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Jaguar x type repair manual download
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Want to get more useful information? Ask on the forum Subscribe to notifications. Go to tips and tricks. Ensure there is adequate ventilation when handling and using gasoline.
Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build up arising from spillages in confined spaces. Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid. Gas - oil Diesel Fuel See warnings and cautions in relevant manual sections.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer. Kerosene Paraffin Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to harmful vapors.
Exposure to mists and vapors from kerosene at elevated temperature should be avoided mists may arise in dewaxing. Avoid skin and eye contact and make sure there is adequate ventilation. Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases e. Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving gas cylinders. It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never over load equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used. Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment. Ensure adequate ventilation to control dusts, mists and fumes. Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions. Never direct a high pressure nozzle, e.
Legal Aspects Many laws and regulations make requirements relating to health and safety in the use and disposal of materials and equipment in workshops. Some of these laws which apply in the U. Similar laws exist for other territories:.
The Factories Act The Asbestos Regulations Control of Pollution Act Health and Safety at Work Act Control of Lead at Work Regulations Abrasive W heels Regulations Workshops should be familiar, in detail, with these and associated laws and regulations. Consult the local factory inspectorate if in any doubt. Lubricants and Greases Avoid all prolonged and repeated contact with mineral oils.
All lubricants and greases may be irritating to the eyes and skin. Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. Adequate means of skin protection and washing facilities must be provided. Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
There are publications describing the problems and advising on precautionary measures. Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags into pockets. Avoid contaminating clothing. Heavily soiled clothing and oil - impregnated footwear should not be worn. First Aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. Wash with soap and water to make sure all oil is removed skin cleansers and nail brushes will help. Preparations containing lanoline replace the natural skin oils which have been removed.
Do not use gasoline petrol , kerosene paraffin , diesel fuel gas oil , thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design.
In the UK the heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0. Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed waste disposal sites, or to the waste oil reclamation trade, batterys should also be disposed off under similar arrangments. If in doubt, contact the relevant local authority for advice on disposal facilities.
It is illegal to pour used oil, antifreeze and automatic transmission fluid on to the ground, down sewers, drains, or into water courses. Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.
Paints See also body and paint manual. See also Solvents, Chemical Materials. Highly flammable, flammable - observe No Smoking policy. Solder Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals normally lead and tin.
Oxy - acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced. Some fumes may be produced by the application of any flame to surfaces coated with grease etc.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead. High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Used in cleaning and dewaxing materials, paints, plastics, resins, thinners etc. Some may be highly flammable or flammable. Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects. Aspiration into the lungs e. W ear protective gloves, goggles and clothing if necessary. Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed.
Do not use in confined spaces. When spraying materials containing solvents, e. Do not apply heat or flame except under specific and detailed manufacturer's instructions. There is always a danger when loads are lifted or suspended.
Never work under an unsupported, suspended or raised load e. Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc. Viton In common with many other manufacturers' vehicles, some components fitted to the Jaguar range have 'O' rings, seals or gaskets which contain a material known as 'Viton'. Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact, into the body. DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work. Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater calcium hydroxide solution to neutralize the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.
Resistance Welding This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected. Arc Welding This process emits a high level of ultra - violet radiation which may cause arc - eye and skin burns to the operator and to other persons nearby.
Gas - shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. This may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on.
These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary. Gas Welding and Cutting Oxy - acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye protection should be used, but the ultra - violet emission is much less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.
These decals must not be removed. The most commonly found decals are reproduced below together with an explanation of the warnings. Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind. Components or assemblies displaying the warning triangle with the electrified arrow and open book symbol give warning of inherent high voltages.
Never touch these with the engine running or the ignition switched on. See Electric Shock in this subsection. Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol. See Asbestos in this subsection. Components or assemblies displaying this symbol give warning that the component contains a corrosive substance. See Acids and Alkalis in this subsection. Vehicles displaying the caution circle with a deleted lighted match symbol, caution against the use of naked lights or flames within the immediate vicinity due to the presence of highly flammable or explosive liquids or vapors.
See Fire in this subsection. All vehicles fitted with the passenger air bag from the factory have a warning sticker attached to the instrument panel, prohibiting the use of rear facing child seats in the front seating position. Failure to follow this instructions may result in personal injury.
