between the two adjacent screw locations.
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Installation
1. Aligning centre points with masking tape markers, position finisher on backlight and press firmly to fully seat
on retaining clips.
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2. Slacken and remove the ten screws securing gutter finisher to BIW.
3. Carefully release gutter finisher from rear quarter light finisher and remove gutter finisher.
Installation
1. Position gutter finisher on BIW aligning it with rear quarter light finisher.
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2. Apply wet sealant behind finisher butt joint between the two adjacent screw locations.
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1999 XK RANGE - Rear View Mirrors - 501-09
The interior rear view mirror is an electrochromic unit that automatically darkens to prevent glare from following vehicle
lights. This automatic function is selected by pressing the switch at the bottom of the mirror. Pressing the switch again
cancels this function. An LED then illuminates when automatic dipping is operative.
A Night Sentinel light sensing unit also incorporated in the mirror casing, provides for automatic control of the vehicle
lights.
The door mirrors are cheater mounted, color-keyed units, remote electrically adjustable and heated. Adjustment of
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1999 XK RANGE - Rear View Mirrors - 501-09
both mirrors is carried out from the driver's door switchpack. A slider switch selects the mirror to be adjusted, and a
disc switch adjusts the selected mirror to the required position.
Mirror adjustment can only be made when the ignition switch is in position I or II or the driver's door is open, and the
selector switch is moved from the central position.
When fitted, electrochromic door mirrors automatically darken under control of the interior rear view mirror. Mirror
heating elements operate on selection of backlight heating.
Automatic dipping of passenger door mirror for kerb view when reversing, is fitted as part of the memory pack. With
the ignition switch in position II, the mirror selector switch in the left or right position and reverse gear selected,
automatic dipping is initiated by moving the mirror toggle switch rearwards and releasing.
On receipt of the dip signal, the passenger door mirror is driven downwards either 7 degrees, bottom of travel, or 4,5
to 5,5 seconds, whichever occurs first. Subsequent rearward movement of the toggle switch achieves further dipping
of the mirror in the same increments and sequence.
The mirror can be manually returned to the normal memorised position by moving the toggle switch forward with
reverse gear selected. The mirror will automatically return to memorised position on deselection of reverse gear, or
moving ignition switch from position II.
Door mirror fold-back where fitted, to facilitate parking in confined spaces, can be initiated when the ignition switch is
in position I or II, the mirror selector switch is in the central position and vehicle speed is below 19 km/h (12 mph).
Mirror fold-back is then initiated by moving the toggle switch rearwards and releasing it. The door mirrors are returned
to the normal driving position by again moving toggle switch rearwards. There is no speed constraint on this operation.
In the event of a fold-back mirror becoming 'out of position' due to accidental impact, it must only be re-positioned by
initiating the fold-back sequence.
Loss of power supplies will result in loss of mirror fold-back memory. In the event of such a memory loss with mirrors
in the normal position, fold-back will operate on second movement of the toggle switch. On loss of memory with
mirrors in the fold-back position, they will return to the normal position on next fold-back operation.
Automatic dipping of passenger door mirror for kerb view when reversing, is fitted as part of the memory pack. With
the ignition switch in position II, the mirror selector switch in the left or right position and reverse gear selected,
automatic dipping is initiated by moving the mirror toggle switch rearwards and releasing.
On receipt of the dip signal, the passenger door mirror is driven downwards either 7 degrees, bottom of travel, or 4,5
to 5,5 seconds, whichever occurs first. Subsequent rearward movement of the toggle switch achieves further dipping
of the mirror in the same increments and sequence.
The mirror can be manually returned to the normal memorised position by moving the toggle switch forward with
reverse gear selected. The mirror will automatically return to memorised position on deselection of reverse gear, or
moving ignition switch from position II.
Door mirror fold-back where fitted, to facilitate parking in confined spaces, can be initiated when the ignition switch is
in position I or II, the mirror selector switch is in the central position and vehicle speed is below 19 km/h (12 mph).
Mirror fold-back is then initiated by moving the toggle switch rearwards and releasing it. The door mirrors are returned
to the normal driving position by again moving toggle switch rearwards. There is no speed constraint on this operation.
In the event of a fold-back mirror becoming 'out of position' due to accidental impact, it must only be re-positioned by
initiating the fold-back sequence.
Loss of power supplies will result in loss of mirror fold-back memory. In the event of such a memory loss with mirrors
in the normal position, fold-back will operate on second movement of the toggle switch. On loss of memory with
mirrors in the fold-back position, they will return to the normal position on next fold-back operation.
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1999 XK RANGE - Rear View Mirrors - 501-09
Removal CAUTION:
When removing mirror from base, care must be exercised to ensure that base is not detached from
windshield.
1. Remove roof console for access and disconnect interior mirror harness multiplugs. Refer to <<76.13.69>>.
Installation
1. Position mirror at bottom of base and apply firm upward pressure to fully seat and secure in position.
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2. Remove door frame cheater trim and memory foam for access.
Installation
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1. Pass harness and multiplug through cheater aperture and position mirror foot on cheater, locating the
two dowels correctly and ensuring correct seating on seal.
Fit and tighten the mirror assembly securing screw.
Connect mirror assembly harness multiplug, position in door and reposition door foam.
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Installation
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Removal CAUTION:
If as a result of accidental impact, a powered fold-back mirror is moved 'out of position', it must only be
re-positioned by initiating the fold-back sequence as described in this section. No attempt must be made to
manually return the mirror to the normal position. Failure to adopt this procedure will result in vibration of
the unlocked mirror head and consequent loss or distortion of rear vision.
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Installation
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Installation
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Removal CAUTION:
When removing mirror from base, care must be exercised to ensure that base is not detached from
windshield.
Installation
1. Position mirror at bottom of base and apply firm upward pressure to fully seat and secure in position.
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1999 XK RANGE - Rear View Mirrors - 501-09
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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7. Commencing at the top and exercising care to avoid windshield damage, use a thin plastic knife to ease block
free.
8. Using a suitable solvent, clean residual adhesive from block mounting area.
Installation
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3. Apply a bead of Permabond F246 to bottom and each vertical side of block over 2/3 of block height.
4. Press mounting block onto marked area and hold in position for one minute.
7. NOTE:
The following time is the MINIMUM PERIOD required for adhesive curing. Failure to allow this period will
result in bonding failure, necessitating repeat of the complete procedure.
After a further period of at least 6 hours, install mirror on mounting block. Refer to <<76.10.51>> or
<<76.10.56>>.
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1999 XK RANGE - Rear View Mirrors - 501-09
11. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Seating - 501-10
Torques
Component Nm
Cushion to slide 22 - 28
Slide to floor 22 - 28
Recline to squab frame 7 - 10
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Seats
Front Seats
The front seat frames are common to the coupe and convertible. Standard seats have leather trimmed facings and
cloth centers, with ambla cushions, squab borders and rear map pockets. Seat movement control switch assemblies
installed in outboard side of driver and passenger seats, operate motors for fore and aft, recline and raise and lower
adjustments via control modules installed below seat frames. Options and market variations include leather/ambla trim
with lumbar support adjustment, seat heating, driver's seat position memory and passenger seat height adjustment.
Only one of the slide recline or height adjustment motors can be driven under manual control at any one time. On
vehicles fitted with driver's seat memory each motor is fitted with feedback potentiometers. When fitted, seat heating
is controlled via illuminated on/off switches installed in the center console.
Rear Seats
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Styled for dedicated installation in the coupe or convertible, the rear seats are wire framed units trimmed to match the
front seats. There is no provision for rear seat adjustment on either model. Child seat mountings are provided where
legally required.
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1. Turn ignition key to position II and motor seat to fully rearward position.
3. Motor seat to fully forward position and turn ignition key to position O.
4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Seating - 501-10
6. Position front seat for access, disconnect seat harness multiplug and remove seat from vehicle.
Installation
3. Fit the two seat rear securing bolts and screw them almost home but do not tighten.
4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
7. Motor seat fully forward and fully tighten the rear securing bolts.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Remove the nine clips securing the squab cover to the seat frame.
4. Remove the squab heater element harness from the mounting undo the velcro strap and disconnect the
multiplug.
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Installation
1. If squab cushion has been renewed, apply suitable adhesive to foam and fit and fully seat heating element.
2. Carefully insert and position foam cushion in squab cover and secure with velcro fasteners.
4. Connect seat harness multiplug, position in mounting and secure with velcro fastener.
5. Position squab to seat frame and secure with the nine clips.
7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Seating - 501-10
1. Remove battery cover and disconnect ground cable from battery terminal.
3. Remove the nine clips securing the squab cover to the seat frame.
4. Remove the squab heater element harness from the mounting undo the velcro strap and disconnect the
multiplug.
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1999 XK RANGE - Seating - 501-10
Installation
1. Apply suitable adhesive to foam and fit and fully seat heating element.
2. Carefully insert and position foam cushion in squab cover and secure with velcro fasteners.
4. Connect seat harness multiplug, position in mounting and secure with velcro fastener.
5. Position squab to seat frame and secure with the nine clips.
7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Seating - 501-10
1. Using rear passenger access knob, release the seat back and move it to the fully forward position.
3. Slacken and remove the two screws securing the lower section of the seat back finisher to the frame.
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1999 XK RANGE - Seating - 501-10
4. Withdraw the trim and 32 clips from seat back finisher and position trim for access.
Installation
3. Fit and tighten the two screws securing the lower section of the back finisher to the seat.
4. Fit escutcheon and rear passenger access knob and return seat back to the upright position.
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1999 XK RANGE - Seating - 501-10
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Release seat cushion riser harness multiplug from mounting bracket clip and disconnect multiplug.
4. Remove and discard star securing clip from seat riser motor clevis pin.
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5. Slacken but do not remove the two driver seat fore and aft adjustment motor securing bolts.
6. Withdraw seat riser motor clevis pin from upper mounting bracket.
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1999 XK RANGE - Seating - 501-10
8. Remove spring clip from runner to pivot bar clevis pin and withdraw pin.
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1999 XK RANGE - Seating - 501-10
Installation
2. Fit and fully seat clevis pin and fit new star securing clip.
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1999 XK RANGE - Seating - 501-10
3. Position motor runner on pivot bar and check position of clevis pin aperture.
4. Remove motor runner from pivot bar, adjust runner to required length and re-fit to pivot bar.
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5. Fit motor to pivot bar clevis pin and fit and fully seat securing clip.
6. Connect seat riser motor harness multiplug and fit multiplug onto mounting bracket securing clip.
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7. Fully tighten seat fore and aft adjustment motor securing bolts.
9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Disconnect harness multiplug from motor and sever and remove tiestrap securing harness to seat frame.
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6. Position motor and mounting bracket for access and remove the two motor to bracket securing bolts.
Installation
2. Position motor and bracket assembly on seat frame and install securing bolt.
6. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Seating - 501-10
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Release seat motor harness multiplug from mounting bracket and disconnect multiplug.
4. Release seat cushion riser motor harness multiplug. from mounting bracket and disconnect multiplug.
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5. Remove and discard tiestrap securing seat harness and position harness for access.
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7. Position motor from frame for access and withdraw drive cable from one side.
8. Release motor from remaining drive cable and remove motor from seat.
Installation
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3. Finally position motor on seat frame ensuring locating tangs are fully seated.
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5. Position seat harness, connect seat motor harness multiplug and fully seat multiplug on mounting bracket.
6. Connect seat cushion riser motor multiplug and fully seat multiplug on mounting bracket.
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1999 XK RANGE - Seating - 501-10
9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Seating - 501-10
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Position squab for access and release six hooks securing inflatable cushion to seat frame.
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5. Sever and remove tiestraps securing lumbar motor/bag assembly and harness to seat frame.
Installation
4. Using a new tiestrap, secure lumbar support motor/bag assembly to seat frame.
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5. Position seat squab on seat frame and secure with retaining strap.
7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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2. Slacken and remove the two rear seat squab securing screws.
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4. Position rear seat belts for access and remove squab from vehicle.
Installation
2. Finally position squab, engaging body tangs by applying downward hand pressure.
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1. Using the rear passenger access knobs, position the back of each front seat fully forward.
2. Slacken and remove the two rear seat cushion securing nuts.
3. Raise seat cushion for access, pass seat belt anchors through central penetration and remove seat cushion
from vehicle.
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Installation
1. Position seat cushion for access and pass rear seat belt anchors through central penetration.
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2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Remove front seat from vehicle and place on clean work surface. Refer to 76.70.01.90.
4. Release seat harness multiplugs from mounting bracket and disconnect multiplugs.
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7. Remove bolts securing seat slide assembly to seat frame and withdraw slide assembly.
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9. Positioning cushion foam for access, use a screwdriver to release switchpack securing tab.
Installation
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. Turn ignition key to position II and motor door glass to fully lowered position.
3. Remove door switchpack and door casing and disconnect switchpack harness multiplug. Refer to
<<76.34.01>>.
WARNING:
THE FOLLOWING STEPS NECESSITATE WORKING IN THE DOOR INTERIOR WITH THE POWER
SUPPLIES CONNECTED. TO AVOID INADVERTENT GLASS OPERATION AND POSSIBLE INJURY, NO
OTHER WORK MUST BE CARRIED OUT SIMULTANEOUSLY.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
8. Turn ignition key to position II and motor door glass up until top edge is just below upper seal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
10. Using guide runner lower adjusters, laterally align glass top edge with the upper seal.
11. Remove tape from access hole in PVC secondary water shedder and slacken glass regulator stop adjuster
bolt.
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12. Motor door glass further up until the horizontal datum line aligns with the upper seal.
13. Move glass regulator stop to abut quadrant and tighten adjuster bolt.
14. Motor door glass to fully up position, measure any lift adjustment required and re-mark glass in that position.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
16. Slacken glass regulator stop adjuster bolt, move stop required amount and tighten bolt.
17. Motor door glass to fully raised position and check glass seating in upper seal.
18. Repeat operations 14 to 17 as necessary, until door glass seats satisfactorily in upper seal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
19. With glass in fully raised position, slacken door waist adjuster lock nuts and hand screw adjusters in until
they abut the door glass stops.
20. Adjust gap for parallelism between rear edge of door glass and front edge of quarter light.
Slacken glass lift regulator channel adjuster lock nut.
Move channel to achieve a parallel gap of 8mm on coupe model, 11mm on convertible.
Tighten lock nut.
21. Motor door glass fully down and fully up and check all gaps and alignments.
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26. Fit new tape to access hole in PVC secondary water shedder
28. Fit door switchpack to door casing, connect multiplug and fit casing. Refer to <<76.34.01>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
The windshield, which is of 5 mm laminated glass with a black obscuration band and has the interior mirror fitted, is
common to the coupe and convertible. The windshield finisher is a one-piece, single color unit with seal. The backlight
is 4 mm tempered glass, green tinted and heated. The windshield, backlight and quarter lights, except for the
convertible model, are direct glazed to the body.
The windshield and coupe backlight are supplied as assemblies complete with trim which is secured to the glass by
clips and is fully demountable when the assembly is bonded to the vehicle.
The convertible backlight and outer seal are conventionally glazed to the inner seal, which is stitched and bonded to
the top. On both models, the heated backlight remains on for 21 minutes after being switched on unless it is manually
switched off before the time delay expires. Some backlights are fitted with a security antenna. A fine wire heated
windshield offered as an option on some markets, is controlled from the air conditioning panel.
The door glass on both models is a frameless system with 5 mm green tempered glass. The window glass is
operated electrically and raised and lowered by a scissor mechanism.
Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or
lowered, closing when either the door is shut or the top is fully raised and latched in position. The door glass can be
closed via the remote control unit. Glass operation is internally controlled from switchpacks located in the driver and
passenger arm rests via the driver and passenger door modules. The switchpacks are illuminated when the sidelights
are on.
One-touch up operation causes the door glass to fully close unless an object is detected or if the glass is already
within 45 mm of top of travel when the door is opened. On detection of an object, the glass will drop fully open or to
200 mm below the obstruction. All door glass operates with the ignition switch in either position I or II and after ignition
is switched off, until either door is opened.
Before commencing work within a door interior, all Warnings and Notes within the appropriate Removal and
Installation procedures must be read and fully understood.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit direct glazed to the tonneau. The rear
quarter glass of the convertible is 5 mm, tempered, semi-flush and green tinted. A drum and wire lowering and raising
system provides automatic full glass drop when the top is lowered. Rear glass control is incorporated in the
convertible top switch and operation of the rear quarters is as follows.
Press and release the rear part of the convertible top switch (one touch down).
When lowering the rear quarters at vehicle speeds up to 16 km/h (10 mph), failure to release the switch on operation
of the audible alarm will result in lowering of the top.
Rear quarter glass is automatically powered to the bottom position when the top is lowered and further operation is
inhibited until the top is raised and latched.
General Operation
The rear quarters are operated automatically up or down respectively when raising or lowering the convertible top.
When the top is raised, with the door glass at the top of its travel, the glass will be powered down 12 mm and the
rear quarters will be powered to the bottom of their travel. When the top is fully raised all glass will be powered up to
close, forming a seal with the top.
If the front glass has been either fully or partially lowered manually, the rear quarters only will be powered up. If the
power supply to the driver or passenger door module is disconnected (battery disconnected, module unplugged or
fuse removed) then the glass/system must re-learn the glass operating characteristics. The last known glass position
is regarded as top of travel by one touch operation until re-learning has taken place. One touch down, manual up and
down control and the automatic lowering of the glass for door opening are unaffected.
To re-learn the glass operating characteristics, the associated door must be closed (door ajar switch inactive). The
glass must then be driven fully down and held stalled at the bottom of its travel for a minimum of one second. The
glass is finally driven to the fully up position and held stalled for a minimum of one second. The re-learning procedure
must also be accomplished to regain the automatic glass closing sequence.
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4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.15>>.
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10. Release cover to latch inner locating boss and remove cover.
11. Release door glass drop switch securing tangs and remove switch from latch assembly.
13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from
multipug.
Installation
1. Fit and fully seat switch terminal pins in harness multiplug and fit terminal pin protector.
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2. Fit door glass drop switch to latch assembly, ensuring that both tangs are fully seated.
6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
4. Remove battery cover and disconnect ground cable from battery terminal.
7. Remove main water shedder and position secondary shedder clear of regulator assembly. Refer to
<<76.58.07>>.
8. Slacken and remove glass rear guide runner upper retaining screw.
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9. Slacken and remove rear guide runner lower adjuster and securing screws and position guide runner clear of
glass guide.
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16. Slacken and remove screw securing door glass guide to front guide runner retaining bracket and remove
bracket.
17. Remove clips from nylon fixings and retain for re-use.
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19. Lift glass upwards, tilt rear end outwards pass upwards between top adjuster screws and remove glass
from door.
