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Workshop Manual
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JagDocs |
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X-TYPE
Sedan and Estate (Wagon)
2.0L, 2.5 L and 3.0 L Gasoline;
2.0L and 2.2 L, Diesel
2001 to 2009
www.JagDocs.com
TABLE OF CONTENTS
1: General Information |
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100: Service Information |
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100-00: General Information |
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Description and Operation |
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About This Manual |
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Application and Use of Specifications |
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General Service Information |
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Health and Safety Precautions |
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How To Use This Manual |
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Important Safety Instructions |
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Road/Roller Testing |
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Solvents, Sealants and Adhesives
Standard Workshop Practices
100-01: Identification Codes
Description and Operati n
Identification Codes
100-02: Jacking and Lifting
Description nd Operation acking
Lifting
100-04: Noise, Vibration and Harshness
Description and Operation
Noise, Vibration and Harshness (NVH)
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
General Procedures
Exhaust System Neutralizing
2: Chassis
204: Suspension
204-00: Suspension System - General Information
Specification |
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Description and Operation |
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Wheel Alignment Angles |
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Diagnosis and Testing |
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Suspension System |
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General Procedures |
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Front Toe Adjustment (57.65.01) |
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Rear Toe Adjustment (57.65.08) |
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Wheel Bearing Inspection |
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204-01: Front Suspension |
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Specification |
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Description and Operation |
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Front Suspension
Diagnosis and Testing
Front Suspension
Removal and Installation
Lower Arm (60.35.02)
Shock Absorber and Spring Assembly (60.30.02)
Front St bilizer B r (60.10.01)
Front St bilizer B r Bushing (60.10.04)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
Disassembly and Assembly
Shock Absorber and Spring Assembly (60.30.21)
204-02: Rear Suspension
Specification
Description and Operation
Rear Suspension
Diagnosis and Testing
Rear Suspension
Removal and Installation |
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Damper |
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Front Lower Arm (64.35.51) - 4-Door |
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Front Lower Arm (64.35.51) - Wagon |
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Rear Lower Arm (64.35.52) |
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Spring (64.20.01) |
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Rear Stabilizer Bar (64.35.08) |
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Rear Stabilizer Bar Link (64.35.24) |
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Upper Arm (64.25.31) |
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Wheel Hub (64.15.14) |
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Wheel Knuckle (64.15.22) |
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Wheel Knuckle Front Bushing (64.15.28) |
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Wheel Knuckle Rear Bushing (64.15.30) |
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204-04: Wheels and Tires |
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Specification |
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Description and Operation |
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Safety Precautions |
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Wheels and Tires
Diagnosis and Testing
Wheels and Tires
Removal and Installation
Tire Low Pressure Sensor - VIN Range: J28493->V99999
Tire Pressure Monitoring System (TPMS) Front Antenna - VIN Range: J28493-
>V99999
Tire Pressure Monitoring System (TPMS) Main Antenna - VIN Range: J28493-
>V99999
Tire Pressure Monitoring System (TPMS) Module - VIN Range: J28493->V99999 Tire Pressure Monitoring System (TPMS) Rear Antenna - VIN Range: J28493- >V99999
Wheel and Tire (74.20.05)
205: Driveline
205-00: Driveline System - General Information
Description and Operation
Driveline System
Diagnosis and Testing
Driveline System
205-01: Driveshaft |
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Specification |
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Description and Operation |
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Driveshaft |
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Diagnosis and Testing |
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Driveshaft |
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General Procedures |
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Driveshaft Runout and Balancing |
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Removal and Installation |
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Driveshaft (47.15.01) |