Fuel vapor is extremely flammable, hence great care must be taken whilst working on the fuel system. Adhere strictly to the following precautions: Do not smoke in the work area.
Display 'no smoking' signs around the area. Disconnect the battery before working on the fuel system. 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. Trichloroethane, white spirit, sbp3, methylene chloride, perchlorethylene. Do not smoke in the vicinity of volatile degreasing agents.
Whenever possible, use a ramp or pit whilst working beneath a vehicle, in preference to jacking. Position chocks at the wheels as well as applying the parking brake. Never rely on a jack alone to support a vehicle. Use axle stands, or blocks carefully placed at the jacking points, to provide a rigid location. Check that any lifting equipment used has adequate capacity and is fully serviceable.
Ensure that a suitable form of fire extinguisher is conveniently located. W hen using electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed. Disconnect the earth grounded terminal of the vehicle battery. Do not disconnect any pipes of the air conditioning refrigeration system unless you are trained and instructed to do so.
A refrigerant is used which can cause blindness if allowed to come into contact with the eyes. Ensure that adequate ventilation is provided when volatile degreasing agents are being used.
Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from naked flames and other sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as causing damage to protective coatings, there is a risk of damage from stray heat to electronic equipment and brake lines. Do not leave tools, equipment, spilt oil etc. Wear protective overalls and use barrier cream when necessary.
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. Copyright Statement Copyright. Jaguar Cars Ltd. 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.
Workshop Manual Organization This manual covers descriptive, diagnostic including OBD , and repair aspects to service the vehicle effectively. The manual is arranged in sections, each section dealing with a specific part of a vehicle system. For example, Section covers air conditioning, which is part of the climate control system. The first digit of the section number indicates the group. There are five groups: General Information. Body and Paint. The second and third digits of the section number indicate the vehicle system.
The last two digits of the section number indicate the part of the system covered by the section. Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the safety of the person doing the work.
This manual provides general directions for accomplishing service and repair work with tested effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the person doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in the manual must first establish that neither personal safety or vehicle integrity is compromised from choices of methods, tools or parts.
Road or roller testing may be carried out for various reasons and a procedure detailing pre - test checks, through engine starting and stopping, pre - driving checks, on - test checks to final checks on completion of the test is given overleaf. Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Pre - Test Checks WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.
Engine oil level Engine coolant level Tires, for correct pressure, compatible types and tread patterns, and wear within limits. There is sufficient fuel in the tank to complete the test. All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test.
With the ignition switched off, check: The handbrake is applied. The gear lever is in neutral. All instrument gauges except fuel gauge read zero. NOTE: On initial drive away from cold and within the first 1. Never operate at high engine speed or with the accelerator pedal at full travel whilst the engine is cold. Ignition controlled warning lights come on. Engine temperature gauge registers a reading compatible with the engine temperature. Fuel gauge registers a reading appropriate to the fuel level in the tank.
The operation of the handbrake warning light and fluid level warning indicator light. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified. Clutch pedal operation is not stiff or heavy. Initial gear engagement is smooth and there is no evidence of clutch drag. Handbrake control operates smoothly and the handbrake releases quickly and completely. Clutch takes up the drive smoothly, without slip or judder.
The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or heavy, and engine speed returns to idle correctly. There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions.
Steering operation, including power steering where fitted, is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does not pull to one side and self centres smoothly after cornering. Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer where fitted register the correct readings or operate correctly.
Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction indicator control self cancels when the steering is returned to the straight ahead position.
Heating and ventilation systems work correctly and effectively. Brake operation and efficiency. Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.
New brake friction components will not reach full efficiency until the bedding - in process is complete. Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release. Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding. After stopping the vehicle not immediately after a period of heavy braking , carefully check the brake temperature.
A disc which feels hot, or appreciably hotter than the others, indicates that the brake is binding. After completion of the test, check for: Oil, coolant, hydraulic, air and fuel leaks.
Abnormal temperature of any moving components or assemblies, e. Some contain chemicals or give off fumes which can be dangerous to health. Always follow the manufacturers instructions. CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the manufacturer of the product for information regarding storage, handling and application.
The Solvents, Sealers and Adhesives subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken. Adhesives and Sealers Highly flammable, flammable, combustible observe No Smoking policy.
Generally should be stored in No Smoking' areas. Cleanliness and tidiness in use should be observed e. Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.