20. Remove nylon fixings from lower channel and refit clips to fixings.
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Installation
1. Lubricate glass lower channel and fit nylon fixings ensuring that looped ends of clips face outwards.
2. Position glass in door aperture and fit front guide onto guide runner.
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3. Check that the three buffers are fitted to outer waist reinforcer.
4. Fit and align glass front guide retaining bracket and tighten securing screw.
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5. Fit glass regulator assembly onto nylon fixings and fit and fully seat retaining clips.
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10. Fit and tighten rear guide runner adjuster securing screws.
11. Fit and tighten rear guide runner upper securing screw ensuring that a clearance of 9mm is maintained
between glass and outer waist rail flange inner face.
12. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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2. Commencing at door release button recess, carefully use a thin blade to ease inner waist seal from rear of
door waist flange.
3. Working from rear, and exercising care toavoid distortion, progressively remove seal from waist flange.
Installation
1. Ensure that top edge of PVC water shedder is correctly positioned on door waist flange.
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2. Commencing at front and ensuring that end of seal aligns with front of door waist flange,fit and fully seat seal
on door.
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4. Clean carrier seal locating channel and apply a thin film of Johnson KY Jelly or equivalent.
Installation
3. Fully raise convertible top and align seal to abut frame rear seal.
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4. Remove battery cover and disconnect ground cable from battery terminal.
7. Remove main water shedder and position secondary shedder clear of regulator assembly. Refer to
<<76.58.07>>.
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10. Manually raise glass to uppermost position and using linen or similarly strong tape, secure glass to top of
door.
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11. Accessing via speaker aperture, disconnect harness multiplug from lift motor.
12. NOTE:
The position of this stud is critical to glass alignment and must be measured accurately.
Using vernier calipers, measure position of regulator channel securing stud in elongated hole and slacken and
remove nut.
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14. Lower motor/regulator assembly into bottom of door and close scissor mechanism.
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15. Turning it to achieve clearance, withdraw motor/regulator assembly through door aperture.
16. Place assembly on bench, slacken and remove screws securing lift motor to regulator and remove motor.
Installation
1. Position lift motor on regulator assembly and fit and tighten securing screws.
2. Close scissor mechanism and pass assembly through aperture into door.
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4. Fit but do not tighten motor to door securing screws and regulator channel securing nut.
5. NOTE:
Accurate positioning of this stud is critical to glass alignment.
Position regulator channel securing stud in elongated hole as measured during removal and fit and fully tighten
securing nut.
7. Supporting door glass, remove linen tape and lower glass onto regulator assembly.
8. Press regulator ball joints into nylon seats on lower channel and fit retaining clips.
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11. Align speaker and new gasket in door and fit and tighten securing screws.
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1. Remove battery cover and disconnect ground cable from battery terminal.
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Installation
1. If switch has been renewed, fit and fully seat veneer panel in retaining clips.
3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. Remove battery cover and disconnect ground cable from battery terminal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
Installation
1. If switch has been renewed, fit and fully seat veneer panel in retaining clips.
4. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
4. Displace door aperture seal from B post seal carrier and drip rail seal carrier. Refer to <<76.40.30>>.
5. Remove rear quarter light finisher and drip rail seal carrier. Refer to <<76.43.81>>.
6. Slacken and remove three screws securing B post seal carrier to B post and remove carrier.
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9. NOTE:
Penetrating the seal in the wrong position can result in contact with the glass to body mounting stud.
Using a suitable long bladed tool, penetrate quarter light Betaseal at B post three inches from top of glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
10. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.
11. With assistance, use cheese wire to cut around the glass moving downwards then rearwards and exercising
care to avoid damaging paintwork at the corners.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
12. Fit lifting handle to glass and ease upper edge away from aperture for access.
13. Supporting the glass, use a suitable cutter to sever remaining Betaseal.
14. Remove glass from aperture and place on clean cloth on bench.
16. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and
discard cheese wire.
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18. Ensuring that the paintwork is not damaged, use a suitable vibroknife to remove residual sealant from body
flange.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
20. If 3mm thick button or spacer block become detached, retain and refit before priming.
When refitting spacing block, apply suitable adhesive and fit block to glass edge maintaining a 2mm
clearance between glass and bottom of block groove.
Installation
2. Apply glass primer ensuring that it is taken right up to the radiused front edge.
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3. Position seal carrier on B post and fit and tighten securing screws.
4. Cut Betaseal cartridge nozzle to achieve a triangular section bead 8mm wide by 10mm high.
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5. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge.
6. Fit lifting handle to glass. Align glass to body, ensuring that location stud engages in body clip and press glass
firmly to fully seat.
7. Remove lifting handle, remove masking tape and clean off residual sealant using Betawipe spirit.
8. Fit quarter light finisher, maintaining 4mm clearance from waist seal finisher. Refer to <<76.43.81>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
10. Apply wet sealant behind finishers butt joint between the two adjacent screw locations.
15. Fit rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
Rear Quarter Window Glass Weatherstrip Vehicles With: Convertible Top 76.40.33
Removal
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Installation
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3. Clean carrier seal locating channel and apply a thin film of Johnson KY Jelly or equivalent.
Installation
2. Fully raise convertible top and align seal to abut frame rear seal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
3. Clean carrier seal locating channel and apply a thin film of Johnson KY Jelly or equivalent.
Installation
2. Fully raise convertible top and align seal to abut adjacent seals.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
Rear Quarter Window Regulator Motor Vehicles With: Convertible Top 86.25.11
Removal
5. Remove seal carrier front screw and remove carrier from vehicle.
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9. If earlier PVC water shedder is installed, route glass lift motor link lead through penetration and remove water
shedder from body.
10. Connect a switched 12 volt supply to motor link lead connector and power glass to fully raised position.
11. Switch off 12 volt supply and disconnect from motor connector.
12. Remove three nuts securing glass lift motor/regulator assembly to body.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
13. Feeding link lead and multiplug through water shedder (later moulded type), withdraw motor/regulator
adjusters from body and remove assembly.
Installation
1. Guiding link lead through water shedder (later type), lower motor/regulator assembly through upper aperture
and locate adjusters in body apertures.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
3. Install water shedder (early PVC type), routing motor link lead through penetration and leaving access for
glass installation.
4. NOTE:
Do not install speakers, rear quarter casing or rear seat at this stage
Install and manually raise and latch convertible top assembly. Refer to <<76.86.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
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10. Connect switched 12 volt supply to rear quarter glass motor harness multiplug.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
11. Carefully motor rear quarter glass up to just contact top seal.
12. Carefully close adjacent door ensuring glass does not contact rear quarter glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
14. Move rear quarter glass to achieve a parallel 15mm gap between front edge of rear quarter glass frame
and rear edge of door glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
17. Turn upper adjuster to achieve lateral alignment of rear quarter glass upper edge with top seal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
20. Turn rear adjuster to achieve lateral alignment of rear quarter glass rear edge with top seal.
22. Fully raise rear quarter glass, check alignment with seals and adjust as necessary.
23. Disconnect 12 volt supply from rear quarter glass link lead multiplug.
24. Connect rear quarter glass motor link lead to harness multiplug.
25. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
26. Turn ignition key to II, fully lower and raise convertible top, turn ignition key to position O.
27. Check rear quarter glass alignment with top seal and re-adjust as necessary.
28. Turn ignition key to II, fully lower and raise convertible top, turn ignition key to position O.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. Remove battery cover and disconnect ground cable from battery terminal.
2. Using masking tape, mark top and bottom central positions of finisher on BIW.
4. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
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11. If high level stop lamp is fitted, withdraw lamp cover from two clips on base assembly.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
14. Use masking tape to mark the positions of the eighteen finisher securing clips then remove clips from glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
15. If original backlight is to be re-fitted, mark top and bottom central positions with masking tape to aid
re-positioning.
17. Using a suitable long bladed tool, penetrate backlight Betaseal at lower central position.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.
19. With assistance, use the cheese wire to cut around the backlight glass exercising particular care at the
corners to avoid damage to paint
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
20. Fit lifting handles to glass, carefully remove backlight from vehicle and place on clean cloth on bench.
22. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and
discard cheese wire.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
26. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange.
Installation
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. If original backlight is to be refitted, remove residual sealant from glass mating surface using a suitable
scraper.
2. Thoroughly clean mating surface using Betawipe spirit and fit finisher securing clips at positions marked by
masking tape.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
3. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher apply masking tape to
back of finisher.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
5. If backlight is being renewed, fit lifting handles to glass, with assistance position it correctly in aperture and
using masking tape, mark top and bottom central positions on glass and BIW.
6. Remove glass from vehicle, position on bench and remove lifting handles.
7. Clean glass mating edge and body aperture flange using Betawipe spirit.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
9. Cut Betaseal nozzle to achieve a triangular section bead 8mmwide by 10mm high.
10. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing
at bottom center and overlapping the ends approximately 100mm.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
11. Fit lifting handles and with assistance, carefully align glass with body markings and press firmly into place.
14. Aligning central joints with tape markers on BIW, fit finisher to backlight. Refer to <<76.43.46>>.
19. Fit and fully seat high level stop lamp on backlight retainers.
20. Fit harness connector to high level stop lamp and fit and fully seat cover onto lamp retaining clips.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
25. Fit rear seat squab and cushion. Refer to <<76.70.37>> and <<76.70.38>>.
26. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
8. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle.
9. Slacken and remove headlining rear header rail clip securing nuts, remove clips and release tension cables.
10. Exercising care to avoid damage to top, use a plastic or similarly soft lever to remove backlight seal.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
11. Apply masking tape around backlight aperture up to glass edge to protect top and liner.
13. Using a pointed tool, penetrate backlight Betaseal at lower central position, ensuring that contact is not
made with fabric or glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
14. Remove tool, pass free end of cheese wire through penetration and fit secong cutting handle.
15. With assistance, use cheese wire to cut around the backlight glass, exercising particular care at corners to
avoid damage to fabric and glass.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
16. Fit lifting handles to glass and with assistance, carefully remove backlight from vehicle and place on clean
cloth on bench.
18. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and
discard cheese wire.
19. Exercising care to avoid damaging top, use a knife to remove residual Beatseal from sealing flange.
20. If original backlight is to be fitted, use a similar tool to remove residual Betaseal.
Installation
1. Fit and fully seat new rubber seal to backlight ensuring that joint is at bottom and central on glass.
2. Fit lifting handles to glass and with assistance, position it correctly in aperture and mark position with tape.
3. Remove glass from vehicle, position on bench and remove lifting handles.
4. Using Betawipe spirit, clean glass mating edge and body aperture flange.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
6. Cut Betaseal nozzle to achieve a triangular section bead 8mm wide by 10mm high.
7. Using a pneumatic gun, apply a uniform bead of sealant to the glass edge, commencing at bottom center and
overlapping the ends approximately 100mm.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
13. Position outer brackets to liner and body studs and fit and tighten bracket securing nuts.
14. Position inner brackets on liner and body studs and fit and tighten bracket securing nuts.
15. Position stiffener bracket on rear bulkhead and fit and tighten securing bolts.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
23. Connect ground cable to battery terminal and fit battery terminal. Refer to <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
Removal
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
7. Slacken and remove RH water deflector securing bolt and remove deflector.
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8. Slacken and remove LH water deflector securing bolt and remove deflector.
10. Marking the positions with masking tape, remove windshield finisher securing clips from edge of glass.
11. Remove each A post upper trim by carefully easing the three spring clips free.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
14. Apply suitable protective tape around windshield aperture to protect paintwork.
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17. Using a suitable long bladed tool, penetrate Betaseal approximately 6in (150mm) from top of one A post.
18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.
19. Place a suitable protective sheet over fascia and place a protecting board over sheet.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
20. With assistance and exercising care at corners to avoid damaging paintwork, cut around windshield
commencing downwards and along the bottom.
21. Fit lifting handles to glass and with assistance lift windshield clear of vehicle and place on cloth covered
bench.
23. Remove cheesewire cutter from windshield aperture, remove cutting handles and discard cheesewire.
24. Remove protective board from fascia, leaving protective sheet in position.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
25. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange.
Installation
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
2. Thoroughly clean surface using Betawipe spirit, fit finisher securing clips at positions marked and remove
masking tape.
4. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher, apply masking tape
to back of finisher.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
5. Fit lifting handles to glass and with assistance, correctly position windshield in body aperture and mark
position with masking tape.
6. With assistance, remove windshield from vehicle and place on cloth covered bench.
8. Thoroughly clean glass edge and aperture flange with Betawipe spirit.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
10. Cut Betaseal nozzle to achieve a triangular section bead 8mm wide by 10mm high.
11. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing
at bottom center and overlapping the ends approximately 100mm.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
12. Fit lifting handles and with assistance, carefully position windshield in aperture aligning glass with body
markings and press firmly into place.
19. Install LH and RH water deflectors and fit and tighten securing bolts.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
22. If heated windshield is fitted, connect LH power supply cable to connector on secondary bulkhead.
23. If heated windshield is fitted, connect RH power supply cable to connector on secondary bulkhead.
25. Connect ground cable to battery terminal and fit battery cover. Refer to Section <<86.15.15>>.
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1999 XK RANGE - Glass, Frames and Mechanisms - 501-11
3. Using a trim removal tool, carefully release windshield finisher from upper joint retaining clip.
Installation
1. Position finisher at 'A' post and press firmly to fully seat in retaining clips
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1999 XK RANGE - Instrument Panel and Console - 501-12
Torques
Component Nm
Fascia lower mounting bracket to fascia centre panel. 17-23
Fascia lower mounting bracket to BIW. 7-10
Airbag carrier platform to airbag support strut. 7-10
Airbag support strut to BIW. 17-23
Support reinforcement bracket to BIW tunnel. 7-10
Fascia inner panels to support reinforcement bracket. 17-23
Fascia top roll duct to BIW. 7-10
Fascia end panel to BIW. 17-23
Driver side lower rail. 7-10
Airbag ECU to fascia. 10.5-13.5
Fascia to A pillar ground connection. 14-18
Driver's underscuttle to fascia. 7-10
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1999 XK RANGE - Instrument Panel and Console - 501-12
Instrument Panel
The full-width, moulded PVC instrument panel is located by a dowel at each 'A' post and secured by bolts at the
bulkhead and 'A' posts. Faced with maple or walnut burr veneer, the panel accepts two separate instrument clusters,
one containing four major instruments, the other containing three auxiliary instruments.
The major instrument cluster is situated directly ahead of driver, whilst the auxiliary cluster is located inboard from the
driver, above the center console.
Center Console
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1999 XK RANGE - Instrument Panel and Console - 501-12
The center console is an injection moulded armature trimmed in matching ambla with maple or burr walnut veneer top
finisher. A lined stowage tray/pen holder is incorporated forward of the 'J' gate and an illuminated smoker's
compendium with press and release lid is fitted at the rear of the ' J' gate. The rear section of the console forms a
deep stowage box with rear hinged lid which is padded to form a central arm rest. A hinged cup holder is incorporated
in the front end of the stowage box lid. A color-keyed 'J' gate surround surmounts the veneer top finisher and the
'SPORT' mode selector switch is situated immediately to the rear of the 'J' gate.
Two tongues at the front of the console locate in slots in the lower fascia, and the center and rear of the console are
secured by screws to floor brackets.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.15>>.
3. Remove center console assembly for access. Refer to operations in this section.
4. Slacken and remove the six radio console securing screws and partially withdraw the console for access.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Slacken and remove nut securing earth lead to radio and remove lead from stud.
Disconnect radio harness multiplug and position harness clear of center console.
6. Remove radio.
1. Withdraw radio console, remove radio from console and remove radio retaining plate.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Installation
1. Connect aerial co-axial lead to radio and stow excess harness and lead lengths in radio mounting aperture.
2. Fully seat radio in console, ensuring that harnesses and leads do not obstruct.
4. Position the air conditioning control module in the console and fit and tighten the three securing screws.
6. Holding radio console in position, route radio harness multiplugs into center console.
9. Finally position radio console and fit and tighten the six securing screws.
10. Fit earth lead to the radio stud and fit and tighten securing nut.
12. Ensuring harness and leads do not obstruct, push radio fully home.
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1999 XK RANGE - Instrument Panel and Console - 501-12
15. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Slacken and remove the four center console veneer panel securing screws and remove the mounting plates.
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1999 XK RANGE - Instrument Panel and Console - 501-12
5. Position the veneer panel for access and disconnect the panel switch multiplugs.
6. Remove console end trim cover and slacken and remove the two rear securing bolts.
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1999 XK RANGE - Instrument Panel and Console - 501-12
8. Position console for access, disconnect cigar lighter and valet switch harness multiplugs, lift console clear of
'J' gate and remove from vehicle.
Installation
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1999 XK RANGE - Instrument Panel and Console - 501-12
Position veneer panel for access and connect panel switch harness multiplugs.
Reposition and seat veneer panel.
Align and fit panel mounting brackets.
Fit and tighten panel securing screws.
Fit 'J' gate surround. Refer to <<76.25.24>>.
Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
5. Release bulb housing tangs and withdraw bulb and housing from underside complete with flying lead.
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1999 XK RANGE - Instrument Panel and Console - 501-12
6. Position console for access, slacken and remove the four ashtray securing screws and remove ashtray from
console.
Installation
3. Fit and fully seat cigar lighter housing in ashtray and fit and tighten retaining ring.
11. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
2. Depress brake pedal, move gear selector to position N and turn ignition key to O.
3. Remove battery cover and disconnect ground cable from battery terminal.
5. Remove Sport mode and Cruise Control switches from surround finisher.
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6. Slacken and remove the four screws securing the two console veneer panel clamp plates and remove the
clamp plates.
7. Withdraw veneer panel, passing switches through the aperture. On the convertible model, disconnect the roof
operating switch harness multiplug.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Installation
4. Route Sport mode and Cruise Control switches through panel aperture.
6. Position veneer panel clamp plates and fit and tighten securing screws.
8. Fit and fully seat Sport mode and Cruise Control switches in finisher.
11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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2. Slacken and remove latch securing screws and remove latch assembly.
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3. Slacken and remove liner rear securing screws and remove liner.
Installation
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1999 XK RANGE - Instrument Panel and Console - 501-12
2. Slacken and remove lid stay securing screw and remove stay from lid.
3. Slacken and remove glovebox latch securing screws and remove latch from glovebox.
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4. Slacken and remove glovebox liner rear securing screws and remove liner for access.