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205-02: Rear Drive Axle/Differential |
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Specification |
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JagDocs |
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Description and Operation |
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Rear Drive Axle and Differential |
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Diagnosis and Testing
Rear Drive Axle and Differential
In-Vehicle Repair
Axle Shaft Seal (51.20.04) (51.20.36)
Drive Pinion Flan e
Drive Pinion Seal (51.20.01)
Remov l nd Inst ll tion
Axle Assembly (51.25.13)
205-04: Front Drive Halfshafts
Specification
Description and Operation
Front Drive Halfshafts
Diagnosis and Testing
Front Drive Halfshafts
Removal and Installation
Front Halfshaft LH (47.10.15)
Front Halfshaft RH (47.10.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 – AJ27
Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Inner Constant Velocity (CV) Joint Boot (47.10.18)
Intermediate Shaft
Outer Constant Velocity (CV) Joint Boot (47.10.19)
205-05: Rear Drive Halfshafts |
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Specification |
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Description and Operation |
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Rear Drive Halfshafts |
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Diagnosis and Testing |
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Rear Drive Halfshafts |
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Removal and Installation |
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Rear Halfshaft (47.10.13)
206: Brake System
206-00: Brake System - General Information
Specification
Description and Operati n
Brake System
Diagnosis and Testing
Brake System
General Procedures
Outer Constant Velocity (CV) Joint Boot (47.10.32)
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JagDocs
Brake Disc Runout Check
Brake System Bleeding (70.25.03)
206-03: Front Disc Brake
Specification
Description and Operation
Front Disc Brake
Diagnosis and Testing
Front Disc Brake
Removal and Installation
Brake Caliper (70.55.02)
Brake Disc (70.10.10)
Brake Pads (70.40.02) |
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206-04: Rear Disc Brake |
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Specification |
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Description and Operation |
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Rear Disc Brake |
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Diagnosis and Testing |
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Rear Disc Brake |
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Removal and Installation |
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Brake Caliper (70.55.03) (70.55.25) |
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Brake Disc (70.10.11) |
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Brake Disc Shield (70.10.19) |
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Brake Pads (70.40.03) |
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206-05: Parking Brake and Actuation |
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Specification |
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JagDocs |
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Description and Operation |
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Parking Brake |
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Diagnosis and Testing
Parking Brake
General Procedures
Removal and Installation
Parking Brake Cable (70.35.29) - Vehicles With: Manually Adjusted Parking Brake Parking Brake Cable (70.35.29) - Vehicles With: Self-Adjusting Parking Brake Parking Br ke Control (70.35.08) - Vehicles With: Manually Adjusted Parking Brake
Parking Brake Control (70.35.08) - Vehicles With: Self-Adjusting Parking Brake
206-06: Hydraulic Brake Actuation
Specification
Description and Operation
Hydraulic Brake Actuation
Diagnosis and Testing
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)
Brake Pedal and Bracket (70.35.03)
Brake Pedal Cross-Shaft
206-07: Power Brake Actuation
Specification
Description and Operation
Brake Booster
Diagnosis and Testing
Power Brake System
Removal and Installation
Brake Booster (70.50.17) - LHD AWD/LHD FWD |
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Brake Booster (70.50.17) - RHD AWD/RHD FWD |
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Brake Vacuum Pump - 2.0L NA V6 - AJV6 |
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Brake Vacuum Pump - 2.0L Duratorq-TDCi/2.2L Durat rq-TDCi (110kW/150PS) |
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– Puma |
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JagDocs |
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206-09: Anti-Lock Control - Stability A |
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Specification |
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Description and Operation
Anti-Lock Control - Stability Assist
Diagnosis and Testing
Anti-Lock Control - Stability Assist - VIN Range: C00344->J12991
Anti-Lock Control - Stability Assist - VIN Range: J12992->V99999
Removal and Installation
Anti-Lock Br ke System (ABS) Module (70.60.02) - VIN Range: C00001->J12991 Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: C00001->J12991 Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: J12992->V99999 Rear Wheel Speed Sensor (70.60.04)
Stability Assist Module
Steering Wheel Rotation Sensor (86.56.58)
Yaw Rate Sensor (86.56.57) - 2.0L Duratorq-TDCi/2.0L NA V6 - AJV6/2.5L NA V6 – AJV6/3.0L NA V6 - AJ27
Yaw Rate Sensor (86.56.57) - 2.2L Duratorq-TDCi (110kW/150PS) – Puma
211: Steering System |