In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut - out and adequate extraction.
Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin.
Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact. Some are eye irritants. Skin and eye contact should be avoided and the manufacturer's instructions followed.
If skin or eye tissue is bonded, cover with a clean moist pad and seek immediate medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation to the nose and eyes. Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapor concentrations may result in adverse health effects.
Prolonged contact with the skin may lead to skin irritation and, in some cases, dermatitis. Splashes entering the eye will cause discomfort and possible damage. Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the breathing zone. Wear appropriate gloves, eye and respiratory protection. Protecting the Vehicle Always install covers to protect the fenders before commencing work in the engine compartment.
Always install the interior protection kit, wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid, antifreeze or battery acid on the paintwork.
In the event of spillage, wash off with water immediately. Use polythene sheets in the luggage compartment to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw threads by replacing nuts or installing caps.
Vehicle in Workshop When working on a vehicle in the workshop always make sure that: The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed There is adequate room to jack up the vehicle and remove the wheels, if necessary Fender covers are always installed if any work is to be carried out in the engine compartment The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up CAUTION: W hen electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of current causing damage to the internal components of the generator.
If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available. An additional quick reference and anti forgery identification number is stamped onto a metal plate and fastened to the instrument panel. It is positioned close to the left-hand side of the vehicle and is visible from the outside. The vehicle identification number is also located on a vehicle certification label or vin plate which is mounted on the bottom of the 'B' Post.
World manufacturer identifier Market, air bag specification Transmission and steering code Body code Engine emission system Check digit Model year Assembly plant, model line Production sequence number. Description Rest of World with twin air bags, side air bags and curtain air bags Japan with twin air bags, side air bags and curtain air bags USA with twin air bags, side air bags and curtain air bags Canada with twin air bags, side air bags and curtain air bags Mexico with twin air bags, side air bags and curtain air bags.
Includes the following markets; Croatia and Serbia. Includes the following markets; Belarus, Kazakhstan, Ukraine and Uzbekistan. Engine 2. Vehicle Certification Label The vehicle certification label also contains the 17 character vehicle identification number. This number is used for warranty identification of the vehicle. Description W VTA number printed here when applicable Vehicle identification number Gross vehicle weight Gross train weight Maximum permitted front axle loading Maximum permitted rear axle loading Date of manufacture Interior trim code Paint code.
Description Date of manufacture Vehicle identification number Interior trim code Paint code. Maximum permitted front axle loading Date of manufacture Gross vehicle weight Maximum permitted rear axle loading Vehicle identification number Paint code Interior trim code Type. The serial number of the automatic transmission unit is displayed on a metal label or bar code where equipped attached to the transmission casing.
The serial number of the manual transmission unit is displayed on a metal label or bar code where equipped attached to the transmission casing. The engine number is stamped on an engine web on the right hand side of the cylinder block behind the engine mounting.. The engine number is contained on a bar code label on the front cover and is also stamped in the cylinder block casting.
To avoid damage to the vehicle, never use the jack to raise the vehicle for any other purpose. Refer to the Driver Handbook when using the jack supplied with the vehicle. Failure to follow these instructions can result in personal injury. The following safety precautions must be observed when raising the vehicle to carry out service operations:. Never rely on a jack alone to support a vehicle; use suitable vehicle stands to provide rigid support.
When working beneath a vehicle, whenever possible, use a vehicle hoist instead of a jack and vehicle stands. Make sure that the vehicle is standing on firm, level ground before using a jack. Do not rely on the parking brake alone; chock the wheels and put the automatic transmission into PARK if possible. Check that any lifting equipment used has adequate capacity for the load being lifted and is in correct working order.
Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle. Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. NOTE: Prior to vehicle recovery, make sure that the vehicle keys are available and the security system is disarmed. Vehicle recovery methods are:. When the vehicle is being recovered by transporter or trailer: The parking brake must be applied and the wheels chocked.
Do not select PARK on automatic transmission vehicles, as the parking lock mechanism may be damaged by the forward and backward rocking motion of the vehicle. The vehicle must be securely tied down to the transporter or trailer. The ignition key must be removed from the ignition switch to lock the steering. The front wheels must be correctly positioned in the lifting cradle and securely tied down. Emergency Towing-Vehicles fitted with manual transmission: 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.
