1986-1994 Jaguar XJ6 Service Repair Workshop Manual

The 1986-1994 Jaguar XJ6 Service Repair Workshop Manual provides comprehensive technical information for maintaining and repairing the Jaguar XJ6 luxury sedan. This manual covers Series III and XJ40 models with 3.6L and 4.0L inline-six engines, automatic transmission, braking systems, electrical systems, suspension, steering, and bodywork. Below are key sections for specifications, maintenance procedures, troubleshooting, and technical data.

1. Vehicle Specifications 2. Maintenance Schedules 3. Engine Systems 4. Transmission & Drivetrain 5. Braking System 6. Electrical Systems 7. Suspension & Steering 8. Body & Interior 9. Troubleshooting Guide 10. Technical Data 11. Wiring Diagrams

Vehicle Specifications

Key technical specifications for 1986-1994 Jaguar XJ6 models.

Specification	Details
Engine Type	3.6L/4.0L inline-six, fuel injected
Power Output	181-223 hp (depending on model year)
Transmission	4-speed automatic (ZF 4HP22)
Braking System	Four-wheel disc brakes with ABS
Suspension	Independent front and rear with self-leveling
Fuel System	Lucas/Bosch electronic fuel injection
Electrical System	12-volt negative ground
Wheelbase	112.8 inches (Series III), 113.0 inches (XJ40)
Curb Weight	3,800-4,100 lbs
Fuel Capacity	23.8 gallons

Maintenance Schedules

Recommended maintenance intervals for optimal performance.

Oil and filter change: Every 3,000 miles or 3 months
Spark plugs: Replace every 30,000 miles
Timing belt: Inspect every 60,000 miles, replace at 90,000 miles
Brake fluid: Flush every 2 years or 24,000 miles
Coolant: Replace every 2 years or 30,000 miles
Transmission fluid: Change every 30,000 miles
Air filter: Replace every 15,000 miles
Fuel filter: Replace every 30,000 miles

WARNING! Always use Jaguar-approved fluids and parts. Follow torque specifications precisely.

Engine Systems

Detailed procedures for engine maintenance and repair.

Engine removal and installation procedures
Cylinder head removal and valve adjustment
Fuel injection system diagnosis and repair
Cooling system maintenance and radiator replacement
Exhaust system inspection and component replacement
Ignition system timing and component service
Oil pump and lubrication system service

CAUTION! Engine components operate at high temperatures. Allow cooling before servicing.

Transmission & Drivetrain

Transmission Type: ZF 4HP22 4-speed automatic
Fluid Capacity: 9.5 quarts (with torque converter)
Fluid Type: Dexron II or equivalent ATF
Drive Shaft: Two-piece with center support bearing
Differential: Independent rear suspension with limited-slip differential
Transmission Mounts: Rubber insulated with torque reaction rod
Shift Linkage: Cable-operated with manual override capability

Braking System

Service procedures for hydraulic and anti-lock braking systems.

Front Brakes: Ventilated discs, 11.0 inches diameter. Rear Brakes: Solid discs, 10.4 inches diameter.

Brake Pad Replacement: Remove wheels, caliper bolts, replace pads, compress pistons, reassemble. Brake Disc Inspection: Measure thickness and runout; replace if below minimum specification. ABS Diagnosis: Use diagnostic connector under hood; check wheel sensors and hydraulic modulator.

Electrical Systems

Diagnosis and repair of electrical components and systems.

Battery: 12V 72Ah, located in trunk (right side)
Alternator: 70-90 amp output, brush replacement procedure
Starter Motor: Lucas M45G, removal from underneath vehicle
Instrument Cluster: Bulb replacement and gauge testing
Lighting Systems: Headlight adjustment and switch replacement
Power Windows: Motor replacement and regulator service
Central Locking: Actuator diagnosis and replacement

Tip: Disconnect battery negative terminal before electrical work to prevent short circuits.

Suspension & Steering

Maintenance and repair of suspension and power steering systems.

Front Suspension: Double wishbone with anti-roll bar
Rear Suspension: Independent with self-leveling (optional)
Shock Absorbers: Gas-filled, replacement procedure
Power Steering: ZF system, fluid type ATF Dexron II
Wheel Alignment: Specifications and adjustment procedures
Ball Joints: Inspection and replacement criteria
Bushings: Polyurethane upgrade recommendations

WARNING! Use proper jacking points and safety stands when working under vehicle.

Body & Interior

Repair procedures for body panels, trim, and interior components.

Troubleshooting Guide

Common problems and diagnostic procedures.

Symptom	Possible Cause	Corrective Action
Engine cranks but won't start	Fuel pump failure, ignition problem	Check fuel pressure, spark at plugs, crank sensor
Transmission slips or shifts hard	Low fluid, valve body issues	Check fluid level and condition, test line pressure
Electrical gremlins	Ground connections, Lucas components	Clean and tighten ground points, check relays
Brake pulsation	Warped rotors, stuck calipers	Measure rotor runout, free up caliper slides
Overheating	Thermostat, water pump, radiator	Pressure test system, check fan operation

Technical Data

Essential technical specifications and torque values.

Spark Plug Gap: 0.025-0.028 inches
Oil Pressure: 40-60 psi at 2000 rpm
Cooling System Pressure: 15 psi cap
Fuel Pressure: 30-36 psi (engine running)
Cylinder Head Bolt Torque: 65 ft-lbs in sequence
Wheel Lug Torque: 85-95 ft-lbs
Main Bearing Clearance: 0.0008-0.0022 inches
Rod Bearing Clearance: 0.0008-0.0024 inches

Wiring Diagrams

Complete electrical schematics for all systems.

Includes: Engine management wiring, ABS system circuits, Instrument cluster connections, Lighting systems, Power accessories, Central locking, Audio system. Diagrams show wire colors, connector locations, and component identification.

Service Support: Jaguar technical service bulletins available through dealer network. Original equipment parts recommended for optimal performance.