6. Slacken and remove screws securing hinge to lid and remove hinge.
Installation
1. Position hinge on console lid and fit and tighten securing screws.
2. Position glovebox lid on centre console and fit and tighten securing screw.
3. Fully seat liner in centre console and fit and tighten rear securing screws.
4. Fit glovebox latch to liner and fit and tighten securing screws.
5. Position glovebox to lid stay, fit and tighten securing screw and close glovebox lid.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. Open glove box lid and slacken and remove four screws securing liner to the fascia.
2. NOTE:
Do not disturb the two inner screws as these are for glovebox alignment only.
3. Position glove box for access, disconnect footwell and glovebox lamp multiplugs and withdraw the glove box
assembly.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Installation
1. Position glovebox at fascia cross-member and connect footwell and glovebox lamp multiplugs.
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2. Move the glove box lid damper cord forward to release clip from lid.
Installation
1. Position glove box lid and secure to hinges with four screws.
7. Slacken two inner screws at bottom of glovebox, adjust alignment of glovebox lid to liner and re-tighten
screws. 1 2012-07-22
1999 XK RANGE - Instrument Panel and Console - 501-12
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Withdraw veneer panel from fascia upper locating slots and disconnect trip computer switch multiplug.
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5. Position veneer panel for access and remove trip computer switch.
6. Slacken and remove instrument panel surround securing nuts and remove surround from veneer panel.
Installation
1. Align instrument surround with veneer panel and fit and tighten securing nuts.
3. Position panel at fascia and connect trip computer switch harness multiplug.
4. Engage panel lugs in fascia upper slots and fit and tighten lower securing screws.
6. Fit ground cable onto battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.15>>.
11. Disconnect 'J' gate and gearshift interlock solenoid harness multiplugs.
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14. Remove left-hand 'A' post lower trim pad. Refer to <<76.13.30>>.
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23. Remove right-hand 'A' post lower trim pad. Refer to <<76.13.30>>.
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32. Disconnect right-hand harness multiplugs at center console rear mounting bracket.
1. Disconnect the three right-hand harness multiplugs and position clear of bracket.
2. Remove two rubber straps securing harnesses to tunnel.
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36. Via glove box aperture, remove two bolts securing fascia to bulkhead mounting bracket.
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37. CAUTION:
The treadplate finishers, can easily be deformed or otherwise damaged during removal.
38. Exercising care, use a thin blade to release driver footrest tangs and spigots from mounting plate.
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39. Remove footrest mounting plate securing bolts and remove mounting from vehicle.
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41. Release carpet from around kickdown switch and toeboard area.
43. Remove handbrake lever trim and ensure that lever is left in fully upright position. Refer to <<76.13.63>>.
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44. Withdraw draught welt and release carpet retaining clips from driver door aperture flange.
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47. Withdraw draught welt and release carpet retaining clips from passenger door aperture flange.
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51. At each side of tunnel, remove nut securing fascia harness earth cables and remove earth eyelets from
studs.
Installation
1. With assistance, align the fascia with the support dowels and position the earth cable in the right-hand fuse
box.
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2. With assistance, ensuring multiplugs and harnesses are not trapped or obstructed, carefully press fascia
forward squarely onto dowels.
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4. Via glove box aperture, install two bolts securing fascia to bulkhead mounting bracket.
7. At left-hand side of tunnel, install new tie strap to secure ICE cable to harness.
9. Install fasteners securing fascia and seat harnesses on tunnel and floor.
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If treadplate finisher is being renewed, peel protective backing from adhesive.
Align finisher and press firmly into place.
Repeat procedure to install opposite side draught welt and treadplate.
13. Position 'J' gate and fit selector cable securing strap and stud to tunnel.
14. Install fascia harness multiplugs at center console rear mounting bracket.
1. Install spare connector at center left-hand position.
2. Connect the six fascia harness multiplugs.
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1999 XK RANGE - Instrument Panel and Console - 501-12
19. Position footwell lamp mounting bracket and secure with screws to air conditioning duct.
20. Connect steering column switch gear harness and column harness.
Connect steering column switchgear harness and column harness multiplugs and install multiplugs on
mounting bracket.
21. Position bonnet release lever assembly on 'A' post studs and install securing nuts.
22. Position fascia harness earth cable eyelets on 'A' post stud and fit and install securing nut.
25. Install two bolts securing fascia center bracket to the transmission tunnel.
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26. Position fascia to transmission tunnel side brackets and install retaining bolts.
28. Connect the 'J' gate harness and gearshift solenoid harness multiplugs.
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39. Connect earth cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. WARNING:
FOLLOWING REMOVAL OF THE PASSENGER AIR BAG DEPLOYMENT DOOR, NEW RETAINING
CLIPS MUST ALWAYS BE FITTED.
Open Glovebox lid.
3. Using a thin plastic lever, carefully release centre vent veneer panel tangs from fascia clips.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Installation
1. Fit and fully seat new veneer panel securing clips in fascia.
2. WARNING:
NEW PASSENGER AIR BAG DEPLOYMENT DOOR, RETAINING CLIPS MUST ALWAYS BE FITTED.
Fit and fully seat veneer panel in securing clips.
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1999 XK RANGE - Instrument Panel and Console - 501-12
2. Slacken and remove the two screws securing the lower underscuttle to the fascia panel cross-member.
3. Withdraw the underscuttle upper fasteners from their locations in the fascia panel.
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7. Release the valet switch securing tangs and remove the switch.
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9. Release the aspirator vent securing tangs and remove the vent from the underscuttle.
Installation
3. Connect battery earth lead and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Instrument Panel and Console - 501-12
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Commencing at rear and exercising care to avoid damaging headlining, use a thin plastic lever to release the
three spring clips securing console to roof.
3. Disconnect roof console harness connector and remove console from vehicle.
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1999 XK RANGE - Instrument Panel and Console - 501-12
4. NOTE:
The only serviceable item in the roof console is the garage door remote switch fitted for certain markets.
Both types of console are supplied as complete assemblies.
Remove three screws and release strap securing switch assembly to roof console.
5. Disconnect switch harness connector and remove switch assembly from console.
Installation
1. Position garage door remote switch on console and connect harness connector.
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6. Ensuring harness is correctly positioned, press console firmly upwards to fully seat spring clips.
7. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>
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1999 XK RANGE - Instrument Panel and Console - 501-12
3. Slacken and remove two screws securing glove box lid to console and remove lid from console.
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1999 XK RANGE - Instrument Panel and Console - 501-12
5. Slacken and remove the ten screws securing inner finisher to glovebox lid.
7. Slacken and remove cup holder latch securing screw and remove latch assembly.
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1999 XK RANGE - Instrument Panel and Console - 501-12
8. Open cupholder, depress tang each side of latch location and withdraw cupholder assembly. from base.
9. Slacken and remove the five cup holder lid trim panel securing screws and remove panel from lid by releasing
lower edge and withdrawing upwards.
Installation
1. Fit and fully seat trim panel to cup holder lid ensuring that panel hook engages lid and panel engages lid
damper wire.
2. Fit and tighten screws securing trim panel to cup holder lid.
3. Fit and fully seat cupholder and trim panel assembly to glove box lid.
4. Position cup holder latch and fit and tighten securing screw.
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6. Fit and fully seat inner finisher to glove box lid and fit and tighten securing screws.
7. Close cup holder lid, position glove box lid assembly on centre console. and fit and tighten securing screws.
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1999 XK RANGE - Instrument Panel and Console - 501-12
Installation
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2. Connect multiplugs.
1. Position cowl to facilitate re-connection of multiplugs.
2. Connect rheostat harness multiplug.
3. Connect column adjustment harness multiplug.
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The central locking system employs single key access to the driver's door, trunk lid and ignition switch/steering column
lock. An additional green headed valet or parking services key permits access via the driver's door, and
ignition/start-up, but denies access to the trunk and glovebox.
A valet switch located in the underscuttle on the outboard side of the steering column, precludes normal internal
access to the trunk.
When the vehicle is not locked, each door catch can be externally released by the corresponding door handle which
operates via a single rod. When unlocked, or 'single action' locked, the door catches can also be internally released by
the interior handles, each of which operates via a single cable. Use of either key in the external door barrel, operates
the lock via a short rod to provide locking of the door latch. These locking functions can also be achieved by use of the
remote transmitter.
The trunk lid can be independently unlocked via a switch located on the driver's side underscuttle. This will only
operate at vehicle speeds up to 8 km/h (5 mph).
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
A lock barrel located between the X and K of the XK8 badge on the RH side of the trunk rear panel provides external
access to the trunk via the black-headed key only.
The fuel filler flap is released via a switch located on the driver's underscuttle. This switch will only operate if the
engine is not running and the vehicle is unlocked, or the ignition is in position I or II.
An emergency filler flap release lever is accessed by removing the LH side trunk lining below the filler.
Key Operation
To 'single action' lock or unlock the vehicle, the key is inserted in the door lock, turned towards the front or rear of the
vehicle respectively, and released. Holding the key in the lock position will close all windows, and on convertible
models, will also raise the top. Releasing the key stops all operations. 'Single action' locking of the vehicle locks both
doors, the trunk lid and the fuel filler flap, and sets the alarm system.
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A 'superlocking' function deadlocks both doors, preventing door opening from the interior, and provides all of the
above functions. To raise the convertible top however, the key must again be held in the 'lock' position. To 'superlock'
the vehicle, the key is inserted in the door lock and turned to the unlock position, then within three seconds, turned to
the lock position and released.
Remote Operation
A four-button transmitter unit provides for remote controlled central locking of the vehicle.
The button bearing a red closed padlock symbol locks the vehicle and arms the security system. To remote 'single
action' lock, the transmitter is pointed towards the vehicle and this button is pressed and released. To 'superlock' the
vehicle, the above operation is repeated within three seconds. This function can also be used to remote close any
windows. Completion of 'superlocking' is indicated by an audible 'chirp' from the security system and a single flash
from the direction indicators. The vehicle is unlocked and the security system disarmed by pressing the button with the
open padlock symbol.
The trunk lock can also be remotely released by operating the button bearing the trunk lid open symbol.
The button with dipped headlamp symbol is for emergency use. When depressed three times within three seconds, it
switches the headlamps on for 25 seconds and operates the vehicle alarm 5 times.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
10. Release cover to latch inner locating boss and remove cover.
11. Release door ajar switch securing tangs and remove switch from latch assembly.
13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from
multiplug.
Installation
1. Fit and fully seat terminal pins in harness multiplug and fit terminal pin protector.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
2. Fit door ajar switch to latch assembly, ensuring that both retaining tangs are fully seated.
9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
10. Release cover to latch inner locating boss and remove cover.
11. Release door lock/unlock switch securing tang, depress pip and remove switch from latch assembly.
13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from
multiplug.
Installation
1. Fit and fully seat terminal pins in harness multiplug and fit terminal pin protector.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
2. Fit door lock/unlock switch to latch assembly, ensuring that tang and pip are correctly located.
9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. WARNING:
BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE GROUND CABLE MUST BE
DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF
THE GLOBAL GLASS CLOSING FEATURE.
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
6. Remove trim mat from rear of door pocket and remove the screw.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
10. Remove door casing from vehicle and detach switch pack.
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15. Disconnect door handle and lock barrel (driver door only) operating rods from lock links.
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16. Remove the three screws and position lock/motor assembly for access.
17. Remove lock motor harness connector from mounting bracket and disconnect connector.
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21. Releasing upper retaining boss, remove cover from lock/motor assembly.
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Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
3. Install cover.
Position cover on lock motor ensuring upper locating boss is correctly located.
Install cover screw.
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9. Connect door handle and lock barrel (driver door only) operating rods to latch assembly.
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16. Position casing at door and connect switch pack and puddle lamp connectors.
17. Align casing to door and press and fully seat securing studs into door locations.
20. Install trim to front of door pocket and fully seat plastic fastener.
26. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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4. Release control cable from bracket, rotate 90 degrees to align with slot in bush and withdraw cable nipple
from latch assembly.
Installation
1. Fit control cable nipple to latch assembly bush, rotate 90 degrees to captive position and locate outer cable
on bracket.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
7. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
8. Slacken and remove the door glass rear runner lower securing screws.
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11. Disconnect door handle and lock barrel (driver door only) operating rods from latch links.
12. Slacken and remove the three latch assembly securing screws and position latch for access.
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13. Remove latch motor harness multiplug from mounting bracket and disconnect multiplug.
Installation
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4. Position latch assembly in door and fit and tighten securing screws.
5. Connect door handle and lock barrel (driver door only) operating rods to latch assembly.
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11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.15>>.
5. Disconnect switch module harness multiplug, release module end locaters and lightly press module out of
console.
Installation
1. Fit switch module to console ensuring that end locaters are fully seated.
6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. WARNING:
BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE
DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF
THE GLOBAL GLASS CLOSING FEATURE.
Remove driver's door casing. Refer to <<76.34.01>>.
4. Slacken and remove screw securing barrel to housing and withdraw barrel.
Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. NOTE:
For re-fitting of original lock barrel, refer to operations 4 to 9.
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6. Position lock assembly in door handle and fit and tighten securing screw.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. WARNING:
BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE
DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF
THE GLOBAL GLASS OPEN/CLOSE FEATURE.
Ensure that door glass is fully up.
2. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.19>>.
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5. Remove tape securing puddle lamp harness to water shedder and reposition harness for access.
6. Carefully peel back main water shedder remove from door and place adhesive face downwards on clean dry
plastic sheet.
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Installation
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7. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
4 2012-07-22
1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. WARNING:
BEFORE COMMENCING WORK WITHIN A DOOR INTERIOR, THE EARTH CABLE MUST BE
DISCONNECTED FROM THE BATTERY TERMINAL TO PREVENT INADVERTENT ACTIVATION OF
THE GLOBAL GLASS CLOSING FEATURE.
Ensure that door glass is fully up.
2. Remove battery cover and disconnect earth lead from terminal. Refer to <<86.15.19>>.
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5. Remove tape securing puddle lamp harness to water shedder and reposition harness for access.
6. Carefully peel back water shedder, remove from door and place adhesive face downwards on clean dry
plastic sheet.
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Installation
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Position door casing center support bracket. and fit and tighten securing bolts.
4. Connect earth cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
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Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
2. Position lock rods inwards and fit and fully seat handle in right-hand mounting bracket.
3. Fit lock barrel to lid.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
2. Release hood open microswitch harness multiplug from body tang and disconnect multiplug.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
Installation
3. Locate and fully seat release outer cable in latch mounting bracket.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
5. Connect hood open microswitch harness multiplug and fit and fully seat multiplug on body tang.
6. Remove fender cover, shut hood and check that latch and microswitch function correctly.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
Luggage Compartment Lid and Fuel Filler Door Release Switch 86.65.95
Removal
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2. Remove driver side underscuttle for access to lower fascia. Refer to <<76.46.11>>.
3. Release retaining tangs and withdraw switch assembly from driver side lower fascia.
4. Disconnect harness multiplug from fuel filler flap/trunk lid release switch assembly.
Installation
1. Install fuel filler flap/trunk lid release switch assembly to driver side lower fascia, ensuring that retaining tangs
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
3. Remove tape securing lock mechanism harness and disconnect harness multiplug.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
5. Position lock mechanism for access and disconnect lock barrel operating cable.
Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
4. Position and fully seat lock mechanism and fit but do not tighten securing bolts.
7. Open trunk lid adjust lock position as necessary and fully tighten securing bolts.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Remove the two trunk lid lock motor mounting bracket securing screws and position bracket/motor assembly
for access.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
6. Disconnect release cable hook from motor rod and withdraw motor/bracket assembly from trunk.
7. Remove two screws securing motor to mounting bracket and remove motor from bracket.
Installation
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
9. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
5. Slacken and remove lock barrel housing securing nuts and release housing from operating cable abutment
bracket.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
6. Disconnect cable from lock barrel operating arm and remove barrel and housing from trunk.
7. Remove circlip securing operating arm to lock barrel and remove operating arm and bias spring from barrel.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
9. Using a flat-bladed screwdriver, ease barrel cover free and discard cover and plastic tension ring.
10. Remove:
1. Closing plate.
2. Shutter flap, tension spring and pivot pin.
3. Retaining key.
4. Shutter housing.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
11. NOTE:
If original discs and spacers are to be fitted, record sequence during removal.
Installation
2. If original discs are to be fitted, proceed to step 3 noting positions recorded during removal.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
5. Align discs and spacers to accept the steel rollers grease rollers and fit into disc recesses via barrel slot.
6. Grease and fit shutter pivot and spring ensuring that spring is correctly tensioned.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
7. Grease and fit detent plunger and spring to lock barrel recess.
8. Grease and fit spring clip into groove in bore of barrel housing.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
9. Aligning detent plunger with groove in housing, push barrel assembly home until plunger engages in rear
recess.
10. Turn key to locate plunger in housing detent, check for satisfactory lock operation and remove key.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
13. Position lock barrel and housing at cable abutment bracket and connect operating cable.
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1999 XK RANGE - Handles, Locks, Latches and Entry Systems - 501-14
14. Position barrel and housing assembly on cable abutment bracket studs and fit and tighten securing nuts.
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Installation
1. Position warning switch on lock mechanism and fit and fully seat tangs.
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1999 XK RANGE - Wipers and Washers - 501-16
Torques
Component Nm
Nut securing wiper arm to spindle 15,5 - 20,5
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1999 XK RANGE - Wipers and Washers - 501-16
Windshield Wipers
The conventional twin wiper system is driven by a single motor controlled from the right hand column stalk switch. The
motor which has 'microswitch overload protection,' is mounted on a bracket below the plenum cover on the driver's
side. Available only as a complete assembly including motor, the wiper system is handed to suit market requirements.
The wiper arms are dedicated to either driver or passenger side installation and incorporate blade carriers that enable
wipers to be parked in lowest possible position on the windshield. The wiper blades are of synthetic rubber.
Windshield washer jet assemblies are mounted on the wiper arms.
Operating modes selected by a column mounted wiper control stalk switch, are normal, high speed, flick wipe, and six
settings of intermittent operation with delays ranging from 2 to 20 seconds. On vehicles with rain sensing installed, the
first intermittent setting is replaced by an AUTO position.
Windshield Washers
The windshield washers are of wiper arm mounted, running jet configuration, with each jet assembly incorporating a
conventional nozzle plus three nozzles of silicone rubber 'duckbill' design. If the system is initially operated at low
ambient temperatures, the 'duckbill' nozzles permit any frozen residual washer fluid to be ejected under pump
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1999 XK RANGE - Wipers and Washers - 501-16
pressure. The windshield wash feed tubes supplied assembled in the associated wiper arms fit at their lower ends
onto connectors in the plenum cover. Located on the rear face of the washer fluid reservoir the windshield wash pump
is connected by feed tubes to the plenum cover. The seven liter washer fluid reservoir is situated in a cavity formed by
the front bumper, LH front valance and the front wing liner.
