2005年捷豹Jaguar XK/X100维修手册

    Published: 14-Nov-2018

    1997.0 X100, 100-00

    General, PDI and Accessory Information

    General Service Information (G222714)

    DESCRIPTION AND OPERATION
    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.

    Notes, Cautions and Warnings

    Throughout this manual, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.

    Copyright Statement

    Copyright.© Jaguar Cars Ltd. 1997.

    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.

    Workshop Manual Organization

    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.

    5. Body and Paint.

    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.

    Each section comprises one or more of the following sub-sections:

    Specification

    • 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

    • Descriptions of how to identify system problems.
    • Inspection and verification information.
    • Symptom charts comprising fault conditions, possible sources and actions.

    General Procedures

    • 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.
    Repairs and Replacements

    When service parts are required, it is essential that only genuine Jaguar/Daimler replacements are used.

    Attention is drawn to the following points concerning repairs and the fitting of replacement parts and accessories:

    • Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain territories, legislation prohibits the fitting of parts which are not produced to the vehicle manufacturer's specification.
    • Torque wrench setting figures given in this manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.
    • Owners purchasing accessories while travelling abroad should 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.
    Thread Locking Devices

    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

    JZB 10060; JZB 10061; JZB 10078.

    JZH 100027.

    JZS 100082; JZS100087; JZS 100088; JZS 100089; JZS 100090; JZS 100118; JZS 100157; JZS 100164; JZS 100166.

    NCA 1451 AA.

    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.

    Service Repair Operation Numbering

    A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd.

    Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation Times schedule. The number consists of six digits arranged in three pairs.

    Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the minimum time, as specified in the Repair Operation Times schedule for this range of vehicles.

    References to Left- and Right-Hand

    References to the left- or right-hand side of the vehicle are made as if viewing from the driver's seat.

    References to Engine Banks

    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.

    Disconnecting/Connecting the Battery

    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.

    Use of Control Modules

    Control modules may only be used on the vehicle to which they were originally fitted. Do not attempt to use or test a control module on any other vehicle.

    Functional Test

    On completion of a maintenance procedure, a thorough test should be carried out, to ensure that the relevant vehicle systems are working correctly.

    Protecting the Vehicle

    Always fit covers to protect the fenders before commencing work in the engine compartment. Cover the seats and carpets, wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid, antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use polythene sheets in the trunk to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw threads by replacing nuts or fitting caps.

    Preparation

    Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed by component removal, with tapered hardwood plugs or readily visible plastic plugs. Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts. Before dismantling a component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the materials within the component. Clean the bench and obtain marking materials, labels, containers and locking wire before dismantling a component.

    Dismantling

    Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems. Clean all tapped holes, crevices, oilways and fluid passages with compressed air. Do not permit compressed air to enter an open wound. Always use eye protection when using compressed air.

    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
    WARNINGS:

    • 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.

    • FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHYLENE. DO NOT SMOKE IN THE VICINITY OF VOLATILE DEGREASING AGENTS.

    General workshop practices:

    • Disconnect the grounded terminal of the vehicle battery.
    • Do not apply heat in an attempt to free seized nuts or fittings; as well as causing damage to protective coatings, there is a risk of damage from stray heat to electronic equipment and brake lines.
    • Keep oils and solvents away from naked flames and other sources of ignition.
    • Adhere strictly to handling and safety instructions given on containers and labels.
    • Ensure that a suitable form of fire extinguisher is conveniently located.
    • When using electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed.
    • Do not leave tools, equipment, spilt oil etc. around the work area.

    Working beneath a vehicle:

    • Whenever possible, use a ramp or pit in preference to jacking.
    • Position chocks at the wheels as well as applying the parking brake.
    • Never rely on a jack alone to support a vehicle; use axle stands, or blocks carefully placed at the jacking points, to provide a rigid location.
    • Check that any lifting equipment used has adequate capacity and is fully serviceable.

    Working on air conditioning systems:

    • 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.

    Observe these recommendations:

    • Wear protective clothing and impervious gloves when necessary.
    • Do not put oily rags in pockets. Avoid contaminating clothes, particularly underwear, with oil.
    • Overalls must be cleaned regularly; discard oil impregnated clothing and footwear which cannot be washed or cleaned.
    • First Aid treatment should be obtained immediately for open cuts or wounds.
    • Use barrier creams, applying before each work period, to enable easier removal of dirty oil and grease from the skin.
    • Wash with soap and water to ensure that all oil is removed (skin cleaner and a nail brush will help). The use of preparations containing lanolin will help to replace the natural skin oils which have been removed.
    • Do not use petrol, kerosene, gas oil, thinners or solvents for washing skin.
    • If skin disorders develop, obtain medical advice immediately.
    • Where practicable, degrease components prior to handling.
    • Where there is a risk of fluids coming into contact with the eyes, suitable eye protection should be worn - goggles or face shield. An eye wash facility should be provided.
    • Ensure that adequate ventilation is provided when volatile degreasing agents are being used.
    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.

