Introduction
This manual provides comprehensive step-by-step instructions for the maintenance, servicing, and overhaul of Jaguar XJ6 and Daimler luxury saloons, commonly known as the XJ40 model, manufactured between 1986 and 1994. It is specifically designed for owners who wish to perform their own vehicle servicing and repairs, ensuring the vehicle remains in optimal condition.
The content covers models equipped with 2.9, 3.2, 3.6, and 4.0 litre engines. Detailed drawings and illustrations are included throughout to clarify complex procedures and amplify the textual instructions.
Figure 1: Front cover of the Jaguar XJ6 Workshop Manual, illustrating the vehicle model covered.
General Information and Safety
Before commencing any work on the vehicle, it is crucial to read and understand all relevant sections of this manual. Always prioritize safety by using appropriate tools, wearing protective gear, and following established safety procedures. Disconnect the battery before working on electrical components, and allow hot engine components to cool before handling.
This manual assumes a basic understanding of mechanical principles. If you are unsure about any procedure, it is recommended to consult a qualified technician.
Engine Systems
This section provides detailed instructions for the inspection, maintenance, and repair of the engine and its associated systems. Topics covered include:
- Engine Overhaul: Procedures for disassembly, inspection, and reassembly of engine components.
- Fuel System: Maintenance and repair of fuel delivery components, including pumps, lines, and injectors.
- Engine Management: Diagnostics and service procedures for electronic engine control units and sensors.
- Emission Control: Information on maintaining and repairing emission reduction systems.
- Exhaust System: Inspection and replacement of exhaust components.
- Cooling System: Servicing of the radiator, water pump, thermostat, and associated hoses.
Transmission and Driveline
This chapter details the servicing and repair of the vehicle's power transmission components:
- Clutch: Adjustment, removal, and installation procedures for manual transmission clutches.
- Manual Gearbox: Overhaul and maintenance instructions for manual transmissions.
- Automatic Transmission: Service procedures and diagnostic information for automatic transmissions.
- Propeller and Drive Shafts: Inspection, removal, and installation of driveline components.
Chassis Systems
Instructions for maintaining and repairing the vehicle's chassis components are provided here:
- Suspension: Service procedures for front and rear suspension components, including springs, shock absorbers, and control arms.
- Hubs: Maintenance and replacement of wheel hubs and bearings.
- Steering: Inspection and repair of the steering rack, power steering system, and associated linkages.
- Brakes: Comprehensive guide to the braking system, including disc brakes, calipers, master cylinder, and ABS components.
Electrical System
This section covers the vehicle's electrical components and wiring:
- General Electrical: Diagnostics and repair of various electrical circuits and components.
- Wiring Diagrams: Detailed schematics to assist in troubleshooting electrical issues.
- Lighting: Service procedures for interior and exterior lighting systems.
- Instrumentation: Repair and calibration of dashboard instruments.
Bodywork and Interior
Information regarding the vehicle's body structure and interior features:
- Bodywork: Minor repair procedures and panel removal/installation.
- Heating & Air Conditioning: Maintenance and repair of the climate control system.
- Interior Trim: Removal and installation of interior panels and components.
Maintenance Schedule
Regular maintenance is essential for the longevity and performance of your Jaguar XJ6/XJ40. This manual outlines recommended service intervals and procedures for routine checks and component replacements. Adhering to these schedules will help prevent potential issues and ensure reliable operation.
Refer to specific chapters for detailed instructions on each maintenance task, such as oil changes, filter replacements, fluid checks, and brake inspections.
Troubleshooting
This section provides guidance for diagnosing common problems that may arise with your vehicle. It includes symptom-based troubleshooting charts and diagnostic procedures to help identify the root cause of issues related to the engine, transmission, electrical system, and other major components. Always follow a systematic approach to troubleshooting to avoid unnecessary repairs.
Technical Data and Specifications
A comprehensive collection of technical data is provided, including:
- Torque Specifications: Essential tightening torques for various fasteners throughout the vehicle.
- Fluid Capacities: Recommended volumes and types of engine oil, coolant, transmission fluid, and brake fluid.
- Dimensions and Weights: Key physical specifications of the vehicle.
- Performance Data: Relevant engine and vehicle performance figures.
These specifications are critical for accurate repairs and adjustments.
Warranty and Support
This workshop manual focuses exclusively on providing technical repair and maintenance instructions for the Jaguar XJ6/XJ40 models. It does not contain information regarding product warranties, customer support contacts, or service agreements from the original manufacturer or any third-party vendors. For warranty-related inquiries or official manufacturer support, please refer to your vehicle's original documentation or contact an authorized Jaguar service center.