When the vehicle is being towed with all four wheels on the ground:. 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 ignition switch must be in the RUN position to release the steering lock and make the direction indicators, horn and stop lamps operate. A distance of 48 kms 30 miles must not be exceeded.
The tow rope must be attached to the front towing eye. 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.
A distance of 0. Noise, vibration and harshness NVH is becoming more important as vehicles become more sophisticated and passenger comfort levels increase. This section is designed to aid in the diagnosis, testing and repair of NVH concerns.
Diagnostic Theory Diagnosis is more than just following a series of interrelated steps in order to find the solution to the specific condition. It is a way of looking at systems that are not functioning the way they should and finding out why.
Also it is knowing how the system should work and whether it is working correctly. There are basic rules for diagnosis. If these rules are followed, the cause of the condition is usually found the first time through the system. Know the System know how the parts go together. Look for the simple rather than the complex. For example: - Electrical conditions usually occur at connections rather than components.
Know the difference between impossible and improbable. Certain failures in a system can be improbable but still happen. New parts are just that, new. It does not mean they are always good functioning parts. Do Not Cure the Symptom and Leave the Cause Lowering the pressure in a front tire may correct the condition of a vehicle leaning to one side, but it does not correct the original condition. Diagnostic Charts Charts are a simple way of expressing the relationship between basic logic and a physical system of components.
They help discover the cause of a condition in the least time. Diagnostic charts combine many areas of diagnosis into one visual display: probability of certain things occurring in a system speed of checking certain components or functions before others simplicity of carrying out certain tests before others elimination of checking huge portions of a system by carrying out simple tests certainty of narrowing down the search to a small portion before carrying out in-depth testing The fastest way to find a condition is to work with the tools that are available.
This means working with proven diagnostic charts and the correct special equipment for the system. Inspection and Verification 1. Verify the customer concern. Visually inspect for obvious signs of mechanical damage. If an obvious cause for an observed or reported concern is found, correct the cause if possible before proceeding to the next step.
If the concern s remains after the inspection, determine the symptom s and go to the Symptom Chart. This section is designed as an aid to identifying these situations. The section provides diagnostic procedures based on symptoms.
If the condition occurs at high speed, for instance, the most likely place to start is under High Speed Shake. The road test procedure will tell how to sort the conditions into categories and how to tell a vibration from a shake. A series of Road Test Quick Checks is provided to make sure that a cause is either pinpointed or eliminated. Name the condition, proceed to the appropriate section and locate the correct diagnosis.
When the condition is identified, the job is partly done. Follow the diagnostic procedure as outlined. Quick Checks are described within the step, while more involved tests and adjustments are outlined in General Procedures.
Always follow each step exactly and make notes to recall important findings later. The road test and customer interview if available provide information that will help identify the concerns and will provide direction to the correct starting point for diagnosis.
It is important, therefore, that an NVH concern be isolated into its specific area s as soon as possible. The easiest and quickest way to do this is to carry out the Road Test as outlined. The five most important sources of non-axle noise are exhaust, tires, roof racks, trim and mouldings, and transmission. Therefore, make sure that none of the following conditions are the cause of the noise before proceeding with a driveline teardown and diagnosis.
In certain conditions, the pitch of the exhaust may sound very much like gear noise. At other times, it can be mistaken for a wheel bearing rumble. Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear noise. Radial tires, to some degree, have this characteristic. Also, any non-standard tire with an unusual tread construction may emit a roar or whine type noise. Trim and mouldings can also cause whistling or a whining noise.
Clunk may be a metallic noise heard when the automatic transmission is engaged in reverse or drive, or it may occur when the throttle is applied or released. It is caused by backlash somewhere in the driveline.
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a damaged wheel bearing. Noise Conditions Gear noise is typically a howling or whining due to gear damage or incorrect bearing preload.
It can occur at various speeds and driving conditions, or it can be continuous. Chuckle is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. The frequency varies with vehicle speed. Knock is very similar to chuckle, though it may be louder and occurs on acceleration or deceleration. The teardown will disclose what has to be corrected.
Check and rule out tires, exhaust and trim items before disassembling the transmission to diagnose and correct gear noise. The noises described under Road Test usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard on the road test and the driving conditions. Clicking, popping or grinding noises may be caused by the following: cut or damaged drive half shaft joint boots resulting in inadequate or contaminated lube in the outboard or inboard CV joint bearing housings.
