JAGUAR XJ40 XJ6 Master Workshop Manual

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

🏷️ Basic Information Identification Make: Jaguar Model: XJ Model Code: XJ40 Generation Generation Name: XJ40 Production Years: 1986-1994 Codes Engine Codes: AJ6 (2.9L, 3.2L, 3.6L, 4.0L) Transmission Codes: ZF 4HP22/24,...

29 people are viewing this right now

Type: Car

Vendor:

Sku: 275010

Tags: Car Cars Jaguar XJ XJ40 XJ6

Product variants

Description

🏷️ Basic Information

Identification

Make:

Jaguar

Model:

Model Code:

Generation

Generation Name:

Production Years:

1986-1994

Codes

Engine Codes:

AJ6 (2.9L, 3.2L, 3.6L, 4.0L)

Transmission Codes:

ZF 4HP22/24, Getrag 5-speed manual (limited)

👋 Introduction

Market Position

Positioning:

The Jaguar XJ40 was positioned as a luxurious, executive saloon, competing with other premium marques of the era.

Competitive Analysis

Competitors:

Mercedes-Benz S-Class (W126/W140), BMW 7 Series (E32), Lexus LS 400 (later in the generation).

Key Features

Design:

Distinctive, clean-sheet design from Geoff Lawson, moving away from traditional Jaguar styling.

Technology:

Introduction of computer management for engine, transmission, and often advanced features like ABS and early traction control.

Luxury:

High levels of interior refinement, premium materials, and comfortable ride quality.

📋 Manual Details

Coverage Areas

Systems Covered Summary:

Engine, transmission, drivetrain, suspension, steering, brakes, electrical, climate control, fuel system, cooling system, body, interior, diagnostics.

Page Count

Total Volumes:

Service Manual Volumes:

Repair Manual Volumes:

Manual Type

Type:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Printed Volumes

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, and reassembly of all engine components including crankshaft, pistons, connecting rods, cylinder heads, valves, camshafts, timing chains/belts.

Engine Management:

Fuel injection systems (Lucas/Bosch), ignition systems, engine control unit (ECU) diagnostics and calibration, sensors, actuators.

Transmission Automatic:

ZF 4HP22/24 automatic transmission overhaul, fluid service, torque converter diagnostics, valve body repair, electronic control system.

Transmission Manual:

Getrag 5-speed manual transmission overhaul, clutch replacement, gearbox servicing.

Drivetrain:

Rear axle assembly, differential overhaul, driveshafts, U-joints, driveshaft center bearing.

Suspension Front:

Independent front suspension, wishbones, coil springs, shock absorbers, ball joints, bushings, anti-roll bar.

Suspension Rear:

Independent rear suspension (IRS), trailing arms, driveshafts, shock absorbers, coil springs, bushings.

Steering:

Power steering system, steering rack and pinion, steering column, power steering pump and hoses.

Brakes Front:

Ventilated disc brakes, calipers, brake pads, rotors, brake lines, ABS system components.

Brakes Rear:

Solid disc brakes, calipers, brake pads, rotors, brake lines.

Electrical System:

Wiring diagrams, fuse box locations, relay assignments, starter motor, alternator, battery charging system, lighting systems, horn, wipers.

Climate Control:

HVAC system, A/C compressor, condenser, evaporator, heater core, blower motor, climate control module, refrigerant system service.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, evaporative emissions control system.

Cooling System:

Radiator, water pump, thermostat, cooling fan, heater matrix, coolant hoses, expansion tank.

Bodywork Exterior:

Body panel removal and installation, door mechanisms, hood, trunk lid, bumpers, glass replacement, seals.

Bodywork Interior:

Seat removal and installation, dashboard disassembly, trim panel replacement, interior lighting, sound insulation.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules for oil changes, filter replacements, coolant flushes, brake fluid changes, spark plug replacement, belt inspections/replacements.

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon faults, fault codes, symptom-based troubleshooting guides.

Engine Repair:

Complete engine overhaul procedures, head gasket replacement, piston ring replacement, bearing replacement, timing chain/belt replacement.

Transmission Repair:

Automatic and manual transmission rebuilds, solenoid replacement, seal replacement.

Brake System Repair:

Brake caliper overhaul, brake line replacement, ABS module diagnostics and replacement, brake bleeding procedures.

Electrical Diagnostics:

Wiring harness repair, component testing, sensor calibration, ABS/ECU troubleshooting.

Suspension And Steering Repair:

Component replacement (bushings, ball joints, tie rods), alignment procedures, power steering pump replacement.

Body And Trim Repair:

Panel alignment, door hardware adjustment, interior trim panel repair, glass replacement.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to full engine and transmission rebuilds, with detailed diagnostic procedures.

Diagnostic Capabilities:

Includes diagnostic trouble codes (DTCs), system schematics, and step-by-step troubleshooting flowcharts for electronic systems.