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211-00: Steering System - General Information |
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Specification |
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Description and Operation |
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Steering System |
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Diagnosis and Testing |
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Steering System |
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General Procedures |
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Power Steering System Filling |
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Power Steering System Flushing (57.15.08) |
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211-02: Power Steering |
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Specification |
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Description and Operation |
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Power Steering |
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Diagnosis and Testing |
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Power Steering |
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General Procedures |
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Start Up Procedure After P |
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Removal and Installation
Power Steering Control Valve Actuator (57.10.32) - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Power Steering Fluid Cooler (57.15.11) - 2.0L Duratorq-TDCi
Power Steering Fluid Cooler (57.15.11) - 2.2L Duratorq-TDCi (110kW/150PS) –
Puma
Power Steering Fluid Reservoir (57.15.08)
Power Steering Pump (57.20.14) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Power Steering Pump (57.20.14) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Steering Gear (57.10.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Steering Gear (57.10.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –
AJ27
211-03: Steering Linkage
Specification
Description and Operation
Steering Linkage
Diagnosis and Testing
Steering Linkage
Removal and Installation
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.02)
211-04: Steering Column |
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Specification |
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Description and Operation |
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Steering Column |
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Diagnosis and Testing |
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Steering Column |
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Removal and Installation |
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Ignition Switch Lock Cylinder (57.40.29)
Steering Column (57.40.01)
Steering Column Coupling
Steering Wheel (57.60.01)
211-05: Steering Column Switches
Description nd Operation
Steering Column Switches
Diagnosis and Testing
Steering Column Switches
Removal and Installation
Steering Column Multifunction Switch LH (86.65.78)
Steering Column Multifunction Switch RH (86.65.41)
3: Powertrain |
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303: Engine |
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303-00: Engine System - General Information |
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Specification |
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Description and Operation |
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Engine |
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Diagnosis and Testing |
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Engine |
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General Procedures |
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Bearing Inspection |
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Camshaft Bearing Journal Clearance |
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Camshaft Bearing Journal Diameter |
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Camshaft End Play |
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Camshaft Lobe Lift |
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Camshaft Surface Inspection |
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Connecting Rod Cleaning |
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Connecting Rod Large End B |
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Crankshaft End Play |
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Crankshaft Main Bearing urnal Clearance
Crankshaft Main Bearing Journal Diameter
Cylinder Block Distortion
Cylinder Bore Out-of-Round
Cylinder He d Distortion
Exhaust Manifold Cleaning and Inspection
Flywheel Inspection
Piston Diameter
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Seat Inspection
Valve Spring Free Length
Valve Stem Diameter
Leakage Test Using Smoke Test Equipment
303-01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification |
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Description and Operation |
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Engine |
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Diagnosis and Testing |
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Engine |
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General Procedures |
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Valve Clearance Adjustment (12.29.48) |
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Valve Clearance Check (12.29.47) |
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In-Vehicle Repair |
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Camshafts LH (12.13.19) |
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Crankshaft Front Seal (12.21.14) |
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Crankshaft Pulley (12.21.09) |