    On-Board Diagnostics (OBD)

    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).

    OBD related information can be found in the following sections:

    • General Information
    • Engine Management System
    • Automatic Transmission
    • Anti-lock Braking System

    Where appropriate a section comprises the following sub-sections:

    Description and Operation

    • 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)

    • Recommended special tools.
    • Symptom chart; a chart containing all relevant Diagnostic Trouble Codes (DTC), their possible causes and an indication of the appropriate test.
    • Specific pinpoint test(s), designed so that fault diagnosis can be carried out in a logical and efficient manner.
    NOTE:

    For convenience, pinpoint test illustrations indicating voltage measurements do not always accurately reflect the conventional method of connecting a multimeter. More explicitly, if the multimeter probes are connected as shown in some illustrations (positive probe to ground), the voltage reading would be preceded by the negative sign '-', indicating that the probes have been connected in the reverse manner to the normal convention. The accuracy of the reading is not affected and the '-' sign can be ignored when comparing the reading with the results indicated in the text of the pinpoint test.

    Removal and Installation

    • Removal procedure(s), formatted in the recommended sequence
    • Illustrated guide to the use of special tools
    • Illustrations to support the relevant text
    • Installation procedure as above and including special recommendations for processes, lubricants and tightening torques.

    Circuit Diagrams

    To understand the relationship between the vehicle electrical system and the system circuit diagrams, refer to the appropriate Electrical Guide.

    Fault Identification (DTC)

    The diagnostic trouble codes (DTCs) are listed in Section 303-00 under Diagnostic Trouble Codes and include, where applicable, the corresponding manual section reference.

    PECUS CONFIG Error codes

    PECUS (Programmable Electronic Control Unit System) or CONFIG (Configuration) Error displayed in Instrument Pack (IPK) on Legacy Jaguar models from 1997 to 2002 model year, this error occurs when a module is not configured or the configuration is not fully completed.

    Steps required to clear PECUS or CONFIG error

    NOTES:

    • Some early XK X100 & S-Types X200 depending on model year have a VCATS (Vehicle Configuration And Test System) label attached in the boot area, these vehicles modules are ordered VIA this label and come programmed directly with the information from the label.

    • Depending on vehicle variant and model year you may see (B2477) logged in a module, and accompanied by “PECUS” or “CONFIG” error.

    • depending on vehicle variant and model year you may either a “PECUS” or “CONFIG” error within the Instrument pack.

    Error IDPECUS & CONFIG error module ID
    EEngine Control Module (ECM)
    IInstrument Pack (IPK)
    SSecurity Locking Module (SLCM)
    DDDriver Door Module (DDM)
    PDPassanger Door Module (PDM)
    RDriver Rear Door Module (DRDM)
    KPassanger Rear Door Module (PRDM)
    DDriver Seat Module (DSM)
    PPassanger Seat Module (PSM)
    GGeneric Electronic Module (GEM)
    BBody Processor Module (PBM)
    BBody Processor Module (PBM)(B2477 logged in module)
    TTransmission Control Module
    CAdaptive Cruise Control(ACC) Module
    AAnti-lock Braking System (ABS) control module

    Actions required to clear “PECUS” or “CONFIG” error:

    • Connect a Midtronic battery conditioner/power supply to the vehicle.
    • Connect SDD to the vehicle and begin a new diagnostic session, by entering the correct VIN for the current vehicle, SDD may go into Legacy mode depending on the vehicle line

    Legacy IDS mode:

    • Follow the SDD prompts to read the vehicle configuration.
    • When prompted 'Do you wish to read diagnostic trouble codes? Select 'NO' and then press 'tick' to continue.
    • When the 'Content Model' is displayed select 'Vehicle Configuration' tab.
    • Select 'Module Programming' from the 'Vehicle Configuration' menu.
    • Select from the menu 'Configure New modules'. From the drop down menu select the required module. Press 'tick' to continue.
    • Follow all on-screen instructions to complete this task.
    • When the task is completed, exit the current session.
    • Disconnect a Midtronic battery conditioner/power supply.

    SDD Mode:

    • Connect SDD to the vehicle and begin a new diagnostic session, SDD will read the correct VIN for the current vehicle.
    • Follow the SDD prompts.
    • Select 'Diagnostics' tab from the Session Type Section screen.
    • Select 'Selected symptoms'.
    • Select Electrical / Instruments / Information and message center / Message display area / Powertrain - then select continue.
    • Select from the menu new module option for the module required which as the PECUS or CONFIG error.
    • Follow all on-screen instructions to complete this task.
    • Disconnect a Midtronic battery conditioner/power supply.