Jaguar XJ6 2003-2009 Workshop Service Manual for Repair
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๐ท๏ธ Basic Information Identification Make: Jaguar Model: XJ6 Generation Generation Designation: X350/X358 Codes Chassis Code: X350 (2003-2007), X358 (2007-2009 facelift) ๐ Introduction Market Position Segment: Full-size luxury sedan Brand Perception: Represents the pinnacle of Jaguar's luxury and performance offerings, known for its elegant design, refined ride, and powerful engines. Competitive Analysis Key Competitors: BMW 7 Series, Mercedes-Benz S-Class, Audi A8, Lexus LS, Porsche Panamera. Key Features Aluminum Monocoque: Revolutionary bonded and riveted aluminum monocoque construction for enhanced rigidity, reduced weight, and improved handling characteristics. Adaptive Dynamics Suspension: Sophisticated air suspension system with adaptive damping control that continuously monitors road conditions and adjusts suspension settings for optimal ride comfort and handling. V8 Engines: Availability of naturally aspirated and supercharged V8 engines providing potent performance and a distinctive Jaguar exhaust note. ๐ Manual Details Coverage Areas Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009 Page Count Total Pages: 6470 Manual Type Type: Workshop Service Manual Language Language: English Format File Format: PDF ๐ Manual Coverage Systems Covered Engine Mechanical: Comprehensive diagnosis, repair, and overhaul procedures for all XJ6 engine variants (e.g., 3.0L V6, 3.5L V8, 4.2L V8 Supercharged). Engine Electrical: Detailed diagnostic procedures, wiring diagrams, component testing, ignition system, fuel injection system, engine control module (ECM) operations. Transmission: Repair and overhaul of automatic transmissions (e.g., ZF 6HP26), including torque converter, valve body, and electronic control. Drivetrain: Front and rear axle assemblies, drive shafts, differentials, and wheel bearings. Suspension: Detailed information on the advanced Adaptive Dynamics air suspension system, including components, diagnostics, and calibration. Steering: Power steering system, steering rack, column, and associated components, including hydraulic and electronic power steering (EPS) where applicable. Brakes: Hydraulic brake system, ABS, DSC (Dynamic Stability Control), brake disc and pad replacement, bleeding procedures, and component diagnostics. Electrical System: Comprehensive coverage of the vehicle's electrical architecture, including lighting, power windows, seats, mirrors, central locking, and fuse/relay locations. Body And Chassis: Body panel removal and installation, interior trim, doors, hood, trunk, structural components, and corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system operation, component testing, refrigerant handling, and troubleshooting. Infotainment And Electronics: Audio system, navigation, climate control interface, and other electronic modules and their integration. Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, and general upkeep. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex faults across all vehicle systems. Repair: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Installation: Correct procedures for installing new or reconditioned components, including torque specifications and alignment. Adjustment: Procedures for calibrating and adjusting various systems, such as suspension height, door alignment, and sensor settings. Technical Depth Depth: Extremely comprehensive, covering everything from basic fluid checks to complete engine rebuilds, complex electrical diagnostics, and suspension system overhauls. ๐ Manual Specifications File Format Quality: High-resolution PDF, allowing for clear viewing and printing of all diagrams and text. Print Quality Printability: Fully printable, allowing users to create physical copies of sections or the entire manual. Binding Type Delivery Method: Instant Download (digital) Paper Type Digital Format Details: PDF format requires Adobe Reader for viewing. โ๏ธ Engine Specifications Primary Engine Engine Options: 3.0L V6 (AJ-V6), 3.5L V8 (AJ-V8), 4.2L V8 (AJ-V8), 4.2L V8 Supercharged (AJ-V8). Performance Horsepower Range: Approx. 235 hp (3.0L V6) to 400 hp (4.2L V8 Supercharged). Torque Range: Approx. 