Shudder or vibration during acceleration may be caused by the following: Excessively worn or damaged outboard or inboard CV joint shaft pilot bearing housing Excessively high CV joint operating angles caused by incorrect ride height. Check ride height, verify correct spring rate and check items under Inoperative Conditions. Leakage Conditions 1. Inspect the CV joint boots for evidence of cracks, tears or splits. Inspect the underbody for any indication of grease splatter in the vicinity of the front or rear wheel drive half shaft joints and boots.
If any grease is present this indicates damage to the half shaft joint boot or boot clamp. Inspect the inboard CV joint stub shaft pilot bearing housing seal for leakage at the inboard CV joint pilot bearing housing. A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and may be audible at certain speeds or under various driving conditions as on a newly paved blacktop road.
The slight noise is in no way detrimental and must be considered normal. The road test and customer interview if available provide information needed to identify the condition and give direction to the correct starting point for diagnosis.
Make notes throughout the diagnosis routine. Make sure to write down even the smallest bit of information, because it may turn out to be the most important. Do not touch anything until a road test and a thorough visual inspection of the vehicle have been carried out. Leave the tire pressures and vehicle load just where they were when the condition was first observed. Adjusting tire pressures, vehicle load or making other adjustments may reduce the conditions intensity to a point where it cannot be identified clearly.
It may also inject something new into the system, preventing correct diagnosis. Make a visual inspection as part of the preliminary diagnosis routine, writing down anything that does not look right. Note tire pressures, but do not adjust them yet. Note leaking fluids, loose nuts and bolts, or bright spots where components may be rubbing against each other. Check the luggage compartment for unusual loads.
Road test the vehicle and define the condition by reproducing it several times during the road test. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify the correct diagnostic procedure. Carry out the Road Test Quick Checks more than once to verify they are providing a valid result. Remember, the Road Test Quick Checks may not tell where the concern is, but they will tell where it is not. Road Test Quick Checks 1. It is usually worse at a particular engine speed and at a particular throttle setting during acceleration at that speed.
It may also produce a moaning sound, depending on what component is causing it. It is a low frequency vibration around cycles per second. It may or may not be increased by applying brakes lightly.
High Speed: A vibration is felt in the front floor pan or seats with no visible shake, but with an accompanying sound or rumble, buzz, hum, drone or booming noise.
Coast with the clutch pedal depressed or shift control selector lever in neutral and engine idling. If vibration is still evident, it may be related to wheels, tires, front disc brake discs, wheel hubs or front wheel bearings.
Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm. It will disappear in neutral coasts. The vibration can be duplicated by operating the engine at the problem rpm while the vehicle is stationary.
It can be caused by any component, from the accessory drive belt to the clutch or torque converter which turns at engine speed when the vehicle is stopped. Noise and Vibration While Turning: Clicking, popping, or grinding noises may be due to the following: worn, damaged, or incorrectly installed front wheel bearing worn, damaged or incorrectly installed half shaft.
Road Conditions An experienced technician will always establish a route that will be used for all NVH diagnosis road tests. The road selected should be reasonably smooth, level and free of undulations unless a particular condition needs to be identified. A smooth asphalt road that allows driving over a range of speeds is best. Gravel or bumpy roads are unsuitable because of the additional road noise produced.
Once the route is established and consistently used, the road noise variable is eliminated from the test results. NOTE: Some concerns may be apparent only on smooth asphalt roads. If a customer complains of a noise or vibration on a particular road and only on a particular road, the source of the concern may be the road surface.
If possible, try to test the vehicle on the same type of road. Vehicle Preparation Carry out a thorough visual inspection of the vehicle before carrying out the road test.
Note anything which is unusual. Do not repair or adjust any condition until the road test is carried out, unless the vehicle is inoperative or the condition could pose a hazard to the technician.
After verifying the condition has been corrected, make sure all components removed have been installed. Lift Test After a road test, it is sometimes useful to do a similar test on a lift.
Failure to follow these instructions may result in personal injury. W hen the CV joint is run at a very high angle, extra vibration as well as damage to the seals and joints can occur. The suspension lower arms should be supported as far outboard as possible. To bring the vehicle to its correct ride height, the full weight of the vehicle should be supported in the rear by floor jacks. Raise and support the vehicle. Explore the speed range of interest using the Road Test Quick Checks as previously described.