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Crankshaft Rear Seal (12.21.20) |
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Cylinder Head LH (12.29.02) |
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Engine Front Cover (12.65.01) |
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Engine Front Mount (12.45.01)
Exhaust Manifold LH (30.15.55)
Flexplate (12.53.13)
Exhaust Manifold RH (30.15.56)
Flywheel (12.53.07)
Intake Manifold (30.15.01)
Lower Int ke M nifold (30.15.61)
Oil Cooler (12.60.68)
Oil Pan (12.60.44)
Oil Pressure Sender
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Removal
Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6-
Speed Manual Transaxle - MMT6
Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-Speed
Automatic Transaxle - AWF21
Disassembly
Engine
Disassembly and Assembly of Subassemblies
Cylinder Head (12.29.22)
Piston (12.17.02)
Assembly
Engine
Installation
Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6- |
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Speed Manual Transaxle - MMT6 |
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Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-Speed |
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Automatic Transaxle - AWF21 |
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303-01B: Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma |
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JagDocs |
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Specification |
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Description and Operation |
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Engine
In-Vehicle Repair
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Engine Front Cover (12.65.01)
Engine Front Mount (12.45.01)
Flexpl te (12.53.13)
Flywheel (12.53.07)
Intake Manifold (30.15.01)
Oil Pan (12.60.44)
Timing Chain
Valve Cover
Removal
Engine (12.41.01) - 2.0L Duratorq-TDCi
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Disassembly
Engine
Assembly
Engine
Installation
Engine (12.41.01) - 2.0L Duratorq-TDCi
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) – Puma
303-03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification |
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Description and Operation |
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Engine Cooling |
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Diagnosis and Testing |
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Engine Cooling |
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General Procedures |
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Cooling System Backflushing |
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Cooling System Draining, Filling and Bleeding |
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Cooling System Flushing |
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Removal and Installation |
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Block Heater (86.62.18) |
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JagDocs |
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Coolant Expansion Tank (26.15.01) |
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Cooling Fan Module (26.25.38) |
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Cooling Fan Motor (26.25.24)
Cooling Fan Motor and Shr ud (26.25.25)
Cooling Module (26.40.16)
Radiator (26.40.01)
Thermostat (26.45.07)
Water Pump (26.50.01)
Water Pump Housing (26.50.07)
303-03B: Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –
Puma
Specification
Description and Operation
Engine Cooling
General Procedures
Cooling System Draining, Filling and Bleeding
Cooling System Draining and Vacuum Filling
Removal and Installation
Cooling Fan Motor and Shroud (26.25.25)
Cooling Module (26.40.16)
Radiator (26.40.01)
Water Pump (26.50.01)
303-04A: Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls - 2.0L NA V6 - AJV6 |
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Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: |
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E96603->J28492 |
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Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: |
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J28493->V99999 |
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Removal and Installation |
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JagDocs |
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Fuel Charging Wiring Harness (86.70.22).
Fuel Injection Supply Manifold (19.60.13)
Fuel Injectors (18.10.02)
Fuel Pulse Damper (18.30.98) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Throttle Body (19.70.04)
303-04B: Fuel Char ing and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma
Specific tion
Description nd Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Removal and Installation
Fuel Injection Pump
Fuel Injection Supply Manifold (19.60.13)
Fuel Injector (18.10.01)
Fuel Metering Valve
Fuel Return Line Venturi
303-04C: Fuel Charging and Controls - Turbocharger
Specification
Description and Operation
Turbocharger
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger |
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303-05: Accessory Drive |
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Specification |
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Description and Operation |
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Accessory Drive |
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Diagnosis and Testing |
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Accessory Drive |
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JagDocs |
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Removal and Installation .