The windshield washers are operated by pressing the button at the end of the wiper control stalk switch. Pressing and
releasing the button operates the washers for 1 - 1.4 seconds and the wipers complete three sweeps. An optional
drip wipe function adds a further sweep of the wipers after a 4 second delay, to clear residual fluid from the
windshield. If the button is held depressed, the washers and wipers will operate continuously for up to 20 seconds.
The headlamp powerwash system incorporates a telescopic nozzle unit mounted in the lower section of each
headlamp. Each nozzle is connected via snap fittings to a powerwash pump mounted above the windshield wash pump
on the rear face of the washer fluid reservoir.
The powerwash system operates in conjunction with the windshield washers when the ignition switch is in position II
and the headlamp switch is in the dip or main beam position. When the powerwash pump is activated, the nozzle units
under fluid pressure, extend forward approximately 72 mm and commence the wash cycle. The wash cycle consists of
two 800 ms pulses separated by a six second delay. To conserve washer fluid, headlamp powerwash will only
function on every sixth operation of the windshield wash switch.
When the 'WASHER FLUID LOW' message is illuminated, the windshield washers will continue to operate for a limited
period but the headlamp powerwash will not function until the fluid level is restored.
The rain sensing system installed for some markets, provides automatic wiper operation when rain is detected on the
windshield. The system detects differing levels of rainfall and varies wiper operation ranging from intermittent to
maximum continuous, to suit prevailing requirements.
The system which is brought into operation by selecting AUTO on the wiper control switch bezel, does not preclude
normal manual control of wiper operation.
The system consists of a rain sensor, an electronic control module and a dedicated wiper control switch.
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1999 XK RANGE - Wipers and Washers - 501-16
The rain sensor is an optical transducer that is sensitive to changes in infra-red light penetration of the windshield
created by the refractive effects of water droplets. The sensor elements consist of two groups of light emitting diodes
which alternately project infra-red light onto the windshield and a photo-diode that receives resulting reflections from
the glass. All of the infra-red light is reflected back from a moisture-free windshield, resulting in a constant 5V output
signal from the sensor and no wiper activation. Rain falling on the light sensing area of the windshield results in
refraction and diffusion of a proportion of the projected light with a corresponding imbalance of light received by the
photodiode. This results in pulsed outputs from the sensor, the frequency and duration of which are directly
proportional to the number and size of water droplets respectively. These pulses together with wiper switch position
signals are received by the sensor control module and processed to mimic column switchgear operation. In this
recognisable form, signals are input to the body processor module (BPM) where they are interpreted as normal wiper
operation requests.
The rain sensor unit is installed on the inside of the windshield within the rear view mirror stem cover. The unit is
secured to the glass by a special adhesive that facilitates service removal. When installing a rain sensor unit, it must
be positioned in the clear circle within the obscuration band.
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1999 XK RANGE - Wipers and Washers - 501-16
The rain sensor control module is a non-serviceable unit installed on the passenger side dash panel and connected to
the rain sensor unit and the body processor module.
The column mounted wiper control stalk switch on vehicles with rain sensing installed, has an AUTO position (this
replaces the first intermittent setting on non rain-sensing wiper controls), five intermittent settings, and normal, high
speed and flick wipe positions.
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1999 XK RANGE - Wipers and Washers - 501-16
1. Turn steering wheel to full lock position that provides access to appropriate wheel arch liner.
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1999 XK RANGE - Wipers and Washers - 501-16
Installation
3. Fit but do not fully tighten headlamp upper and lower securing bolts.
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1999 XK RANGE - Wipers and Washers - 501-16
10. Fit and fully seat front of wheelarch liner and secure with new fasteners.
11. Fit and fully seat access panel to wheelarch liner and rotate fastener 1/4 turn to secure.
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1999 XK RANGE - Wipers and Washers - 501-16
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Wipers and Washers - 501-16
4. Using a thin plastic blade, carefully remove sensor unit from windshield.
6. If sensor is to be re-used, remove adhesive pad and clean base of unit using an approved solvent.
Installation
2. Ensuring sensor is correctly orientated, press firmly into position on adhesive pad.
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1999 XK RANGE - Wipers and Washers - 501-16
4. Install cover over sensor and mirror base ensuring tangs fully engage.
5. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Wipers and Washers - 501-16
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to 86.15 19.
4. Disconnect harness connector from module and remove module from vehicle.
Installation
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1999 XK RANGE - Wipers and Washers - 501-16
4. Connect ground cable to battery terminal and install battery cover. Refer to <<86.15.15>>.
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1999 XK RANGE - Wipers and Washers - 501-16
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1999 XK RANGE - Wipers and Washers - 501-16
7. Remove and discard pump to reservoir sealing washers and clean surrounding area of reservoir.
Installation
3. Positioning pump at reservoir, press and firmly seat connectors firmly in sealing washers.
7. Close hood.
11. Raise vehicle, remove stands and lower vehicle onto wheels.
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1999 XK RANGE - Wipers and Washers - 501-16
5. Remove windshield washer and headlamp powerwash pumps from reservoir. Refer to <<84.10.21>>.
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1999 XK RANGE - Wipers and Washers - 501-16
8. Slacken and remove the three reservoir to BIW securing bolts and remove reservoir from vehicle.
Installation
1. Position reservoir in wheelarch, align with BIW holes and fit and tighten the three securing bolts.
3. Fit and fully seat new windshield washer and powerwash pump sealing washers to reservoir apertures.
4. Fit and fully seat new filler neck lower sealing ring to reservoir aperture.
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1999 XK RANGE - Wipers and Washers - 501-16
6. Position filler neck upper end in BIW aperture and fully seat lower end in sealing ring.
8. Fit new 'O' ring seal to upper end of filler neck. and apply suitable lubricant.
9. Fit and firmly seat filler elbow to upper end of filler neck.
15. Raise vehicle, remove stands and lower vehicle onto wheels.
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1999 XK RANGE - Wipers and Washers - 501-16
1. Remove battery cover and disconnect earth cable from battery terminal. Refer to <<86.15.19>>.
2. Remove wiper arm and blade assemblies. Refer to operations in this section.
4. Slacken and remove the bolt securing the driver side water deflector to the plenum chamber and remove the
deflector.
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1999 XK RANGE - Wipers and Washers - 501-16
6. Sever the strap securing the wiper motor multiplug to the securing bracket and disconnect the multiplug.
7. Slacken and remove the three wiper motor/linkage securing bolts and withdraw the motor and linkage from
the plenum chamber.
Installation
1. Fit mounting rubbers and treat the bores with a suitable lubricant.
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1999 XK RANGE - Wipers and Washers - 501-16
3. Position wiper motor/linkage assembly in the plenum chamber and fit and tighten securing bolts.
4. Connect wiper motor harness multiplug and secure to bracket with new retaining strap.
6. Position driver side water deflector in plenum chamber and fit and tighten securing bolt.
9. Connect earth cable to battery terminal and fit battery cover. Refer to Section <<414-01>>.
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1999 XK RANGE - Wipers and Washers - 501-16
Removal
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1999 XK RANGE - Wipers and Washers - 501-16
Installation
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
Convertible Top
Description
The convertible top has a fully lined and padded interior, and is mounted on an aluminum frame with steel linkages
providing lightness with good structural strength.
When lowered, the top folds to a low stack height in the body and is concealed by a matching soft cover. A front seal
shot moulded to the windshield header and 'A' posts, achieves highly efficient weatherproofing, reduced noise levels
and improved aerodynamics.
The green tinted glass backlight is bonded to the top to achieve a semi-flush finish.
Power Operation
Powered actuation and latching is provided by an electrically driven hydraulic pump installed in RH side of trunk. With
the ignition switch in position I or II, both the convertible top and rear quarter glass are operated by a single switch
located forward of the 'J' gate and marked 'ROOF. The top is lowered by pressing and holding the rear of the switch
until top movement ceases.When the top unlatches, an audible alarm sounds for 0.7 seconds , the rear quarters fully
open and any fully closed door glass lowers 12 mm. The audible alarm operates again when the top starts to move. If
the door glass is closed, the rear quarters close, then all glass lowers 12 mm.
When the top is fully lowered, the audible alarm operates and the door glass returns to the fully closed position. The
top is raised by pressing and holding the front of the switch until the top is fully erected and latched.When the top is
fully raised and latched, the audible alarm operates again and all glass closes.
Operation of the convertible top is inhibited at vehicle speeds in excess of 16 km/h (10 mile/h). If the vehicle exceeds
this speed when the top is moving to the lowered position, it will continue to the fully down position. Should the vehicle
exceed this speed when the top is being raised, further movement will be inhibited until the speed is reduced.
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1999 XK RANGE - Convertible Top - 501-18
In the event of latch failure when the top is raised, a visual warning will illuminate on instrument panel. In such an
emergency, the top must be manually positioned using a center pull down facility, then latched using a key stowed
alongside the top operating pump. To manually operate the latch, the key is inserted in the recess in the windscreen
header, turned clockwise to ensure the latch is fully released, then turned counter-clockwise to lock.
The top can also be manually raised in the event of failure to power operate. In such a situation, the pump isolating
valve must first be turned fully counter-clockwise to the manual operation position. Manual latching is then achieved as
described above. When manually raising the top, the linkages from the frame to the wheel arches must be moved to
the over-center position.
In the event of failure of powered lowering of the top, the following procedure must be adopted. Failure to follow this
procedure when manually lowering the top can result in damage to the frame and operating linkages.
1. Lower the rear quarter glass by pressing the rear of the 'ROOF' button once.
2. Rotate the pump valve (located in the RH side-well of the trunk) counter-clockwise to the manual operation
position.
3. Remove the blanking plug from the header trim, insert the Allen key provided (stowed alongside the top
pump) and unlatch the top by turning the key clockwise.
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1999 XK RANGE - Convertible Top - 501-18
4. Reaching behind the top rear quarter curtains, pull the rams and linkages at both sides firmly downwards as
far as possible.
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1999 XK RANGE - Convertible Top - 501-18
3. Ensuring that backlight heater harness is clear, power top to fully lowered position.
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1999 XK RANGE - Convertible Top - 501-18
9. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle.
11. Slacken and remove bolt securing ground cable to frame and position cable clear of frame.
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1999 XK RANGE - Convertible Top - 501-18
12. Slacken and remove security aerial retaining clip securing bolt.
13. Slacken and remove security aerial mounting bracket securing screws and position aerial clear of top.
14. NOTE:
Do not allow top to latch.
15. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
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1999 XK RANGE - Convertible Top - 501-18
16. Position trunk RH liner for access and turn hydraulic pump valve fully counter- clockwise to the manual
operation position.
17. Remove backlight link lever securing clips and position link levers for access.
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1999 XK RANGE - Convertible Top - 501-18
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1999 XK RANGE - Convertible Top - 501-18
20. Slacken and remove nuts securing rear tack strip to BIW.
21. Withdraw tack strip from vehicle and remove end covers from tack strip.
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1999 XK RANGE - Convertible Top - 501-18
22. Remove over-centre link lever retaining clips, remove nylon spacers and position link levers for access.
23. Disconnect hydraulic cylinder actuating rods from convertible top frame.
Remove spring clip/pin securing each hydraulic cylinder rod to frame.
Partially retract cylinder rod and withdraw from frame.
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1999 XK RANGE - Convertible Top - 501-18
24. Move each hydraulic cylinder clear of outer half pivot, position cylinder to facilitate top removal and remove
and retain wavy washer from pivot.
25. Tape plastic sheet over trunk lid, rear panel and fenders to protect paint
26. Slacken and remove upper bolts securing mounting brackets to BIW.
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1999 XK RANGE - Convertible Top - 501-18
27. Slacken but do not remove mounting bracket lower securing bolts.
29. Slacken and remove rear quarter glass inner seal rear securing screws.
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1999 XK RANGE - Convertible Top - 501-18
30. Release and discard rear quarter glass inner seal front fir tree fasteners and remove seals from carriers.
31. Slacken the front bolt securing each seal carrier to BIW.
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1999 XK RANGE - Convertible Top - 501-18
32. Slacken and remove the rear bolts securing each seal carrier to BIW and remove seal carriers.
33. Ensure that mounting bracket lower bolts are sufficiently slackened, then with assistance, carefully lift and
remove convertible top assembly from vehicle.
Installation
1. With assistance, carefully lift convertible top assembly and position in vehicle, locating lower slot in each
mounting bracket on BIW bolt.
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1999 XK RANGE - Convertible Top - 501-18
3. Position rear quarter glass inner seal carriers and fit but do not tighten rear securing bolts.
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1999 XK RANGE - Convertible Top - 501-18
5. Fit and fully seat inner seals in carriers and fit and tighten rear securing screws.
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1999 XK RANGE - Convertible Top - 501-18
8. Fit wavy washers onto half pivots and fit and fully seat hydraulic cylinders.
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1999 XK RANGE - Convertible Top - 501-18
10. Position over-centre link levers, fit nylon spacers and fit link rod securing clips.
12. Commencing in centre, fit and tighten tack strip securing bolts.
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1999 XK RANGE - Convertible Top - 501-18
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1999 XK RANGE - Convertible Top - 501-18
15. Position headlining rear quarters over mounting bracket cover plates and fit and tighten lower securing
screws.
16. Position backlight link levers and fit and fully seat securing clips.
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1999 XK RANGE - Convertible Top - 501-18
17. Turn hydraulic pump valve fully clockwise to power operation position.
20. Manually guiding latch striker into header mechanism, power convertible top to fully raised position
21. Accessing through cover plate apertures, tighten mounting bracket securing bolts.
22. Tighten rear quarter inner seal carrier rear securing bolts.
24. Power convertible top to fully lowered position and back to fully raised position, checking for satisfactory
operation and ensuring thar cover is correctly tensioned and fre from ripples or sagging
25. Position security aerial and fit and tighten mounting bracket securing screws.
26. Fit and tighten security aerial 'P' clip securing bolt.
27. Position ground cable eyelet and fit and tighten securing bolt.
28. Position squab panel stiffener bracket and fit and tighten securing bolts.
31. Fit rear speaker assembly (premium ICE only). Refer to 86.51.06
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1999 XK RANGE - Convertible Top - 501-18
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1999 XK RANGE - Convertible Top - 501-18
2. Disconnect heated backlight harness connectors and position harness clear of top.
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1999 XK RANGE - Convertible Top - 501-18
9. Slacken and remove squab panel stiffener bracket to body securing nuts and remove bracket.
10. NOTE:
Do not allow top to latch.
11. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
12. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation
position.
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1999 XK RANGE - Convertible Top - 501-18
14. Slacken and remove screws securing RH cantrail seal to frame and remove seal.
15. Slacken and remove screws securing RH cantrail seal carrier and remove seal carrier.
18. Slacken and remove screws securing RH main column seal carrier and remove carrier.
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1999 XK RANGE - Convertible Top - 501-18
20. Slacken and remove screws securing latch plate to frame and remove latch plate.
21. Noting positions for installation, release bonded sections of cover from frame.
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1999 XK RANGE - Convertible Top - 501-18
23. Release cover front retaining rod from retaining clips in frame and remove rod from cover.
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1999 XK RANGE - Convertible Top - 501-18
24. Noting the positions for installation, release bonded areas of padding bag from frame and withdraw bag
from front of frame.
25. Slacken and remove eight screws and outer clips securing padding bag to frame.
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1999 XK RANGE - Convertible Top - 501-18
27. Position top cover and padding bag rearwards and release both headlining rear tension rods.
28. Slacken and remove screws securing headlining to main column bracket covers.
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1999 XK RANGE - Convertible Top - 501-18
29. Drill out the two rivets each side, securing rear of headlining.
30. Release section of headlining secured by velcro strips to frame around pull-down handle aperture (bonded
on early vehicles).
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1999 XK RANGE - Convertible Top - 501-18
31. Exercising care to avoid damaging cords, drill out the two pop rivets securing tension cords to frame.
33. Drill out the seven pop rivets securing front bow rail to top frame and remove rail.
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1999 XK RANGE - Convertible Top - 501-18
34. Withdraw the front bow rail from the headlining piping, tension cords and straps.
36. Drill out pop rivets securing centre bow rail to top frame and remove rail from headlining piping.
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1999 XK RANGE - Convertible Top - 501-18
37. Withdraw headlining rear edge flange from retaining slot in rear bow rail and position rear tension cables for
disconnection.
38. Release and remove tension cable retaining bushes, and disconnect cables from frame.
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1999 XK RANGE - Convertible Top - 501-18
39. Release headlining fir tree or press stud fasteners from cantrails. Refer to Note in Step 42.
41. Release the side tension cords and rear tension cables and remove headlining from vehicle.
42. NOTE:
On certain early model year vehicles, press-stud fixings securing the the headlining to the frame must be
removed and replaced by fir-tree fixings. The procedure for this modification is detailed in Technical Bulletin
Number <<501-14>>.
Clean rivet swarf from convertible top area and remove double-sided tape from front of frame.
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1999 XK RANGE - Convertible Top - 501-18
Installation
1. Place headlining in vehicle, positioning and seating rear of lining in rear bow rail slot.
2. Move padding bag forward for access and check that lining is fully seated on rear bow rail.
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1999 XK RANGE - Convertible Top - 501-18
4. Connect rear tension cables onto frame and fit and fully seat retaining bushes.
6. To prevent damage to headlining during fitting, apply protective tape to leading end of centre bow rail.
7. Ensuring correct orientation, feed centre bow rail into the headlining.
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1999 XK RANGE - Convertible Top - 501-18
10. To prevent damage to headlining during fitting, apply protective tape to leading end of front bow rail.
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1999 XK RANGE - Convertible Top - 501-18
12. Ensuring correct orientation, feed the front bow rail into the headlining, simultaneously threading tension
cords and straps through the piping slits onto the bow rail.
13. Align front bow rail to frame and secure with pop rivets.
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1999 XK RANGE - Convertible Top - 501-18
14. Using a piece of welding rod or similar draw wire, pull the outer tension cords through the headlining piping.
15. Position the outer tension cords to the frame and secure with pop rivets.
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1999 XK RANGE - Convertible Top - 501-18
17. Align rear of headlining, pierce it through existing holes at riveting points in the retaining brackets and pop
rivet headlining to retaining brackets.
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1999 XK RANGE - Convertible Top - 501-18
19. Fit and fully seat new fir tree fasteners securing headlining to frame.
20. Remove backing from double-sided tape on front of headlining and position and firmly seat lining on frame.
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21. Align padding bag to frame and secure with 'P' clips and retaining screws.
22. Apply adhesive to front edge of padding bag and position and fully seat on frame.
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1999 XK RANGE - Convertible Top - 501-18
24. Using a piece of welding rod or similar draw wire, pull side tension cables through outer cover and secure
them to frame.