Carry out a coast down in neutral. If the vehicle is free of vibration when operating at a steady indicated speed and behaves very differently in drive and coast, a transmission concern is likely.
Note, however, that a test on the lift may produce different vibrations and noises than a road test because of the effect of the lift. It is not unusual to find vibrations on the lift that were not found in the road test.
If the condition found on the road can be duplicated on the lift, carrying out experiments on the lift may save a great deal of time.
Pinpoint Tests NOTE: These Pinpoint Tests are designed to take the technician through a step-by-step diagnosis procedure to determine the cause of a condition. It may not always be necessary to follow the chart to its conclusion. Carry out only the Pinpoint Test steps necessary to correct the condition.
Then check operation of the system to make sure the condition is corrected. After verifying that the condition has been corrected, make sure all components removed have been installed. Does the vibration disappear during the neutral coast test?
No GO to D1. Check the air cleaner, inlet tube, outlet tube, resonators and all other components associated with the air induction system for correct installation and tightness of all connections. Are the components OK? Yes GO to B2. Is the exhaust system OK? Yes GO to B3. Is the tip-in moan OK? Yes GO to C2. Is the driver air bag module OK?
Yes GO to C3. Check the radiator installation for any component that may have a touch condition. Are the installation and bushings OK? Yes GO to C4. Are the tires OK? Yes GO to D2. Are the wheel bearings OK? Yes GO to D3. Yes GO to D4. Are the front wheel drive half shaft joint boots OK?
Yes GO to D5. Carry out the Wheel and Tire Check procedure. Is the wheel and tire runout OK? Yes Balance the wheels and tires. Refer to the wheel balance equipment manufacturers instructions. Are the vehicle trim components causing the noise? No GO to E2. No GO to E3. Example: grounding body-to-frame, antennas, visors, bug deflectors and fog lights? Are the accessories the cause of the noise? No Verify the customer concern. Loosen the muffler inlet pipe and resonator pipe to exhaust manifold fasteners at the flanges and the muffler inlet connection.
Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. Tighten the muffler connection. Position the exhaust pipes to the manifolds and tighten. Make sure that the catalytic converters and heat shields do not contact the frame rails. With the complete exhaust system tight and cooled the rear hanger insulator should be angled forward, to allow the system to expand rearward when heated during normal running.
RH All the above figures are measured at "kerb" height -all fluids at full and a full fuel tank. Tires must be inflated to normal pressure For additional information, refer to: Specifications Wheels and Tires, Specifications.
Toe is adjustable on the front and rear suspension system. The front toe is adjusted by use of the front tie-rod. The rear toe is adjusted by the use of cam bolts in the lower control arm to the rear crossmember. NOTE: All ride height measurements are carried out with vehicle empty and 9 litres of fuel in the tank showroom condition.
Front Ride Height Measurement. Item Description 1 Front track 2 Rear track crabbing Crabbing is the condition in which the independent rear suspension IRS system is not square to the chassis.
Heavily crowned roads can give the illusion of crabbing. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road.
Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver. Poor Returnability of the Steering Poor returnability of the steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed.
Drift describes what a vehicle with this condition does with hands off the steering wheel. Vague On-Center Feel Vague on-center feel is characterized by little or no build up of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead under 20 degrees of steering wheel turn. Efforts may be said to be "flat on center.
In the diagnosis of a road ability problem, it is important to understand the difference between wander and vague on-center feel. Verify the customer's concern by carrying out a road test on a smooth road. If any vibrations are apparent, refer to Section Noise, Vibration and Harshness. Visual Inspection Chart. Mechanical Damaged tires W heel bearing s Loose or damaged front or rear suspension components Loose, damaged or missing suspension retainer s Incorrect spring usage Damaged or sagging spring s Damaged or leaking shock absorber s Damaged or leaking strut s W orn or damaged suspension bushing s Loose, worn or damaged steering system components Damaged axle components 3.
If an obvious cause for an observed or reported condition is found, correct the cause if possible before proceeding to the next step.
If the fault is not visually evident, verify the symptom and refer to the following Symptom Chart. Drive axle damaged.
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