Accessory Drive Belt (12.10.40) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Accessory Drive Belt (12.10.40) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Accessory Drive Belt Tensi ner (12.10.41) - 2.0L Duratorq-TDCi/2.2L DuratorqTDCi (110kW/150PS) - Puma
Accessory Drive Belt Tensioner (12.10.41) - 2.0L NA V6 - AJV6/2.5L NA V6 – AJV6/3.0L NA V6 - AJ27
Power Steering Pump Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Power Steering Pump Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Water Pump Belt (12.10.44) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 – AJ27
Water Pump Belt Tensioner (12.10.45) - 2.0L NA V6 - AJV6/2.5L NA V6 – AJV6/3.0L NA V6 - AJ27
303-06: Starting System
Specification
Description and Operation
Starting System
Diagnosis and Testing
Starting System - 2.0L NA V6 - AJV6
Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal and Installation
Starter Motor (86.60.01) - 2.0L Duratorq-TDCi
Starter Motor (86.60.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –
AJ27
303-07A: Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 |
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Specification |
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Description and Operation |
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Engine Ignition |
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Diagnosis and Testing |
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Engine Ignition - 2.0L NA V6 - AJV6 |
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JagDocs |
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Engine Ignition - 2.5L NA V6 - AJV6/3 0L NA V6 - AJ27
Removal and Installation
Ignition Coil-On-Plug LH (18.20.44)
Ignition Coil-On-Plug RH (18.20.43)
303-07B: Glow Plug System
Specification
Description and Operation
Glow Plug System
Diagnosis nd Testing
Glow Plug System
Removal and Installation
Glow Plugs
303-08: Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Specification
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
Removal and Installation
Exhaust Gas Recirculation (EGR) Cooler
Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
303-12A: Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 –
AJV6/3.0L NA V6 - AJ27 |
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Description and Operation |
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Intake Air Distribution and Filtering |
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Diagnosis and Testing |
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Intake Air Distribution and Filtering |
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Removal and Installation |
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Air Cleaner (19.10.05) |
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Air Cleaner Element (19.10.08) |
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Air Cleaner Outlet Pipe (19.10.31) |
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JagDocs |
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303-12B: Intake Air Distribution and Filtering - 2 0L Duratorq-TDCi/2.2L Duratorq- |
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TDCi (110kW/150PS) - Puma |
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Specification
Description and Operati n
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cle ner (19.10.05)
Air Cle ner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
Charge Air Cooler - 2.0L Duratorq-TDCi
Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) – Puma
303-13: Evaporative Emissions
Specification
Description and Operation
Evaporative Emissions
Diagnosis and Testing
Evaporative Emissions - 2.0L NA V6 - AJV6
Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal and Installation
Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6
Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Evaporative Emission Canister Purge Valve (17.15.30)
303-14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27 |
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Specification |
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Description and Operation |
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Electronic Engine Controls |
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Diagnosis and Testing |
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Electronic Engine Controls - 2.0L NA V6 - AJV6
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: J28493->V99999 .
GeneralJagDocsProcedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Camshaft Position (CMP) Sens r (18.30.63)
Catalyst Monitor Sens r 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)
Fuel Temper ture Sensor (18.30.99) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Heated Oxygen Sensor (HO2S) LH (18.30.79)
Heated Oxygen Sensor (HO2S) RH (18.30.78)
Knock Sensor (KS) (18.30.69)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Throttle Position (TP) Sensor (18.30.17)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14B: Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
Removal and Installation
Camshaft Position (CMP) Sensor (18.30.63)
Catalytic Converter Temperature Sensor
Crankshaft Position (CKP) Sensor (18.30.12)
Cylinder Head Temperature (CHT) Sensor (18.30.97)
Diesel Particulate Filter (DPF) Temperature Sensor
Engine Control Module (ECM) (18.30.01) |
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Engine Oil Pressure (EOP) Sensor |
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Fuel Temperature Sensor (18.30.99) |
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Knock Sensor (KS) (18.30.69)
Manifold Absolute Pressure and Temperature (MAPT) Sensor
Manifold Absolute Pressure (MAP) Sensor.(18 30.86)
307: Automatic Transmission/Transaxle
307-01A: Automatic Transmissi n/Transaxle - Vehicles With: 5-Speed Automatic Transaxle - JATCO
Specification
Description and Operation
Transmission Description - Vehicles With: 5-Speed Automatic Transaxle - JATCO Diagnosis nd Testing
Diagnostic Strategy - Vehicles With: 5-Speed Automatic Transaxle - JATCO
General Procedures
MassJagDocsAir Flow (MAF) Sensor (18.30.15)
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
Transmission Range (TR) Sensor Adjustment (44.15.37)
In-Vehicle Repair
Halfshaft Seal LH (37.23.10)
Halfshaft Seal RH
Main Control Valve Body (44.40.01)
Shift Solenoids (SS) (44.15.50)
Transaxle Support Insulator (37.16.42)
Transmission Control Module (TCM) (44.15.32)
Transmission Range (TR) Sensor
Removal
Transaxle (44.20.01)
Disassembly and Assembly of Subassemblies
Input Shaft Seal (44.32.07)
Installation
Transaxle (44.20.01)
307-01B: Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic
Transaxle - AWF21 |
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Specification |
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Description and Operation |
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Transmission Description - Vehicles With: 6-Speed Aut atic Transaxle - AWF21 Transmission Electronic Control System - Vehi les With: 6-Speed Automatic Transaxle - AWF21 .