25. Apply adhesive to adjacent front positions of cover and frame and fully seat cover on frame.
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1999 XK RANGE - Convertible Top - 501-18
26. Fit front retaining rod to cover and seat rod in securing clips.
27. Position latch plate and fit and tighten securing screws.
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1999 XK RANGE - Convertible Top - 501-18
28. Position guide pins and latch striker and fit and tighten securing screws.
30. Fit and fully seat cantrail seals in carriers and fit and tighten securing screws..
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1999 XK RANGE - Convertible Top - 501-18
32. Turn hydraulic pump valve fully clockwise to power operation position and return trunk RH liner to correct
position.
33. Ensuring that rear quarter lights are fully lowered, power top to fully up and latched position.
34. Apply adhesive to adjacent areas of cover and frame at main column and fully seat cover on frame.
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1999 XK RANGE - Convertible Top - 501-18
39. Position headlining and fit and fully seat rear securing rods.
40. Position headlining over cover plates and fit and tighten securing screws.
42. Power top from fully down to fully up positions, checking for satisfactory operation and ensuring that cover is
correctly tensioned and free from rippling.
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1999 XK RANGE - Convertible Top - 501-18
43. Position squab panel stiffener bracket and fit and tighten securing nuts.
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1999 XK RANGE - Convertible Top - 501-18
3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
9. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation
position.
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1999 XK RANGE - Convertible Top - 501-18
12. Disconnect hydraulic cylinder harness multiplug (RH hydraulic cylinder only).
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1999 XK RANGE - Convertible Top - 501-18
14. Move hydraulic cylinder clear of half pivot and remove and retain wavy washer from pivot.
15. Position a piece of absorbent cloth below hydraulic cylinder to protect paintwork from any fluid spillage.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
16. Identify and mark position of hoses relative to hydraulic cylinder connectors, disconnect hoses and remove
and discard 'O' ring seals.
Installation
3. Position hydraulic cylinder in vehicle and ensuring correct orientation as marked during removal, fit and tighten
hose connectors to cylinder.
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1999 XK RANGE - Convertible Top - 501-18
4. Fit wavy washer to mounting bracket pivot and install and fully seat hydraulic cylinder on pivot.
5. Fit mounting bracket cover plate, ensuring that inner half pivot locates in cylinder recess and fit and tighten
upper securing screws.
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1999 XK RANGE - Convertible Top - 501-18
6. Position headlining rear quarters over mounting bracket cover plates and fit and tighten lower securing screws.
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1999 XK RANGE - Convertible Top - 501-18
10. Turn hydraulic pump valve fully clockwise to power operation position.
12. Check hydraulic system for satisfactory operation and freedom from leaks.
1. Power top to fully raise position.
2. Power top to fully lowered position.
3. Power top to fully raised position.
4. Check all connections for leakage.
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1999 XK RANGE - Convertible Top - 501-18
18. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
19. CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level
when the top is fully lowered and the lower mark denotes the level when the top is fully raised.
NOTE:
The convertible top hydraulic system is 'self-bleeding' and does not require further action to expel entrapped
air.
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal.
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1999 XK RANGE - Convertible Top - 501-18
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1999 XK RANGE - Convertible Top - 501-18
3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
8. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
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1999 XK RANGE - Convertible Top - 501-18
16. Position a piece of absorbent cloth below hydraulic cylinder to protect paintwork from any fluid spillage.
19. Route free end of each hose under headlining and rear harnesses and around seat squab support panel to
RH side of vehicle (LH hydraulic cylinder hoses only).
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1999 XK RANGE - Convertible Top - 501-18
20. Sever, remove and discard tie straps securing hoses and rear harness to BIW.
21. Slacken and remove the two pump assembly securing bolts, release pump from outboard grommet locations
and position for access to outboard hoses.
2. RH cylinder: Pump front connectors - hydraulic cylinder top hose to lower connector.
23. Disconnect appropriate hoses from pump, remove and discard 'O' ring seals and fit blanking plugs to hoses
and pump connectors.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
24. Carefully withdraw hoses through BIW aperture into vehicle interior and remove hoses from vehicle.
Installation
2. LH hydraulic cylinder only: Route pump connecting ends of hoses across top stowage compartment to RH
side of vehicle.
3. Pass pump connecting ends of hoses through BIW RH aperture and into trunk.
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1999 XK RANGE - Convertible Top - 501-18
4. LH cylinder only: Route hydraulic cylinder end of hoses around LH end of seat squab support panel and under
rear harnesses and headlining to cylinder location.
5. Remove blanking plugs from hydraulic cylinder and corresponding hose connectors, fit new 'O' ring seals to
hose connectors.
6. Noting identifying marks applied during removal, connect and tighten hoses onto cylinder.
7. Remove blanking plugs from hydraulic pump and corresponding hose connectors and fit new 'O' ring seals to
hose connectors.
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1999 XK RANGE - Convertible Top - 501-18
8. Connect and tighten hoses on pump outboard connectors ensuring corrct orientation as follows:
1. LH cylinder: Pump rear connectors - cylinder bottom hose to lower connector.
NOTE:
Pump inboard connectors are for latch operating hoses only.
9. Fit new tie straps to BIW, position harness and hoses in straps and tighten straps to secure.
11. Position pump on platform and fully seat rubber mounting grommets.
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1999 XK RANGE - Convertible Top - 501-18
14. Turn hydraulic pump valve fully clockwise to power operation position.
16. Check hydraulic system for satisfactory operation and all connections for freedom from leaks.
1. Power top to fully raise position.
2. Power top to fully lowered position.
3. Power top to fully raised position.
4. Check hose connections for leakage.
17. CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level
when the top is fully lowered and the lower mark denotes the level when the top is fully raised.
NOTE:
The convertible top hydraulic system is 'self-bleeding' and does not require further action to expel entrapped
air.
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal.
7 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
8 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
7. Sever and remove tie strap securing pump harness multiplug to pump hose and disconnect multiplug from
pump motor.
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1999 XK RANGE - Convertible Top - 501-18
8. Disconnect harness multiplugs from raise and lower solenoid control valves.
9. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
10. Identify and mark position of inboard hoses relative to pump, disconnect hoses, remove and discard 'O' ring
seals and fit blanks to pump and hose connectors.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
11. Slacken and remove the two pump assembly securing bolts.
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1999 XK RANGE - Convertible Top - 501-18
Installation
2. CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level
when the top is fully lowered and the lower mark denotes the level when the top is fully raised.
Slacken and remove the filler plug, fill the reservoir with correct fluid to the upper mark on the reservoir body
and fit and tighten filler plug.
3. Fit and fully seat rubber mounting grommets to base of pump assembly.
5. Remove blanks and fit new 'O' ring seals to outboard hoses.
7. Noting positional marks made during removal, connect and fully tighten outboard hoses on pump.
11. Fit new 'O' ring seals to inboard hoses and noting positional marks, connect and fully tighten hoses on pump
connectors
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
12. Position pump harness correctly and connect multiplugs to solenoid control valves.
14. Secure pump motor harness to hoses using new tie strap.
16. Check hydraulic system for satisfactory operation and freedom from leaks:
1. Power top to fully raised position.
2. Power top to fully lowered position.
3. Power top to fully raised position.
17. CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes the fluid level
when the top is fully lowered and the lower mark denotes the level when the top is fully raised.
NOTE:
The convertible top hydraulic system is 'self-bleeding' and does not require further action to expel entrapped
air.
18. Check fluid level and top up as necessary to lower mark on reservoir.
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1999 XK RANGE - Convertible Top - 501-18
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
8. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from
header rail.
10. Lift rear edge of seal for access and slacken and remove latch cover LH end securing screw.
11. Remove retaining stud from RH end of header seal, lift rear edge of seal for access and slacken and
remove latch cover RH end securing screw.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
12. Slacken and remove two remaining latch cover securing screws and remove latch cover from header rail.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
14. Release hydraulic hose retaining clips from LH upper 'A' post.
15. Release sun visor harness multiplugs from retainers on latch assembly bracket.
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
16. Slacken and remove the seven latch assembly to BIW header lower securing screws.
17. Slacken and remove the latch assembly to BIW header upper securing screws.
5 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
18. NOTE:
When carrying out the following operation, do not disturb securing bolts installed in the open-ended slots.
Slacken and remove the latch assembly to BIW header rear securing screws.
19. Supporting latch assembly, slacken but do not remove securing bolts installed in the rear inner open-ended
slots.
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1999 XK RANGE - Convertible Top - 501-18
20. Withdraw latch assembly and sever and remove tie straps securing hydraulic hoses to assembly.
21. Remove spring clip from latch actuator clevis pin and withdraw pin.
7 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
23. Lift hydraulic cylinder to vertical position and separate from latch assembly.
Installation
8 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
1. Position hydraulic cylinder vertically in latch assembly slots and lower to engage lugs.
9 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
4. Ensuring that hydraulic hoses are not trapped, position open-ended slots in rear face of latch assembly under
the undisturbed rear screws.
5. Supporting the latch assembly, fit but do not tighten the two top securing screws.
11. Fit and fully seat hydraulic hose retaining clips on upper 'A' post
10 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
13. Position trim finisher on header rail and secure with new fir tree fastener, exercising care to avoid damaging
finisher.
19. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
20. Check hydraulic system for satisfactory operation and all connections for freedom from leaks.
1. Power top to fully raised position.
2. Power top to fully lowered position.
3. Power top to fully raised position.
11 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
2. Sever and remove tie straps securing hydraulic hoses to latch assembly.
4. To protect the vehicle interior from any fluid spillage, position a plastic sheet immediately below the hydraulic
cylinder.
5. Disconnect hydraulic hoses from hydraulic cylinder, remove and discard 'O' ring seals from hose connectors
and fit blanking plugs to hydraulic cylinder and hoses.
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
7. Remove spring clip from hydraulic cylinder clevis pin and withdraw pin.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
9. Lift hydraulic cylinder to vertical position and separate from latch assembly.
Installation
1. Position hydraulic cylinder in latch assembly slots and lower to engage lugs.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
3. Fit and fully seat clevis pin and fit retaining cip.
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
6. Using a new tie strap, secure hydraulic hoses to the latch assembly.
9. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
10. Check hydraulic system for satisfactory operation and freedom from leaks.
1. Power top to fully raised position.
2. Power top to fully lowered position.
3. Power top to fully raised position.
4. Check that hose connections are free from leakage.
11. Position trim finisher on header rail and secure with new fir tree fastener, exercising care to avoid damaging
finisher.
5 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
7. Position a piece of absorbent cloth on trunk floor to protect paintwork from any fluid spillage.
8. Sever and remove tie strap securing hydraulic pump hose to pump harness.
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
9. Mark with location and slacken and disconnect hydraulic hoses from pump.
10. Remove and discard 'O' ring seals from hose connectors and fit blanking plugs to hoses and pump
connectors.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
27. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from
header rail.
28. Remove convertible top latch assembly cover panel. Refer to <<76.86.20>>.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
30. Release hydraulic hose retaining clips from LH upper 'A' post.
31. Release sun visor multiplugs from retainers on latch assembly bracket.
32. Position a piece of absorbent cloth in LH footwell to protect vehicle interior from any fluid spillage.
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
33. Slacken and remove the latch assembly to BIW header lower securing screws.
34. Slacken and remove the latch assembly to BIW header upper securing screws.
5 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
35. NOTE:
When carrying out the following operation, do not disturb securing bolts installed in the open-ended slots.
Slacken and remove the latch assembly to BIW header rear securing screws.
36. Supporting latch assembly, slacken but do not remove securing screws installed in rear open-ended slots.
37. Withdraw latch assembly, position in LH footwell and sever and remove tie straps securing hoses to latch
hydraulic cylinder and harness.
6 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
38. Mark latch hydraulic cylinder hoses with locations and disconnect hoses from cylinder assembly.
39. Remove and discard 'O' ring seals from hoses and fit blanking plugs to hoses and hydraulic cylinder
connectors.
40. Remove and discard tape securing hoses to 'A' post adjacent to top of fascia.
41. Withdraw hoses from retaining clips in fascia LH end fusebox aperture.
7 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
44. Lift edge of LH carpet for access, sever and remove tie straps securing hoses and release hoses from BIW
clips.
45. Release hoses from spring clip at transmission tunnel and draw hoses under carpet to tunnel.
8 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
46. Lift LH carpet at transmission tunnel and heel board and release hoses from retaining clips.
47. withdraw hoses from under transmission tunnel insulation, harness and carpet.
48. Rotate hydraulic pump valve fully counter-clockwise to the manual operation position.
50. Sever and remove tie straps securing hoses to power cable and rear harness.
9 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
51. Carefully withdraw hoses through BIW aperture into vehicle interior and remove from vehicle.
Installation
2. Route hydraulic pump end of hoses through BIW aperture into trunk.
4. Fit new 'O' ring seals to hoses and fit and tighten hoses onto pump.
5. Mark free end of each hose with position of corresponding connector on latch hydraulic cylinder as identified
on removal.
7. Route hydraulic hoses along rear harness and power cable and using new tie straps secure hoses to BIW at
rear quarter above wheel arch.
8. Using new tie straps, secure rear harness and hydraulic hoses to BIW.
11. Route hydraulic hoses under carpet, transmission tunnel insulation and harness.
12. Fit and fully seat hoses in retaining clips on carpet underside.
10 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
14. Route hoses under carpet across rear of footwell to 'A' post.
16. Under front section of carpet, fit new tie straps to BIW and secure hydraulic hoses.
17. Route hoses up LH 'A' post, and accessing through fascia end fuse box aperture, fit and fully seat in
retaining clips.
18. Using linen tape, secure hydraulic hoses to front of inner sill and top and bottom of upper 'A' post.
19. Remove blanking plugs from hose connectors and fit new 'O' ring seals.
11 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
20. Noting positions marked on hose connectors, fit and tighten hoses on hydraulic cylinder.
22. Fit and fully seat hydraulic hose retaining clips on upper 'A' post.
31. Rotate hydraulic pump valve fully clockwise to power operation position.
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1999 XK RANGE - Convertible Top - 501-18
39. CAUTION:
Two fluid levels are marked on the pump reservoir body. The upper mark denotes fluid level when
the top is fully lowered and the lower mark denotes the level when the top is fully raised.
NOTE:
The convertible top hydraulic system is 'self-bleeding' and does not require any further action to dispel
entrapped air.
Slacken and remove reservoir filler plug and remove and discard 'O' ring seal.
40. Check fluid level and top up as necessary to low mark on reservoir.
41. Fit new 'O' ring seal to filler plug and fit and fully tighten on reservoir..
13 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
3. Ensuring that backlight heater harness is clear, power top to fully lowered position.
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
9. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle.
11. Noting their positions, remove staples securing cover to backlight frame and release cover from frame.
12. NOTE:
Do not allow top to latch.
13. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
14. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation
position.
16. Slacken and remove screws securing RH cantrail seal to frame and remove seal.
17. Slacken and remove screws securing RH cantrail seal carrier and remove seal carrier.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
20. Slacken and remove screws securing RH main column seal carrier and remove carrier.
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
22. Slacken and remove screws securing latch plate to frame and remove latch plate.
23. Noting positions for installation, release bonded sections of cover from frame.
5 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
25. Release cover front retaining rod from retaining clips in frame and remove rod from cover.
27. Slacken and remove screws securing headlining rear quarters to main column bracket cover plates.
6 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
29. Slacken and remove bolts securing rear tack strip to BIW.
7 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
30. Withdraw tack strip from vehicle and remove end covers from tack strip.
32. Position tack strip clear of BIW and drill out pop rivets securing tack strip to cover.
8 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
33. Release cover from tack strip and withdraw side tension cables through cover piping.
35. Remove sealing strip from backlight frame and clean off any residual sealant.
36. Noting positions for installation, clean residual adhesive from frame.
37. Using white spirit, ensure that frame is grease free and dry.
Installation
9 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
2. Place cover on clean work surface, fold in half to determine centre and mark centreline with tape at rear edge.
5. NOTE:
It may be necessary to use a suitably soft drift and mallet to fully seat cover in tack strip.
Fit and fully seat rear edge of cover in tack strip retaining flange.
6. Using a suitable pointed tool pierce cover through existing holes in tack strip, drill through penetrations and
pop rivet cover to tack strip.
10 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
8. Position tack strip on BIW and commencing in centre fit and tighten securing bolts.
9. Using a piece of welding rod or similar material, draw side tension cables through cover piping
11 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
13. Apply adhesive to adjacent front positions of cover and frame and fully seat cover on frame.
12 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
14. Fit front retaining rod to cover and seat rod in retaining clips.
15. Position latch plate and fit and tighten securing screws.
13 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
18. Fit and fully seat cantrail seals in carriers and fit and tighten securing screws..
14 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
20. Turn hydraulic pump valve fully clockwise to power operation position.
21. Ensuring that rear quarter lights are fully lowered, power top to fully up and latched position.
22. Apply adhesive to adjacent areas of cover and frame at main column and fully seat cover on frame.
15 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
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1999 XK RANGE - Convertible Top - 501-18
28. Commencing at top centre, staple cover along top and down sides to meet previous stapling, if necessary,
gradually slitting cover within frame to relieve tension in fabric. At each corner, add a further outer row of
staples for reinforcement.
17 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
30. Position headlining and fit and fully seat rear securing rods.
31. Position headlining over cover plates and fit and tighten securing screws.
33. Power top from fully down to fully up positions, checking for satisfactory operation and ensuring that cover is
correctly tensioned and free from rippling.
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1999 XK RANGE - Convertible Top - 501-18
34. Position squab panel stiffener bracket and fit and tighten securing nuts.
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1999 XK RANGE - Convertible Top - 501-18
Installation
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1999 XK RANGE - Convertible Top - 501-18
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
8. Carefully remove and discard fir tree fastener retaining trim finisher on header rail and remove finisher from
header rail.
9. Carefully remove and discard retaining stud from LH end of header seal.
10. Lift rear edge of seal for access and slacken and remove latch cover LH securing screw.
11. Remove and discard retaining stud from RH end of header seal, lift rear edge of seal and slacken and
remove latch cover RH securing screw.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
12. Slacken and remove the latch cover centre securing screws and remove latch cover from header rail.
Installation
1. Position latch cover on header rail and fit and tighten centre securing screws.
2. Lift RH edge of header seal for access and fit and tighten the latch cover RH securing screw.
3. Fit and fully seat new retaining stud to RH end of header seal.
4. Lift LH edge of header seal for access and fit and tighten the latch cover LH securing screw.
5. Fit and fully seat new retaining stud to LH end of header seal.
6. Ensuring that microphone flying lead is routed towards harness multiplug, position trim finisher on header rail
and secure with new fir tree fastener.
12. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
1 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
5. Detach the header rail weatherstrip from the right-hand locating channel.
2 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
7. NOTE:
Note the position of the header rail weatherstrip right-hand insulator.
3 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
8. NOTE:
Note the position of the header rail weatherstrip right-hand locating channel insulator.
Remove and discard the header rail weatherstrip right-hand locating channel insulator.
4 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
10. Detach the header rail weatherstrip left-hand upper retaining clip.
11. Detach the header rail weatherstrip left-hand lower retaining clips.
5 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
12. Detach the header rail weatherstrip from the left-hand locating channel.
6 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
14. NOTE:
Note the position of the header rail weatherstrip left-hand insulator.
15. NOTE:
Note the position of the header rail weatherstrip left-hand locating channel insulator.
Remove and discard the header rail weatherstrip left-hand locating channel insulator.
16. NOTE:
Note the position of the header rail weatherstrip.
7 2012-07-22
1999 XK RANGE - Convertible Top - 501-18
Installation
1. CAUTION:
Make sure all adhesive has been removed from the insulator mating surfaces.
NOTE:
Install the header rail weatherstrip to the position noted during removal.
NOTE:
Install new header rail weatherstrip locating channel insulators to the positions noted during removal.
NOTE:
Install new header rail weatherstrip insulators to the positions noted during removal.
8 2012-07-22
1999 XK RANGE - Bumpers - 501-19
Torques
Component Nm
Bolts securing bumper beam to strut 39 - 51
Bolts securing bumper guide to body 15,5 - 20,5
Bolts securing energy absorbing strut to body 22 - 28
Bolts securing non-energy absorbing strut to body 15,5 - 20,5
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
Bumpers
Front Bumper
The front bumper is part of a fully integrated 'soft front end' that satisfies bumper impact requirements. The bumper
has a polyurethane cover color-matched to the body and moulded to form an elliptical air intake. The cover is secured
to the body via fixings to the fenders and the BIW upper crossmember. The lower section of the cover The cover
lower extremity is attached to a GMT undertray fitted to assist air flow through the cooling pack and is supported in
the center by clips integral with the overrider covers.
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
Front Bumper Beam , Mounting Struts and Splitter Vane
Glass mat thermoplastic (GMT) bumper beams are secured by a single bolt and nut to each of two GMT mounting
brackets, each of which is in turn attached to the BIW by three bolts and nuts. Aluminum bumper beams installed for
certain markets are similarly mounted, but employ menasco energy absorbing struts instead of GMT mounting
brackets.
A chromed splitter vane, located centrally in the air intake, is secured to the bumper beam lower face by three rivets.
Two polycarbonate overrider covers that fit over the splitter vane and overriders are secured by scrivets to the upper
face of the bumper beam.
A plastic air deflector is attached to the undertray in each wheelarch area to improve airflow in the front wheel area.
Left- and right-handed twin circular fog lamps installed in recesses in the lower section of the cover are accessed by
removal of the undertray. Side marker lamps fitted to the bumper cover for some markets, serve only as side
reflectors for other markets. Side marker lamps/reflectors are pressed in from the outside and unclipped from inside.
2 2012-07-22
1999 XK RANGE - Bumpers - 501-19
Rear Bumper Assembly and Mountings
The rear bumper has a color matched, moulded polyurethane cover mounted on a GMT or aluminum beam dependent
upon the market. The beams are respectively mounted on two brackets or energy absorbing menasco struts, each of
which is located and secured to the BIW by three bolts.
The bumper cover incorporates integral LH and RH support armatures which engage in guide blocks secured to the
body by a captive bolt and a nut. Under low speed impact, this configuration enables the bumper to move forward on
the guide blocks, preventing rear body damage.
Rear side marker lamps/reflectors are fitted and removed in the same manner as those at the front.
3 2012-07-22
1999 XK RANGE - Bumpers - 501-19
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
3. Remove and discard rivets securing both overrider covers to beam and remove covers.
4. Remove and discard rivets securing splitter vane to underside of bumper beam.
Installation
1. Position splitter vane on bumper beam and secure to underside with new rivets.
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1999 XK RANGE - Bumpers - 501-19
4. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2 2012-07-22
1999 XK RANGE - Bumpers - 501-19
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>
3. Remove and discard rivets securing covers to bumper beam and remove covers from vehicle.
Installation
1. Fit covers onto overriders and secure to bumper beam with new rivets.
3. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
1. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
6. Release ambient air temoerature sensor from RH horn mounting bracket tang.
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
7. Slacken and remove bolts securing power steering cooler mounting clips to beam.
8. Release clips from powerwash hose and position hose clear of beam.
2 2012-07-22
1999 XK RANGE - Bumpers - 501-19
9. Remove and discard two scrivets securing harness conduit to bumper beam.
10. Slacken and remove the two bolts securing bumper beam to mounting struts, withdraw beam from vehicle
and place on bench.
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1999 XK RANGE - Bumpers - 501-19
Installation
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1999 XK RANGE - Bumpers - 501-19
2. Ensuring that oil cooler and harness conduit are clear, position bumper beam on struts and fit and tighten
securing bolts.
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1999 XK RANGE - Bumpers - 501-19
5. Position power steering oil cooler and clips on beam and fit and tighten securing bolts ensuring cooler is
correctly located in clips.
10. Raise front of vehicle, remove stands and lower vehicle onto wheels.
11. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
6 2012-07-22
1999 XK RANGE - Bumpers - 501-19
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Remove and discard fasteners from both wheelarch liners and remove liners for access. Refer to
<<76.10.90>>.
6. Using a thin plastic lever, carefully release front number plate from plinth..
8. Remove and discard the eight rivets securing undertray to the bumper cover.
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
9. Remove and discard three fasteners securing undertray to lower crossmember and remove undertray.
2 2012-07-22
1999 XK RANGE - Bumpers - 501-19
13. Slacken and remove three bolts securing each fog lamp to bumper cover and remove both lamps from
vehicle.
3 2012-07-22
1999 XK RANGE - Bumpers - 501-19
14. Release sidemarker lamp/reflector clips and remove both lamps/reflectors from bumper cover.
Installation
1. Position fog lamps in bumper cover and fit and tighten securing bolts.
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1999 XK RANGE - Bumpers - 501-19
5 2012-07-22
1999 XK RANGE - Bumpers - 501-19
6. Fit undertray.
Position undertray on vehicle and secure to lower cross-member with three new fasteners
Secure undertray to bumper cover using eight new rivets.
7. At each side of vehicle, reposition and secure wheelarch spoiler and wheelarch liner using new fasteners.
Refer to <<76.10.90>>.
9. Position front number plate plinth on overriders, fit and tighten securing screws and fit number plate to plinth.
10. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
6 2012-07-22
1999 XK RANGE - Bumpers - 501-19
1. Remove battery cover and disconnect ground cable from battery terminal.
6. Slacken and remove three bolts securing strut to front lower cross-member and remove strut from vehicle.
Installation
5. Check bumper to BIW clearances and adjust as necessary. Refer to Section 18.
6. Raise front of vehicle, remove stands and lower vehicle onto wheels.
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1999 XK RANGE - Bumpers - 501-19
1. WARNING:
THE REAR BUMPER IS CLOSE TO THE EXHAUST PIPES WHICH MAY BE HOT. CARE MUST
THEREFORE BE EXERCISED WHEN WORKING IN THIS VICINITY.
Position vehicle on a 4-post ramp with parking brake on and raise ramp to working height.
2. Remove rear wheel arch liners and side marker bulb holders.
1. Slacken and remove rear wheel arch liner plastic nut and remove liner from wheel arch.
On N. American vehicles, rotate side marker bulb holder 1/4 turn, withdraw from lamp and ensure that
leads are free from bumper.
Repeat operations on opposite side of vehicle.
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1999 XK RANGE - Bumpers - 501-19
2 2012-07-22
1999 XK RANGE - Bumpers - 501-19
Installation
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1999 XK RANGE - Bumpers - 501-19
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1999 XK RANGE - Bumpers - 501-19
5 2012-07-22
1999 XK RANGE - Bumpers - 501-19
6 2012-07-22
1999 XK RANGE - Bumpers - 501-19
1. WARNING:
THE REAR BUMPER IS CLOSE TO THE EXHAUST PIPES WHICH MAY BE HOT. CARE MUST
THEREFORE BE EXERCISED WHEN WORKING IN THIS VICINITY.
Remove rear bumper cover and beam. Refer to <<76.22.77>> and <<76.22.27>>.
Installation
1 2012-07-22
1999 XK RANGE - Bumpers - 501-19
2. Fit rear bumper beam and cover. Refer to <<76.22.27>> and <<76.22.77>>.
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
Torques
Component Nm
Front seat buckle 34 - 46
Rear seat buckle 60 - 80
Coupe pillar loop nut 30 - 40
Pre-tensioner arming pin 7 - 10
Webbing guide bracket 7 - 10
Pre-tensioner top mounting 7 - 10
Seat belt pretensioner to B post lower securing bolt. 34-46
Seat belt pretensioner to B post upper securing bolt. 7-10
Front seat belt inertia reel securing bolt 36-46
Rear seat belt inertia reel securing bolt. 34-46
Seat belt guide bracket securing bolts. 7-10
Front seat belt height adjuster securing bolts. 17-23
Front seat belt slider bar securing bolt. 34-46
1 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
Each front seat belt is in color-keyed webbing with plastic moulding on the running loop and tongue and has three
anchorage points. The front seat belts are common to both coupe and convertible models. Differing top fittings are
selected and fitted as appropriate on installation. The coupe also has a manual, four position, belt shoulder height
adjuster installed in each 'B' post. On each model, the front belts are also left- and right-handed.
Rear passenger entry and exit is aided by slider bar outboard lower mountings and each belt buckle is secured to a
moving inboard seat rail by a strap that enables the seat to be moved without adjustment or removal of the belt. Visual
and audible warnings operate if the driver's seat belt is not worn when the driving seat is occupied and the ignition is
switched to position I or II.
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1999 XK RANGE - Safety Belt System - 501-20A
Two rear seat belts are dedicated to installation in the coupe or convertible, each has three anchorage points with
emergency, and where applicable, automatic locking retractors. The belt buckles, common to both models, are each
mounted on twin cables and share a single central floor anchorage. The buckle cables exit the rear seat cushion via a
tailored penetration concealed by a matching gaiter.
Coupe belt retractors are mounted on the outboard sides of the parcel shelf, with belt webbing exiting via color keyed
escutcheons in the quarter casings. Convertible belt retractors are mounted on rear seat pan behind the seat squab.
Belt webbing is routed upwards inside the seat belt tower and exits via color keyed escutcheons surmounting the rear
seat squab. The lower anchorage points, located on outboard sides of the seat pan, are common to both models. All
seat belt retractors incorporate emergency locking (ELR), which locks the retractor unit under rapid deceleration of
the vehicle. At all other times the wearer is free to move the upper torso.
Automatic locking retractor (ALR) fitted for certain markets, enables a child seat to be secured by any passenger seat
belt. When adjusted with all slack removed, the ALR locks, preventing further belt extraction. Unclipping of the buckle
allows the belt to return to the normal stowed position and revert to ELR operation. For some markets, child seat
anchorage points are located on the body.
Each front seat belt has a pyrotechnic device with independent mechanical sensing and pre-tensioning retractor unit,
installed at the base of the 'B' post. In the event of severe frontal impact, this provides additional occupant protection
by removing any excess slack from the seat belt. Seat belt pre-tensioning activates when a frontal impact of sufficient
force occurs within 30 degrees of vehicle center line. Under such an impact, mechanical sensors in the retractor unit
fire, igniting the pre-tensioner gas generator. The gas generator initiates a chemical reaction, producing gases under
pressure. Gas pressure drives the piston/cable up a tube, rotating the retractor spindle and removing excess slack
from the seat belt. The mechanical sensor is made live by screwing the arming pin in to fully depress the red arming
button.
The pre-tensioning system can only be activated if a safety lever is re-set by fitting the associated belt to an occupant
or child seat. When the pre-tensioner unit has been activated, the seat belt will lock and cannot be retracted or pulled
from the reel.
No attempt must be made to dismantle a retractor unit as unactivated pre-tensioning components contain a solid,
flammable material. There are no serviceable parts. If a pre-tensioning unit is inadvertently ruptured and ingestion or
inhalation of the propellant occurs, first aid must be applied and medical advice sought.
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
When handling the piston housing, the piston must be pointed downwards and away from one's self and other
personnel. Fingers must be kept away from the take-up spool mechanism.
Any unit dropped from a height greater than 0.3 m (12 inches) must not be fitted to a vehicle.
If a seat belt pre-tensioner activates, a small quantity (less than 1 liter) of gas is produced containing nitrogen, oxygen
and water vapor.
3 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
1 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
1. On coupe model, slacken and remove securing screw from front seat belt upper escutcheon and
remove escutcheon from rear quarter casing.
6. On coupe model release rear quarter casing fasteners and position casing for access. Refer to
<<76.13.73>>.
7. Pass seat belt anchor plates through rear quarter casing apertures and remove casing from vehicle.
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
8. Slacken and remove two bolts securing seat belt guide to B post and position belt guide along seat belt.
9. Slacken and remove seat belt pretensioner arming bolt located immediately below upper securing bolt.
3 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
10. Slacken and remove two bolts securing seat belt pretensioner assembly to B post, withdraw assembly from
B post and remove from vehicle.
Installation
4 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
3. Position seat belt guide on B post and fit and fully tighten the two securing bolts.
4. Position quarter casing in vehicle and pass seat belt anchor plate and tongue through aperture.
5 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
9. On coupe model:
Fit rear seat belt anchor plate.
Fit securing bolt to rear seat belt anchor plate.
Fit card washer to securing bolt.
Position anchor plate over bolt location and engage and fully tighten securing bolt.
Position and seat rear seat belt escutcheon to casing aperture.
Fit coat hanger hook.
10. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and
tighten three securing screws.
11. Fit rear seat squab and cushion. Refer to <<76.70.38>> and <<76.70.37>>.
6 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
1 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
1. On coupe model, slacken and remove securing screw from front seat belt upper escutcheon and
remove escutcheon from rear quarter casing.
6. On coupe model release rear quarter casing fasteners and position casing for access. Refer to
<<76.13.73>>.
7. Pass seat belt anchor plates through rear quarter casing apertures and remove casing from vehicle.
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
8. Slacken and remove two bolts securing seat belt guide to B post and position belt guide along seat belt.
9. Slacken and remove seat belt pretensioner arming bolt located immediately below upper securing bolt.
3 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
10. Slacken and remove two bolts securing seat belt pretensioner assembly to B post, withdraw assembly from
B post and remove from vehicle.
Installation
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1999 XK RANGE - Safety Belt System - 501-20A
3. Position seat belt guide on B post and fit and fully tighten the two securing bolts.
4. Position quarter casing in vehicle and pass seat belt anchor plate and tongue through aperture.
5 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
9. On coupe model:
Fit rear seat belt anchor plate.
Fit securing bolt to rear seat belt anchor plate.
Fit card washer to securing bolt.
Position anchor plate over bolt location and engage and fully tighten securing bolt.
Position and seat rear seat belt escutcheon to casing aperture.
Fit coat hanger hook.
10. On convertible model, position rear quarter capping, secure to 'B' post extension with fastener and fit and
tighten three securing screws.
11. Fit rear seat squab and cushion. Refer to <<76.70.38>> and <<76.70.37>>.
6 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
1. Remove rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
3. Remove and position rear quarter casing for access. Refer to <<76.13.73>>.
5. Slacken and remove seat belt lower anchor plate to seatpan securing bolt.
6. Remove escutcheon from rear quarter casing and pass belt through gap in lower half.
1 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
7. Slacken and remove inertia reel to parcel shelf panel securing bolt and remove belt and inertia reel assembly
from vehicle.
Installation
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
5. Fit escutcheon over belt and press firmly into casing aperture.
7. Fit rear seat cushion and squab. Refer to <<76.70.37>> and <<76.70.38>>.
3 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
4. Slacken and remove seat belt lower anchor plate to seatpan securing bolt.
1 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
5. Slacken and remove seat belt inertia reel to squab panel securing bolt.
6. Pass seat belt lower anchor plate and tongue over belt guide on squab panel and remove belt and inertia reel
from vehicle.
Installation
1. Position inertia reel at seat squab panel anchorage point, ensuring that dowel correctly locates in reel housing.
2. Fit and tighten inertia reel to seat squab panel securing bolt.
3. Route seat belt lower anchor plate and tongue up belt tower and over guide.
2 2012-07-22
1999 XK RANGE - Safety Belt System - 501-20A
5. Fit escutcheon over belt, position at top of squab and fit and tighten two securing screws.
3 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Torques
Component Nm
Front seat buckle 34 - 46
Rear seat buckle 60 - 80
Coupe pillar loop nut 30 - 40
Pre-tensioner arming pin 7 - 10
Webbing guide bracket 7 - 10
Pre-tensioner top mounting 7 - 10
Seat belt pretensioner to B post lower securing bolt. 34-46
Seat belt pretensioner to B post upper securing bolt. 7-10
Front seat belt inertia reel securing bolt 36-46
Rear seat belt inertia reel securing bolt. 34-46
Seat belt guide bracket securing bolts. 7-10
Front seat belt height adjuster securing bolts. 17-23
Front seat belt slider bar securing bolt. 34-46
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Airbag/SRS units provided for driver and front seat passenger, are installed in the center of the steering wheel and the
passenger side fascia respectively.
The control module(ECU) with integral safing sensor and diagnostic capability is installed by the RH 'A' post. The ECU
also incorporates independent back-up battery power supplies to ensure airbag deployment in the event of loss of
main battery power in a crash. Two primary crash sensors hardwired to the airbags, are fitted forward of the radiator,
inboard of the headlamps. Electronic extension of the primary sensors (dwell enhancement) incorporated in the ECU,
maintains deployment circuitry in the event of loss of primary sensor signals. A disarm feature also incorporated in the
ECU, isolates deployment power from the airbag system until a primary sensor closes. The airbag system will only be
activated when the ignition switch is in position II or III and the air bags will only deploy if at least one primary sensor
and the safing sensor are made.
Before any airbag/SRS service is performed, at least one minute must elapse after disconnection of the battery
positive cable, to allow dissipation of back-up power supply energy.
The airbag/SRS system ECU continuously monitors all system components and wiring connections for faults. If a fault
occurs in the airbag/SRS readiness indication line, a code written into the non-volatile memory of the ECU is
transmitted to the system cluster to display a continuous LED warning. In the event of a further fault being detected
during this condition, an audible tone comprising five sets of five bleeps will sound. The readiness indicator line fault
must be corrected before fault codes can be determined.