📊 Manual Specifications

File Format

Digital Format:

N/A (Printed Product)

Print Quality

Paper Quality:

High-quality, durable paper suitable for workshop environments.

Print Clarity:

Sharp text and clear, detailed diagrams/illustrations.

Binding Type

Binding:

Likely robust, possibly spiral-bound or perfect-bound for ease of use in workshop.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Jaguar AJ6 (Aluminum, Inline-Six)

Displacement Options:

2.9L, 3.2L, 3.6L, 4.0L

Valve Train:

DOHC (Double Overhead Camshafts), 4 valves per cylinder

Fuel System:

Electronic Fuel Injection (EFI) - typically Lucas or Bosch systems depending on year and market.

Performance

Horsepower Range:

165 HP (2.9L) to 245 HP (4.0L variants)

Torque Range:

185 lb-ft (2.9L) to 287 lb-ft (4.0L variants)

Engine Management

ECU Types:

Various ECUs used throughout the production run, often with early diagnostic capabilities.

🔧 Transmission

Standard Transmission

Type:

4-speed Automatic (ZF 4HP22/24)

Optional Transmission

Type:

5-speed Manual (Getrag - less common, typically on earlier models)

Features

Automatic Control:

Electronic control for shift points and mode selection (e.g., Sport/Economy).

Fluid Specifications

Automatic Transmission Fluid:

Typically DEXRON II/III or equivalent (refer to manual for exact spec per year/model).

Fluid Capacities

Automatic Transmission Capacity:

Approx. 8-9 Liters (subject to change).

📐 Dimensions

Exterior

Wheelbase:

Approx. 113 inches (2870 mm)

Length:

Approx. 197 inches (5004 mm)

Width:

Approx. 70.5 inches (1791 mm)

Height:

Approx. 54 inches (1372 mm)

Weights

Curb Weight:

Approx. 3700-4200 lbs (1680-1905 kg) depending on engine and equipment.

Gross Vehicle Weight:

Varies by model and specifications.

🛡️ Safety Features

Ratings

NHTSA Rating:

NHTSA ratings were not as standardized during this era; refer to specific market testing.

Active Features

Anti-lock Braking System (ABS) was standard on most models, often a Lucas Girling system.

Traction Control:

Optional or standard on higher trims and later models (e.g., 'Traction Control System' or similar).

Passive Features

Airbags:

Driver's airbag became standard during the XJ40's production run.

Seatbelts:

Three-point seatbelts front and rear.

Body Structure:

Designed with safety cages and crumple zones typical of luxury sedans of the era.

💡 Technology Features

Infotainment

Audio System:

Premium audio systems, often with cassette players and early CD integration on later models.

Climate Control Interface:

Often incorporated climate control buttons and displays into the dashboard design.

Driver Assistance

Cruise Control:

Standard on most models, electronically controlled.

Memory Seats:

Available on higher trims, allowing saving of seat and mirror positions.

Connectivity

Telecommunications:

No integrated smartphone connectivity in the modern sense; early cellular phone options might have existed.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles or 6-12 months (refer to manual for specific recommendation).

Coolant Flush Interval:

Every 2-3 years or 30,000-45,000 miles.

Spark Plug Replacement:

Varies by spark plug type, but typically 30,000-60,000 miles.

Fluid Specifications

Engine Oil:

Typically 10W-40 or 15W-50, API SG/SH rated (verify with manual).

Coolant:

Ethylene Glycol based antifreeze/coolant, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).

Known Issues

Electrical Gremlins:

Infamous for electrical issues due to complex wiring and early ECUs; headlamp leveling system faults, central locking issues, intermittent dashboard warning lights.

Engine Cooling:

Thermostat housing leaks, radiator leaks, water pump failures, heater matrix leaks (can cause interior water ingress).

Suspension Wear:

Wear in bushings, ball joints, and suspension arms can lead to handling degradation and noise.

Fuel Pump Reliability:

Early models could experience fuel pump failures.

Headliner Sagging:

Common interior issue with aging adhesive for headliner material.

📚 Vehicle History

Brand Heritage

Jaguar Legacy:

Jaguar has a long-standing reputation for building elegant, performance-oriented luxury cars with a focus on handling and refinement.

Model Evolution

Predecessor:

Jaguar XJ (XJ6 Series III), characterized by its more traditional styling.

Successor:

Jaguar XJ (X300/X308), which saw a return to more classic Jaguar design cues.

Production

Manufacturing Plant:

Castle Bromwich, Birmingham, UK.

Production Total:

Over 70,000 XJ40 models produced.

🏆 Awards & Recognition

Recognitions

Design Awards:

While not always cited for specific awards, the XJ40's design was a significant departure and well-received for its modernity.

Ratings

Magazine Reviews:

Consistently praised for its ride quality, handling balance, and powerful inline-six engines.