DiagnosisJagDocsand Testing
Diagnostic Strategy - Vehicles With: 6-Speed Automatic Transaxle - AWF21 General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
In-Vehicle Repair
Main Control Valve Body (44.40.01)
Selector Shaft Seal
Transmission Control Module (TCM) (44.15.32)
Transmission Internal Wiring Harness (44.15.35)
Transmission Fluid Pan (44.24.04)
Removal and Installation
Torque Converter
Torque Converter Seal
Turbine Shaft Speed (TSS) Sensor
Removal
Transmission (44.20.01)
Installation
Transmission (44.20.01)
307-02A: Transmission/Transaxle Cooling - Vehicles With: 5-Speed Automatic
Transaxle - JATCO
Specification
Description and Operation
Transmission Cooling - Vehicles With: 5-Speed Automatic Transaxle - JATCO
Diagnosis and Testing |
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Transmission Cooling |
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Removal and Installation |
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Transmission Fluid Cooler (44.24.10) |
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Transmission Fluid Cooler Tubes (44.24.19) |
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307-02B: Transmission/Transaxle Cooling - Vehicles With: 6-Speed Automatic |
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Transaxle - AWF21 |
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Specification |
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JagDocs |
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Description and Operation .
Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21
Diagnosis and Testing
Transmission Cooling
Removal and Installation
Transmission Fluid Cooler (44.24.10)
Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)
Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)
307-05A: Autom tic Transmission/Transaxle External Controls - Vehicles With:
5-Speed Automatic Transaxle - JATCO
Specification
Description and Operation
External Controls - Vehicles With: 5-Speed Automatic Transaxle - JATCO
Diagnosis and Testing
External Controls
General Procedures
Selector Lever Cable Adjustment (44.15.07)
Removal and Installation
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Assembly (44.15.04)
307-05B: Automatic Transmission/Transaxle External Controls - Vehicles With:
6-Speed Automatic Transaxle - AWF21
Specification
Description and Operation
External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21
Diagnosis and Testing |
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External Controls |
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General Procedures |
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Selector Lever Cable Adjustment (44.15.07) |
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Removal and Installation |
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Selector Lever Assembly (44.15.04) |
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Selector Lever Knob (44.15.06) |
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308: Manual Transmission/Transaxle, Clutch and Transfer Case |
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JagDocs |
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308-00: Manual Transmission/Transaxle and Clut h - General Information |
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Specification |
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Description and Operation
Manual Transmission and Clut h
Diagnosis and Testing
Manual Transmission and Clutch
General Procedures
Clutch System Bleeding (33.15.01) - Vehicles With: 5-Speed Manual
Transmission - MT75
Clutch System Bleeding (33.15.01) - Vehicles With: 6-Speed Manual Transaxle –
MMT6
Gearshift Cable Adjustment (37.16.47)
Release Hub and Bearing Check
308-01: Clutch
Specification
Description and Operation
Clutch
Diagnosis and Testing
Clutch
Removal and Installation
Clutch Disc and Pressure Plate (12.53.13) (33.10.01)
308-02: Clutch Controls
Specification
Description and Operation
Clutch Controls
Diagnosis and Testing
Clutch Controls
Removal and Installation
Clutch Master Cylinder (33.20.01) |
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Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manual Transmission – |
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MT75 |
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Clutch Slave Cylinder (33.35.01) - Vehicles With: 6-Speed Manual Transaxle – |
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MMT6 |
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308-03: Manual Transmission/Transaxle |
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JagDocs |
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Specification |
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Description and Operation |
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Manual Transaxle - Vehicles With: 5-Speed Manual Transmission - MT75 Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6
Diagnosis and Testing
Manual Transaxle
General Procedures
Transaxle Draining and Filling (44.24.02) - Vehicles With: 5-Speed Manual
Transmission - MT75
Trans xle Dr ining and Filling (44.24.02) - Vehicles With: 6-Speed Manual Transaxle - MMT6
In-Vehicle Repair
Halfshaft Seal LH
Halfshaft Seal RH
Input Shaft Seal (37.23.09)