If a fault creates a risk of spurious airbag/SRS deployment, the ECU will attempt to remove deployment power by
rupturing the 10A battery fuse via a solid state switch. To aid fault diagnosis, the ECU will not rupture the fuse again
until the fault is rectified and cleared. The 10A battery fuse must not be renewed until the airbag/SRS system has
been de-activated. The fuse (F4) is located in the fuse-box at the driver's end of the fascia.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Removal WARNING:
BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER
DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER
SUPPLY ENERGY.
WARNING:
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE
FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE
AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE
USED, AS THIS CAN CAUSE DISARM FAILURE.
1. Turn ignition key to position II, power passenger's seat fully rearwards and turn ignition key to position O.
2. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
6. Detach fascia harness fasteners from fascia RH end panel and reposition harness for access.
2 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
8. Remove fascia harness to cabin harness multiplugs from mounting bracket and reposition for access.
Installation
6. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
3 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
1. Turn ignition key to position II, power driver's seat to fully rearward position and turn ignition key to O.
2. WARNING:
BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE
AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF
BACK-UP POWER SUPPLY ENERGY.
WARNING:
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE
FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL
THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST
NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
5. Detach fascia harness fasteners from fascia end panel and reposition harness for access.
2 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
7. Remove fascia harness to forward harness multiplugs from mounting bracket and reposition for access.
Installation
3 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
4 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Removal WARNING:
BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE AFTER
DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF BACK-UP POWER
SUPPLY ENERGY.
WARNING:
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE
FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE
AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE
USED, AS THIS CAN CAUSE DISARM FAILURE.
1. Open hood.
3. Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
4. Remove air bag sensor harness from mounting bracket and disconnect multiplug.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
5. Slacken and remove three bolts securing the sensor to the BIW front cross member and remove the sensor
from the vehicle.
Installation
1. Position sensor on BIW cross member and fit and tighten the three securing bolts.
3. Close hood.
4. Connect ground cable to battery terminal and fit cover to battery. Refer to <<86.15.15>>.
2 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
1. WARNING:
BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE
AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF
BACK-UP POWER SUPPLY ENERGY.
WARNING:
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE (F4 LOCATED IN THE
FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL
THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST
NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
WARNING:
FOLLOWING TEN YEARS IN SERVICE, AN AIR BAG ASSEMBLY MUST BE REMOVED AND
DISPOSED OF IN THE APPROVED MANNER AND A NEW AIR BAG MUST BE INSTALLED
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
3. WARNING:
AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE
ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
Remove air bag module from steering wheel.
1. Carefully withdraw airbag module from steering wheel and position for access.
2. Disconnect air bag module harness multiplug and remove air bag module from vehicle.
Installation
3. Turn steering wheel 90 degrees to right and partially tighten module RH securing bolt.
4. Turn steering wheel 90 degrees to left and partially tighten module LH securing bolt.
5. Repeat steps 3 and 4 to fully tighten securing bolts and return steering wheel to central position.
6. Fit ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
2 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
1. WARNING:
BEFORE ANY AIRBAG/SRS SERVICE IS PERFORMED, AT LEAST ONE MINUTE MUST ELAPSE
AFTER DISCONNECTION OF THE BATTERY POSITIVE CABLE, TO ALLOW DISSIPATION OF
BACK-UP POWER SUPPLY ENERGY.
WARNING:
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE(F4 LOCATED IN THE
FUSE-BOX AT THE DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL
THE AIRBAG/SRS SYSTEM HAS BEEN DE-ACTIVATED. FUSES OF ANY OTHER VALUE MUST
NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
WARNING:
FOLLOWING TEN YEARS IN SERVICE, AN AIR BAG ASSEMBLY MUST BE REMOVED AND
DISPOSED OF AND A NEW AIR BAG MUST BE INSTALLED.
WARNING:
AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE
ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
Remove battery cover and disconnect ground cable from battery terminal. Refer to <<86.15.19>>.
3. Remove deployment door from mounting clips and position for access.
1 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
4. Slacken, remove and discard two bolts securing air bag module to fascia.
5. Slacken and remove the four deployment door mounting bracket securing bolts and partially withdraw bracket
for access.
2 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
6. Remove air bag module multiplug from mounting bracket and disconnect multiplug.
7. Slacken, remove and discard two lower bolts securing air bag module tether bracket to fascia.
3 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
8. WARNING:
AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG MODULE IS BEING RENEWED, THE
ORIGINAL UNIT MUST BE DISPOSED OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
Withdraw air bag module and remove from vehicle.
9. Slacken, remove and discard two bolts securing air bag tether bracket to air bag module.
4 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
Installation
1. Position air bag module on tether bracket and fit and tighten two new securing bolts.
2. Position air bag module and deployment door mounting bracket in fascia.
3. Fit and tighten two new bolts securing air bag module and tether bracket to lower fascia, connect multiplug
and fit to bracket.
5 2012-07-22
1999 XK RANGE - Supplemental Restraint System - 501-20B
4. Fit and tighten four bolts securing door mounting bracket to fascia.
5. Fit and tighten two new bolts securing air bag module to fascia.
8. Connect ground cable to battery terminal and fit battery cover. Refer to <<86.15.15>>.
6 2012-07-22
1999 XK RANGE - Body Repairs - General Information - 501-25
Body Repairs
The body is pre-treated to ensure high resistance to corrosion and stone chip damage. Prior to the first major
pre-treatment process, the body shell is high-pressure washed to remove any metal dust and residual oil.
The first major pre-treatment process consists of phosphate and electro-paint deposition, which together with zinc
coating, forms the basis of the corrosion protection. This process includes high pressure knock-off, alkali de-greasing,
zinc phosphate conversion of body steel (dissolving iron and coating with zinc phosphate crystals), trivalent chrome
rinsing and demineralized water rinsing, sealing all chemicals and impurities.
Both dip and spray techniques are employed and the bodies are submerged to the waistline during the first and third
rinses of the main phosphate clean. Chemical strengths and solution temperatures are continuously monitored and
accurately controlled throughout the process.
An 80% water primer is then cathodic electro-deposition applied to the thoroughly cleansed bodies in a uniform
'sag-free' film 18 to 32 micron thick. Optimum durability of the electroprimer is achieved by finally curing in a stoving
oven at 165 °C for a period of 20 minutes.
All underbody seams of the fully primed bodies are then manually sealed, to prevent water and dust ingress into the
vehicle and to enhance corrosion protection.
A semi-automatic airless spray application of a PVC coating 800 to 1000 g/m2, is applied to the underside of the main
floor panels, trunk floor and rear wheel arches (ref. illustration above).
The upper panels of primed and externally sealed bodyshells are next lightly scuffed to remove imperfections and a
PVC coating is applied to all internal seams by an airless spray technique. A PVC bead seal is also applied to the
doors, hood and trunk clinch joints.
Following anti-corrosion, sealing and priming treatment, the bodies enter the first stage of 'cosmetic' painting. This
consists of the application of two coats of a highly chip resistant polyester surfacer, employing high voltage
electrostatic 'spinning bells', to achieve a final film thickness of 35 to 50 micron. Between surfacer coats, a
polyurethane coat is automatically applied to the sills to impart even greater resistance to stone chipping.
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All interior panels are then painted using a color keyed sealer, wet-on-wet with a surfacer material, after which the
bodyshells are stoved at 160 °C for a period of 20 minutes. Further protection against corrosion is provided by a
medium solids black pigmented wax which is airless spray applied to vehicle undersides.
Critical body box-sections are similarly protected by spray injecting a high solids wax. This is then re-flowed at 70 to
90 °C to achieve optimum seam/joint penetration and form a resilient and durable internal coating (ref. illustration
above).
After full wet sanding, rinsing and drying to provide a good substrate, a color-keyed semi-matt sealer coat is applied
using electrostatic bells to achieve a film build of 25 to 35 micron. The bodies are then stoved for a further 20 minutes
at a temperature of 145 °C and subjected to a local 'seek-and-find' de-nib operation prior to the final two coat
process. The final top coat finish is achieved by using polyester base coat colors and an acrylic sag resistant clear
coat. This clear over base (COB) process produces a high gloss, durable paint finish with a film thickness of 50 to 65
micron, which is finally cured at a temperature of 135 °C for 20 minutes.
The Munsell three dimensional system of color management is employed to achieve highly accurate control of vehicle
colors. This system ensures that paint pigmentations are accurately maintained and facilitates vigorous final checking
of finished vehicles for color match. The hue of individual panels such as trunk lids, doors and hoods is in some
instances adjusted to offset the effects of differing light angles. Where applicable, coachlines are manually applied and
radiant heat cured on the completed and valeted vehicle prior to hand spray application of a protective wax coat.
Introduction
All repairs, whether structural or cosmetic must return the vehicle to the original manufactured condition with regard to
occupant safety, dimensional accuracy, finish and corrosion protection, and ensure continuation of the Paint Surface
and Corrosion warranty where applicable.
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Similarly, repaired vehicles must be fully checked, and where appropriate reset, with regard to steering, suspension,
braking, and occupant restraint systems.
It is the duty of both employer and employee to ensure safe working conditions and practices. Correct safety
procedures and equipment must be applied to any potential hazards that are notified, or identified by an operator.
Employees must observe local legislation governing working conditions and practices at all times and must always act
in a responsible manner in the workplace. In the event of personal injury resulting from any workshop activity, medical
help should be obtained as soon as possible. Self-treatment other than by first aid, should not be attempted.
WARNING:
READ AND UNDERSTAND WORKING PRACTICES CONCERNING CLIMATE CONTROL SYSTEMS,
SECTION 412, WITH SPECIAL REGARD TO: REFRIGERANT MUST NEVER BE DIRECTLY VENTED TO
ATMOSPHERE. ALWAYS USE JAGUAR APPROVED RECOVERY / RECYCLE / RECHARGE EQUIPMENT,
WEAR SUITABLE EYE AND SKIN PROTECTION AND OBSERVE ALL APPLICABLE SAFETY
REQUIREMENTS.
With the constant introduction of new materials in the manufacture of vehicles, an awareness of the potential risks and
appropriate precautions is important.
Notification of Hazards
Symbols, which convey important information, will be positioned at the beginning of any specific operation or text.
Standard symbols will be used where repairs or service procedures are detailed. All symbols will conform to standard
ANSI Z535.3 (American National Standards Institute). The surround shape of the symbol will indicate the basis of the
message to be conveyed (see top three elements of ?) The icon depicting the message will be within the surrounding
shape. Once nominated the icon will retain its meaning.
POTENTIAL RISKS
Paint
Organic solvents, found in paints, may cause damage or severe irritation to liver, kidneys, digestive tracts and
respiratory system if inhaled over long periods of time. Prolonged exposure to isocyanates can cause lung
sensitization with asthma-like symptoms developing on subsequent exposure to even low concentrations of
isocyanates. Solvent inhalation can cause dizziness or loss of consciousness and inhalation of spray dust and sanding
debris may cause lung damage.
Spillage or splashes of solvents, paint activators and additives can cause dermatitis or eye injury. Contact with
peroxide or acid catalysts can cause serious burns.
When heated to a temperature of 300°C, polyurethane based compounds may liberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products which can contain isocyanates,
oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases produced when welding include zinc oxide from zinc coated panels,
and ozone gas from the MIG process.
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Metal Repair
There is considerable risk of damage to eyes, ears and skin when cutting, forming, or dressing metal. Soldering
operations can also be hazardous due to heat generated fumes and the risk of skin contact with hot materials.
PRECAUTIONS
Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided.
Ensure that there is efficient ventilation / extraction at all times. Paint spraying should be confined as far as possible to
spray booths. Personnel with a history of asthma should not be employed in any process involving the use of
isocyanates. Operators working in a spray booth where isocyanate material is present must use air-fed breathing
equipment with air supplied to the visor at the recommended pressure and filtered to remove oil, water, and fumes.
Operators involved in handling mixing or spraying should wear protective clothing including gloves and goggles, to
avoid skin and eye contact. Particle masks or canister type respiratosr should be worn when sanding.
Applied Heat
When welding, flame cutting, brazing etc, the operator should use as appropriate, goggles, mask / fume extractor and
flameproof protective clothing. It is especially important when working with polyurethane compounds to use air-fed
breathing equipment. Appropriate fire fighting equipment and personnel trained in its use must always be available.
Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding. Face
masks or air-fed visors should also be worn when sanding or flatting either body solder or fillers. On completion of a
soldering operation, swarf must be removed from the work area and the operator must wash his hands thoroughly.
The following advice should be noted before any repair work is carried out.
Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take note of
the reconnection procedures as detailed in <<86.15.15>>.
Where structural parts are straightened or renewed, a body alignment / straightening jig must be used. The application
of heat, especially excessive heat, reduces the strength of steels, where appropriate therefore, structural sections
should be straightened by cold processes.
Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts and
Jaguar approved materials are used.
The correct tools, procedures and facilities must always be used. The quality of the work must not be compromised
by using inappropriate methods or equipment.
All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel removal
/ replacement; this is especially important where hollow sections may contain harnesses, tubes or foam, see section
A4.3.5.
WARNING:
DO NOT WORK IN THE VICINITY OF A LIVE AIR BAG. ALWAYS DISCONNECT THE GROUND CABLE
FROM THE BATTERY TERMINAL FIRST. NOTE WORKING PRACTICES FOR AIR BAGS IN SECTION 20.
ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED.
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CAUTION:
Electric arc welding should not be used on Jaguar vehicles. The high voltages produced by this process will
cause irreparable damage to the electrical control and microprocessor systems.
The following welding and gas processes are the only ones recommended by Jaguar Cars Ltd.
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated
metal.
The flanges of panels to be welded together, must be clean, corrosion free and treated as appropriate, with either
weld-through primer or inter-weld sealer. Only materials and processes specified in the 'Body Sealing and
Preservation Manual' should be used in the relevant application areas detailed in this section. Refer to 'Zinc Coated
Panels' Section
Generally, resistance spot welding equipment used in the motor vehicle repair industry does not produce welds of
equivalent strength to those achieved during manufacture. The expression 'single row of resistance spot welds'
indicates that the spots should be spaced on a pitch of 19mm to 25mm, which normally results in more spot welds
than those produced in the original factory joint.
Resistance spot welds should be removed using a resistance spot weld cutter. If the new joint is to be MIG plug
welded, old resistance spot welds should be cut from the panel to be retained and the resulting holes used for plug
welding. Suitable holes may also be drilled or punched; 8,0 mm dia for sections up to 1,6 mm, and 10,0 mm dia for
thicker sections.
PLASTICS-EXPLANATORY NOTES
This table, in conjunction with the illustrations on the following pages will enable rapid identification of the particular
material of any major plastic part.
NOTE:
Only those components suitable for economic reclamation are identified.
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The exterior panel temperature of a vehicle must not exceed 95°C at any time and may only be held at this level for a
maximum of two hours. Similarly, interior vehicle temperature must be limited to 86°C for a maximum duration of two
hours. Exposure to temperatures above those specified may result in distorted or permanently damaged components.
If there is doubt concerning temperature limitations, components that may be adversely affected by exposure to heat
should be removed from the vehicle.
Plastic components that become greasy may be cleaned with an 'SBP 3' spirit wipe, or equivalent.
Recycled Materials
Any of the materials listed in this section, may be recycled provided that they are not contaminated by other
incompatible plastics or metals. For instance, the air conditioning unit case, manufactured from PP (polypropylene),
must be separated from the heater matrix, evaporator, control devices (electronic and mechanical) and all fixings
before it can be considered for recycling. After removal, the case must only be placed for disposal with materials of
the same generic type. Bumper cover assemblies similarly have side armatures of dissimilar materials rivetted to
them, these together with their fixings must be removed prior to recycling. Components manufactured from 'blended'
materials must not be recycled with pure materials. For example do not mix PC/ABS (wheel trim) with ABS ('B' pillar
upper trim).
Body Structure
Introduction
The Jaguar XK8 has a unit construction monocoque body structure with bolt-on front fenders and welded rear fenders.
The door and rear quarter glass are of frameless drop-glass design.
Material Application
High strength low alloy Impact prone areas, ie. seat frame and bumper mountings.
(HLSA).
Double sided zinc plated mild Exterior body panels subject to severe conditions such as stone chipping and
steel. weather exposure (excluding roof panel).
Boron steel. Door intrusion beams
Mild steel. Internal brackets, fillets and strengtheners.
Bake-hardened steel. For increased panel stiffness. e.g. front longitudinals.
BODY ALIGNMENT
The Body Dimensions Plan and Side, Front and Rear views, provide specified body dimensions to facilitate damage
assessment and location of replacement parts. These dimensions must be strictly applied when used for damage
assessment, component location or post repair verification.
NOTE:
The right-hand side is always looking towards the front, from the rear of the vehicle.
The nominated plan view master datums are on the right-hand side of the body with the left-hand datums dimensioned
from them. Right-hand datums must therefore be known to be correct before any other cross-car dimensions are
checked.
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The Front Master Datum (hole in front RH longitudinal to right of crossbeam front mounting) is nominally 440,07mm to
the right-hand side of the body center line. The LH side front datum is measured 879,14/ 881,14mm from the RH.
Refer to the Body Dimensions Plan.
Expressed as a true position in three planes, the centre line of the front master body location is:
Location Position
Centre line of the master body location hole (31mm dia). X 636,58
Y 440,07
Z 1,6
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Key Location
1 Transit skid
2 Jacking plate centres
3 Master body location hole
4 Master jig location rear
5 To LH location
6 For reference
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Body Dimensions- Front and Rear Views
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Key Location
1 Jacking plates
2 Reference
Description
Approximately 70% of the 'body in white' (body) mass is made up of zinc coated panels.
NOTE:
To maintain the protective qualities of the zinc treatment, repairs to any damaged coated area must be made as
soon as possible after the damage has occurred.
All exterior skin panels, with the exception of the roof, are double side zinc plated and this coating (nominally 7,5
microns) provides two way corrosion protection. Should the outer layer of paint become chipped with the zinc coating
remain intact, the zinc will oxidize on contact with air and being impermeable, this coat of oxidation will prevent
corrosion damage of the base metal. If the outer layer of paint and the zinc coating become damaged, the zinc rather
than the base metal will react with the air and 'sacrifice' itself to corrosion as a 'sacrificial anode'.
Welding Preparation
Contamination of the weld with resultant reduction in joint strength increase and increased electrode tip dressing
frequency will occur zinc coating is not removed. In exceptional cases where the zinc coating must remain intact, the
tip pressure and welding current should be increased by 10 to 20%.
