🏷️ 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, 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: 8 Service Manual Volumes: 3 Repair Manual Volumes: 5 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....