Selector Mechanism - Vehicles With: 5-Speed Manual Transmission - MT75
Selector Mechanism - Vehicles With: 6-Speed Manual Transaxle - MMT6
Support Insulator (37.16.42)
Removal
Transaxle (37.20.01) - 2.0L Duratorq-TDCi
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Installation
Transaxle (37.20.01) - 2.0L Duratorq-TDCi
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
308-06: Manual Transmission/Transaxle External Controls
Specification |
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Description and Operation |
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External Controls |
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Diagnosis and Testing |
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External Controls |
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Removal and Installation |
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Gearshift Cables (37.16.45) - Vehicles With: 5-Speed Manual Transmission –
MT75
308-07: Transfer Case
Specification
Description and Operation
Transfer Case
General Procedures
Transfer C se Dr ining and Filling
In-Vehicle Rep ir
Gearshift Cables (37.16.45) - Vehicles With:.6-Speed Manual Transaxle - MMT6 GearshiftJagDocsLever (37.16.04) - Vehicles With: 5-Speed Manual Transmission - MT75 Gearshift Lever (37.16.04) - Vehicles With: 6-Speed Manual Transaxle - MMT6
Halfshaft Seal RH (46.10.03)
Transfer Case Rear Output Shaft Seal (46.10.04)
Removal
Transfer Case (46.10.01)
Installation
Transfer Case (46.10.01)
309: Exhaust System
309-00: Exhaust System
Specification
Description and Operation
Exhaust System
Diagnosis and Testing
Exhaust System
Removal and Installation
Catalytic Converter (17.50.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma |
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Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA |
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V6 - AJ27 |
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Catalytic Converter RH (17.50.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA |
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V6 - AJ27 |
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Diesel Particulate Filter (DPF) |
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JagDocs |
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Diesel Particulate Filter (DPF) Differential Pre sure Sensor |
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Exhaust Flexible Pipe (30.10.57) - 2.0L |
.Duratorq-TDCi/2.2L Duratorq-TDCi |
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(110kW/150PS) - Puma |
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Front Muffler (30.10.18) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Front Muffler (30.10.18) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Muffler and Tailpipe (30.10.52) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, 2.0L
Muffler nd T ilpipe (30.10.52) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Muffler Inlet Pipe (30.10.06) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 – A 27
Muffler Inlet Pipe (30.10.06) - Vehicles With: Diesel Particulate Filter (DPF)
310: Fuel System
310-00: Fuel System - General Information
Specification
Description and Operation
Fuel System
Diagnosis and Testing
Fuel System
General Procedures
Fuel System Pressure Check
Fuel System Pressure Release (19.50.02)
Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –
Puma
Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Quick Release Coupling - Push Connect
Spring Lock Couplings
310-01: Fuel Tank and Lines |
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Specification |
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Description and Operation |
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Fuel Tank and Lines |
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Diagnosis and Testing |
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Fuel Tank and Lines |
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Removal and Installation |
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JagDocs |
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Fuel Filter (19.25.02) - 2.0L Duratorq-TDCi/2 2L Duratorq-TDCi (110kW/150PS) – |
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Puma |
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Fuel Filter (19.25.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 |
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Fuel Level Sender - 2.0L NA V6 - AJV6 |
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Fuel Level Sender - 2.0L Durat |
rq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – |
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Puma |
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Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Level Sensor (88.25.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Fuel Pump Module (19.45.08) - 2.0L NA V6 - AJV6
Fuel Pump Module (19.45.08) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Fuel Tank (19.55.01) - 2.0L NA V6 - AJV6
Fuel Tank (19.55.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –
Puma
Fuel Tank (19.55.01) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Tank Filler Pipe (19.55.33)
Gas Fuel Tank Pressure Sensor (19.55.31)
Fuel Transfer Pump (19.45.21)