Where 'resistance spot welding' is employed, the zinc coating should be lightly abraded away on the mating surfaces
and those in contact with the electrode tips. Do not remove more zinc coating than is absolutely necessary.
Before welding, a weld-through primer or inter-weld sealer should be applied, as detailed in the Body Sealing and
Preservation manual.
Where MIG welding is used as an alternative to resistance spot welding for plug and butt welds or due to limited
access, the problems caused by the presence of zinc coating are much the same, with the added complication of
increased weld spatter and nozzle contamination.
Body Fillers
Conventional polyester fillers do not adhere satisfactorily to zinc plated panels, it is therefore important that only those
products specifically designed for this application are used and the manufacturer's recommendations are followed.
Refinishing
Only use products approved by Jaguar Cars Ltd and exercise special care on zinc coated panels.
Replacement panels are supplied ready primed and only those areas to be welded etc should have bare metal
exposed as decribed in 'Welding Preparation. Where any part of a panel is dressed back to the bare surface, it should
be treated with a zinc rich primer compatible with the paint application system.
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NOTE:
Where other components must be removed for access, refer to the relevant manual section for guidance. This is
particularly important where steering, braking, suspension, electrical and safety systems are affected.
Expose all resistance spot welds, using a rotary wire brush fitted to an air drill or a hand held wire brush on those that
are not clearly visible (1).
WARNING:
DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
Cut out spot welds using a Zipcutter or Roto-Bor (2). At this point it may be necessary to cut out the bulk of the panel
using a pneumatic saw (3).
NOTE:
On some panels, before removing the bulk with a pneumatic saw, it may be necessary to remove brazed areas
and MIG welded seams. Separate spot welded joints and remove the panel remnants.
WARNING:
DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
NOTE:
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Remove weld nuggets with a sander and 36 grit disc and clean all flanges to a bright smooth finish (1). Straighten
existing panel joint edges as required.
Mark off the area of new panel and cut to size leaving approximately two inches overlap on the existing panel. Offer
up new panel or section, align with associated parts, i.e. new rear fender aligned with door / luggage compartment lid
/ backlight aperture and clamp the panel into position.Where necessary, cut the new and original panels to form a butt
joint.
Release all clamps and remove the new panel. If required, apply inner panel protection and or sound insulation.
Prepare the new panel joint edges, including interior and exterior, for welding by cleaning to bright metal (1).
Apply weld-through primer or interweld sealer(2) to all surfaces to be resistance spot welded.
Where appropriate, apply metal-to-metal adhesive or sealer (3) in accordance with the manufacturer's instructions.
NOTE:
Observe all appropriate safety procedures.
Align the replacement panel with adjacent panels, secure with clamps, MIG tack welds or self tapping screws. Finally
check panel alignment and contours and re-adjust as necessary.
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Select the correct 'arms' for resistance spot welding and ensure that tips are correctly trimmed.
NOTE:
It is recommended that 'arms' of not more than 300 mm (12 in.) long are used and the equipment is tested for
satisfactory operation by producing test samples (2). In the absence of test equipment, a satisfactory weld can
be verified by pulling the test samples apart and viewing the weld condition.
Prepare zinc coated panels as detailed in this section and resistance spot weld where required (3).
Dress back all tack welds, then MIG seam-weld the butt joints (4). Finally dress all welds as necessary and final
braze and fill prior to paint preparation.
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Cutting andWelding Symbols
CAUTION:
Reference should always be made to the welding tables and illustrations in the relevant procedures. Observe
all safety precautions with respect to yourself, other people, your equipment and the workplace.
1. Saw Cut
2. Chisel Cut
3. Cut out Spot Weld
4. Resistance Spot Weld
5. MIG Tack Weld
6. MIG Seam/Butt Weld
7. Braze
8. Gas Weld
9. MIG Plug Weld
NOTE:
Cavity wax processes should only be applied on completion of all other refinishing and protection procedures.
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BODY UNDERSEAL
Underseal Application
CAUTION:
Do not apply underseal to hot or rotating components.
Underseal should be applied as indicated by the hatching and omitted from areas indicated in solid black.
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The manufacturer's paint systems listed below are currently approved for refinishing Jaguar vehicles.
NOTE:
* Not available in certain markets but alternatives may be used, provided that they comply with the following
company standards.
Manufacturer Bare metal etch Primer surfacer Base color coat Clear lacquer
primer
Akzo Washprimer Autocryl / Autobase Autoclear 1000 -
Sikkens Autonova 3000 Automat
Dupont Centari 600* Centari 600*
Glasurit Wash Etch+ System 54 Clear lacquer
(solid/metallic) 923-85
System 56
(micatallic)
System 59 and 69
(pearl)
Herberts Metal pre-treatment and Standox Basislak Standox Clearlak
rust remover 301.2595
ICI Autocolor
PPG Galvaprep D840 Wash primer D831 Deltron HS 2 Deltron Concept
Hi-build primer 2001 HS clear
D855 D880
Epoxy surfacer
DP40
Deltron / non
Isocyanate Primer
D828
R-M Eurofill R-M Prof / Maxfill Diamont Diamont
Basecoat Clearcoat
CAUTION:
To avoid damage to the vehicle interior, trim and plastic items, effective panel temperature must not exceed
95°C during paint cure process.
OBSCURATION BANDS
NOTE:
This process is not required on dark colored vehicles.
Unsightly areas visible between panels, through gaps and under bonded glass are masked by applying matt black
paint with heat resistance of 40° to 120°C.
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ANTI-THEFT LABELS
Original Components
On North American specification vehicles, the VIN is marked on all major external panels, certain structural members
and power / transmission units. The labels carrying this information are known as 'Label-Anti-theft VIN (USA body
panel only)' or 'Label-Anti-theft-Engine and Gearbox (U.S.A. only),' drawing reference A .
Replacement Components
Only genuine Jaguar replacement parts must be used in the repair of a vehicle. Furthermore, any new parts replacing
items carrying a VIN label must have either 'Label-Anti-theft Replacement Part (USA body panel only)' or
'Label-Anti-theft Replacement Part-Engine and Gearbox (U.S.A. only),' drawing reference B , fitted in a different
location to the previous label.
A protective mask used to prevent the replacement part label from being damaged or obscured during the refinishing /
protection processes, must be removed prior to customer hand-over.
Procurement
Product Compliance Dept., Jaguar Inc., 555 MacArthur Blvd., Mahwah NJ 07430
CAUTION:
It is a requirement of United States of America federal law that the protective mask is removed from all
anti-theft labels after performing painting and rustproofing operations. Failure to comply with this
requirement may render both the manufacturer and the dealer in violation of the law.
NOTE:
Any attempt to remove an anti-theft label will destroy that label. Ensure correct location before affixing.
Using a suitable solvent clean the area where the anti-theft label is to be affixed. Peel the backing from the label and
position on the panel. Carry out all refinishing / protection processes. Remove the anti-theft label protective mask prior
to vehicle handover to the customer.
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GLAZING
In order that the design condition of the vehicle is preserved when direct glazing repairs are carried out, it is essential
that only approved materials and processes are employed.
Betaseal HV3 System methods and materials, are used on all Jaguar vehicles. Ease of working and extended process
time can however be gained by ensuring that the vehicle body and replacement glass are at a minimum room
temperature of 20°C prior to adhesive application and fitting.
In the event of damage to the body flange finish, rectify as appropriate with the full paint refinishing process as
described in the Paint Refinishing Manual.
The specified adhesive has a high viscosity and is not easily applied at 'room temperature' using conventional
methods. When the adhesive is applied it chills rapidly on contact with the body and reverts to the hard condition,
providing retention strength within minutes.
Raising the temperature of the adhesive will reduce viscosity and speed up the flow. It is recommended that the
adhesive is pre-warmed in a heated cabinet for a minimum of twenty minutes and applied with an extrusion gun
incorporating integral heating elements.
Adhesive Application
CAUTION:
The glass will not bond to the body if the time taken to apply the adhesive and position the glass, exceeds
the stated limit.
NOTE:
The depth of the glass and thus the thickness of the adhesive, is controlled by the screen rubber contacting the
body flange.
It is recommended that the bead of adhesive conforms to the shape and dimensions shown in the Adhesive
Application illustration and is positioned along the edge of the rubber.
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Adhesive Application
1 Fitted condition
2 Bead application
Adhesive Curing
The specified adhesive cures by exposure to moisture (not by heat). Cure times may vary considerably dependent
upon ambient humidity levels. Initial 'chill off' will occur within 1 to 4 minutes ( dependent upon the application
temperature and rate of cooling), after which the screen must not be moved.
BUMPER REPAIR\RENEWAL
Bumper Description
Each bumper comprises a beam mounted to the body via two strut assemblies and a moulded polypropylene cover
incorporating side armatures and chrome plated plastic upper trims. The front bumper cover which is moulded to form
a lower air intake for the cooling pack, also incorporates twin fog lamps, and side marker lamps or reflectors
(dependent upon market). A plastic undertray secured to the lower edge of the front bumper and the body improves
airflow and minimises the ingress of road grime in that area. Standard bumpers have glass mat thermoplastic (GMT)
beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy
absorbing struts.
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Bumper Cover Repair
Prior to commencing any work, bumper damage should be assessed for repairability and categorized in accordance
with the following guidelines. Bumper covers that are torn or holed are not repairable and must be discarded.
CAUTION:
Cosmetic appearance must not jeopardise safety. No attempt must be made to repair bumper covers
damaged beyond category three. Damage of this extent will compromise the protective performance of the
cover and it must be renewed. The thermo-setting nature of the cover material, precludes the repair of splits
by heat or welding techniques.
Category Damage
Cosmetic Abrasion to surface paint finish only
Substrate surface Deep scratches, gouges or localized radial stress cracks.
Substrate penetration Splits not exceeding 100mm. Splits radiating from a gouge and accompanied by
localized stress cracks.
Repair Materials
Repair of accepted damage for categories 2 and 3 may be carried out using 3M '5900 FPRM' (Flexible part repair
material) or Kent Industries 'Urepatch'. Repair product manufacturers' recommendations and procedures must always
be strictly followed.
The paint refinishing system must be approved by Jaguar Cars Ltd., and be appropriate for polyurethane substrate
application. It is essential that the finishing clear lacquer includes a plasticising ingredient (mixed to the manufacturer's
recommendation) that will achieve the 'semi-flex' condition of the factory finished item.
CAUTION:
During heat cure, the effective panel temperature must not exceed 95°C.
Exposure to heat decreases bumper cover rigidity. Covers removed for repair must therefore be supported to prevent
distortion and sagging during the paint curing process. Where the original bumper cover has been repaired, the beam
will provide sufficient support for the centre section. It is recommended that the side armatures are supported as they
would be on the vehicle. If a new cover is required, the beam may be temporarily fitted to provide the necessary
support during refinishing.
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Replacement covers are supplied in a primed condition and must be finished to match the vehicle in accordance with
the procedures included in this section..
New bumper covers and beams and replacement fixings such as bumper beam adjusters and guide blocks must be
fitted and adjusted to achieve the following alignments and clearances:
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Front Bumper to Hood Clearance
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Rear Bumper to Wheel Arch Alignment
The aluminium bumper beams fitted for some markets, should not be over-looked as components suitable for
recycling.
Replacement bumper cover assemblies includer side armatures, which should be removed from discarded bumper
assemblies and routed for recycling.
When any panel, closure or body component is renewed, refitted or reset, the specified clearances and alignments
must be restored. This ensures that vehicle appearance and operation fully satisfy design intent and the customer.
Clearances
Gaps should be uniform around body panel contours and must be parallel to within 1mm in a 400mm linear
measurement. Panels centered between two adjacent panels must have equal gaps on either side. For exceptions to
this, refer to the appropriate specification. Gaps between adjacent panels or components must not expose harnesses,
labels, brackets or visually poor joint or assembly conditions.
NOTE:
Sliding roof panel clearances are specified without the edge seal installed.
Areas of particular concern are, fuel filler flap, trunk lid to fenders and saddle panels, hood to fenders, grill and
headlamps, sliding roof to main roof panel, door gaps at fenders, B\C posts, roof drip rail and rocker panel, and
bumper cover to fenders and cross car assemblies
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Alignment
Panels must be correctly profiled to maintain cosmetic appearance, and ensure correct seating of seals with minimal
wind noise. Areas of particular concern are hood to fenders , trunk lid to fenders and saddle panels, doors to
apertures, doors to fenders and adjacent doors and relationship of the sliding roof panel leading and trailing edges to
the main roof panel.
Exterior Fitments
Bezels, trims and lamps must be concentric with apertures and have equal clearances with adjacent panels.
Areas of particular concern are headlamp to hood, fender and trim panel, exhaust tailpipe trim to bumper cover
cut-out, rear lamp assembly to trunk lid, fender and bumper cover trim, and side feature lines including body side
mouldings, fender to door and door to door.
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Removal 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. See section <<100-00>> for
information.
CAUTION:
Do not attempt to weld or repair the aluminum crossbeam. If it is damaged, a new one must be installed.
3. Open engine compartment to service position, and fit paintwork protection covers to fenders.
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7. Remove undertray.
1. Remove and discard eight scrivets.
2. Remove three screws.
3. Remove undertray.
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18. NOTE:
Make sure steering is in the central position.
19. CAUTION:
To prevent damage to the crossbeam, place a piece of wood between the jack and crossbeam.
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22. CAUTION:
Do not allow the weight of the hub assembly to hang on the ball-joints. Support the weight of the
hubs before releasing the shock absorbers.
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30. CAUTION:
Note the position of the fulcrum bolts, as some vehicles are fitted with an eccentric bolt to the rear
wishbone arm. See General Procedures section <<204-01>> for information.
31. CAUTION:
For installation reference, note position of washers and shims before removing fulcrum bolt.
With assistance remove both vertical link and wishbone assemblies from crossbeam.
1. Remove nut.
2. Remove fulcrum bolt: collect washers and shims.
3. Remove vertical link and wishbone assembly.
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Installation
2. CAUTION:
Support the hub assembly. Do not allow the weight of the hub assembly to hang on the ball-joints.
With assistance, fit the vertical link and wishbone assembly to the crossbeam.
1. Align lower wishbone to crossbeam.
2. Fit nut and bolt to wishbone rear arm: DO NOT tighten at this stage.
3. Align fulcrum tie to front arm of wishbone.
4. Fit front bolt to wishbone.
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2. Fit fulcrum bolt, also fit shims and washers in positions noted in removal.
5. CAUTION:
Make sure the fulcrum bolts are fitted in their original positions as noted in removal.
6. Repeat four previous pictorial procedures to fit opposite-side wishbone and vertical link assembly.
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7. NOTE:
Make sure mounting rubbers are fully seated in stabilizer bar retaining bosses and crossbeam recesses.
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11. CAUTION:
To prevent damage to the crossbeam, place a piece of wood between the transmission jack and
crossbeam.
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14. Fit front engine mounting bolts, but DO NOT tighten at this stage.
Repeat procedure on opposite-side mounting.
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17. NOTE:
Make sure steering wheel and wheels are in the central position before fitting steering column.
18. Remove blanking plugs from PAS hoses and pinion housing ports.
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35. Connect battery ground cable. Refer to section <<414-01>>: Battery Reconnection Procedure.
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Remover/Replacer Adaptor
204-116-05 (JD 143-5)
Removal
1. 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. See
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2. Using a hydraulic press, remove front mounting bush from the crossbeam.
1. Place special tool on the press-bed, with the tool cut-outs upper most.
2. Position crossbeam on press-bed, with special tool aligned underneath bush.
3. Align special tool on top of bush.
Operate press to remove bush from crossbeam.
Installation
1. NOTE:
The bush must be in the position shown when it is fitted to the crossbeam - viewed from the top of the
crossbeam.
Invert the crossbeam and place it, onto the bed of the hydraulic press.
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2. With assistance partially press the mounting bush into the crossbeam.
1. Align bush to crossbeam.
2. Align a suitable mandrel on top of bush.
3. Operate press and partially fit bush into crossbeam.
Make sure bush is aligned correctly as shown in illustration above.
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1999 XK RANGE - Uni-Body, Subframe and Mounting System - 502-00
Removal
1. 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. See
section <<100-00>> for information.
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7. Position steering in the central position and remove ignition keys to lock steering.
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1999 XK RANGE - Uni-Body, Subframe and Mounting System - 502-00
9. NOTE:
Guide shock absorber upper mounting studs through body when raising front of vehicle.
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13. CAUTION:
To prevent damage to the crossbeam, use a wooden block between the jack and crossbeam.
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14. NOTE:
The bolt situated directly above the wishbone will remain captive.
16. CAUTION:
Take care not to damage power steering hydraulic-pipes when lowering crossbeam.
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Installation
4. Raise crossbeam.
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7. Fit front engine mounting bolts, but DO NOT tighten at this stage.
Repeat procedure on opposite-side mounting.
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9. NOTE:
Make sure steering wheel and road wheels are in the central position.
10. NOTE:
Guide shock absorber upper mountings into body apertures when lowering vehicle.
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15. Connect battery ground cable. Refer to section <<414-01>>, Battery Connection Procedure.
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1. 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. See
section <<100-00>> for information.
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4. CAUTION:
Position a piece of wood between the jack and the differential drive coupling.
Position a jack under the differential drive coupling and support the weight of axle assembly.
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Installation
1. CAUTION:
Make sure the fuel pump electrical lead does not become trapped when fitting the suspension
subframe.
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Remover/Replacer Adaptor
204-116/06 (JD143-6B)
Removal 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. See section <<100-00>> for
information.
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4. Invert subframe and position assembly on special tool 204-116-02, with subframe located in the recess.
5. CAUTION:
Ensure special tool 204-116-06 is correctly aligned and does not contact the bush housing bore.
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Installation
1. Use a coarse grade emery cloth to roughen the bush-housing bore, and mating surface of the bush.
2. Using an air line, remove residual dust from bush and housing mating surfaces.
3. Clean the bush-housing bore and bush with cleaning solvent (SPB3 Solvent 30) or equivalent.
6. NOTE:
New bushes are bonded in position using a rapid drying adhesive Application of this adhesive and fitting of
the bush must be completed within 3 minutes. It is therefore strongly recommended that the procedure is
rehearsed to ensure it can be completed within that period.
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7. Apply 'Alphabond Rapid 101' epoxy adhesive to the shaded area of the bush (as shown), and corresponding
area of the bush-housing bore.
8. CAUTION:
Bush alignment error must not exceed 5 degrees.
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12. Wipe off excess adhesive from subframe and bush, and remove masking tape.
13. NOTE:
Allow adhesive at least 30 minutes to cure, before installing subframe on vehicle.
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