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
Fuel Tank Filler Pipe Hose
310-02: Acceleration Control
Specification
Description and Operation
Acceleration Control
Diagnosis and Testing
Acceleration Control
General Procedures
Accelerator Cable Adjustment (12.20.05) - 2.0L NA V6 - AJV6
Removal and Installation
Accelerator Cable (19.20.06) - 2.0L NA V6 - AJV6 |
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Accelerator Pedal (19.20.01) |
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310-03: Speed Control |
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Specification |
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Description and Operation |
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JagDocs |
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Speed Control |
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Diagnosis and Testing |
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Speed Control - 2.0L NA V6 - AJV6 |
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Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 |
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Removal and Installation |
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Speed Control eactivat |
r Switch (19.75.20) |
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Speed Control Module (19.75.26)
Speed Control Switch (19.75.25)
4: Electrical
412: Climate Control System
412-00: Climate Control System - General Information
Specification
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) Compressor Leak Detection
Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30) Contaminated Refrigerant Handling
Discharging and Recovery (82.30.30)
Electronic Leak Detection
Inspection and Assembly Requirements
Leak Detection
Refrigerant Oil Adding
Refrigerant System Tests
412-01: Air Distribution and Filtering |
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Description and Operation |
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Air Distribution and Filtering |
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Diagnosis and Testing |
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Air Distribution and Filtering |
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Removal and Installation |
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JagDocs |
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Center Registers (82.20.38) |
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Driver Side Register (82.20.39) |
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Front Footwell Duct LH (82.20.91)
Front Footwell Duct RH (82.20.92)
Passenger Side Register (82.20.40)
Pollen Filter (76.10.09)
412-02A: Heating and Ventilation
Specific tion
Description nd Operation
Heating and Ventilation
Diagnosis and Testing
Heating and Ventilation
Removal and Installation
Blower Motor (82.25.66)
Evaporator Core Housing (80.20.01)
Heater Core (80.20.29)
Disassembly and Assembly
Evaporator Core Housing
412-02B: Auxiliary Heating |
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Specification |
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Description and Operation |
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Electric Booster Heater |
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Fuel Fired Booster Heater |
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Diagnosis and Testing |
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Auxiliary Heater |
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Fuel Fired Booster Heater |
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Removal and Installation |
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Electric Booster Heater |
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Fuel Fired Booster Heater |
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com |
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412-03: Air Conditioning |
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Specification |
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Description and Operation |
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Air Conditioning |
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JagDocs |
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Diagnosis and Testing |
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Air Conditioning |
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Removal and Installation |
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Air Conditioning (A/C) C |
mpress |
r (82.10.20) - 2.0L NA V6 - AJV6/2.5L NA V6 – |
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AJV6/3.0L NA V6 - AJ27 |
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Air Conditioning (A/C) C |
mpress |
r (82.10.20) - 2.0L Duratorq-TDCi/2.2L |
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Duratorq-TDCi (110kW/150PS) - Puma
Air Conditioning (A/C) Pressure Transducer (82.10.47)
Clutch nd Clutch Field Coil (82.10.25) - 2.0L NA V6 - AJV6/2.5L NA V6 – A V6/3.0L NA V6 - AJ27
Condenser Core (82.15.07)
Evaporator Core (82.25.20)
Evaporator Core Orifice (82.25.67)
Suction Accumulator (82.17.02)
412-04: Control Components
Description and Operation
Control Components
Diagnosis and Testing
Control Components
Removal and Installation
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