277 lb-ft (3.0L V6) to 413 lb-ft (4.2L V8 Supercharged). Fuel System Injection Type: Multi-point fuel injection (MPFI) or sequential multi-port fuel injection (MPI). ๐ง Transmission Standard Transmission Type: 6-speed automatic (ZF 6HP26) for most V8 models, 6-speed automatic for 3.0L V6. Optional Drive Type: Rear-wheel drive (RWD) standard. All-wheel drive (AWD) available on select models/years. Features Shift Modes: Includes Jaguar Sequential Shift (JSS) allowing manual gear selection via gear selector or steering wheel-mounted paddles on some models. ๐ Dimensions Exterior Wheelbase: Approx. 124.3 inches (3157 mm) Length: Approx. 200.1 inches (5083 mm) Weights Curb Weight Range: Approx. 3700 - 4200 lbs (1680 - 1905 kg) depending on engine and configuration. ๐ก๏ธ Safety Features Ratings NHTSA Ratings: General safety ratings were good for its class; specific year-by-year ratings vary. Expected good performance in frontal and side impacts due to robust construction. Active Features Driver Assistance: Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD), Traction Control System (TCS), Dynamic Stability Control (DSC). Passive Features Airbags: Front airbags, front side-impact airbags, curtain airbags. ๐ก Technology Features Infotainment Touchscreen Interface: Central touchscreen for climate control, audio, navigation, and vehicle settings. Audio Systems: Premium audio options from brands like Alpine or Bowers & Wilkins, with CD changer and auxiliary inputs. Driver Assistance Adaptive Cruise Control: Optional Adaptive Cruise Control (ACC) that maintains a set distance from the vehicle ahead. Parking Sensors: Front and rear parking sensors, often accompanied by a rearview camera on later models. Connectivity Bluetooth: Bluetooth connectivity for hands-free...
Represents the pinnacle of Jaguar's luxury and performance offerings, known for its elegant design, refined ride, and powerful engines.
Competitive Analysis
Key Competitors:
BMW 7 Series, Mercedes-Benz S-Class, Audi A8, Lexus LS, Porsche Panamera.
Key Features
Aluminum Monocoque:
Revolutionary bonded and riveted aluminum monocoque construction for enhanced rigidity, reduced weight, and improved handling characteristics.
Adaptive Dynamics Suspension:
Sophisticated air suspension system with adaptive damping control that continuously monitors road conditions and adjusts suspension settings for optimal ride comfort and handling.
V8 Engines:
Availability of naturally aspirated and supercharged V8 engines providing potent performance and a distinctive Jaguar exhaust note.
๐ Manual Details
Coverage Areas
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009
Page Count
Total Pages:
6470
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
File Format:
PDF
๐ Manual Coverage
Systems Covered
Engine Mechanical:
Comprehensive diagnosis, repair, and overhaul procedures for all XJ6 engine variants (e.g., 3.0L V6, 3.5L V8, 4.2L V8 Supercharged).
Repair and overhaul of automatic transmissions (e.g., ZF 6HP26), including torque converter, valve body, and electronic control.
Drivetrain:
Front and rear axle assemblies, drive shafts, differentials, and wheel bearings.
Suspension:
Detailed information on the advanced Adaptive Dynamics air suspension system, including components, diagnostics, and calibration.
Steering:
Power steering system, steering rack, column, and associated components, including hydraulic and electronic power steering (EPS) where applicable.
Brakes:
Hydraulic brake system, ABS, DSC (Dynamic Stability Control), brake disc and pad replacement, bleeding procedures, and component diagnostics.
Electrical System:
Comprehensive coverage of the vehicle's electrical architecture, including lighting, power windows, seats, mirrors, central locking, and fuse/relay locations.
Body And Chassis:
Body panel removal and installation, interior trim, doors, hood, trunk, structural components, and corrosion protection.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation, component testing, refrigerant handling, and troubleshooting.
Infotainment And Electronics:
Audio system, navigation, climate control interface, and other electronic modules and their integration.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, and general upkeep.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex faults across all vehicle systems.
Repair:
Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Installation:
Correct procedures for installing new or reconditioned components, including torque specifications and alignment.
Adjustment:
Procedures for calibrating and adjusting various systems, such as suspension height, door alignment, and sensor settings.
Technical Depth
Depth:
Extremely comprehensive, covering everything from basic fluid checks to complete engine rebuilds, complex electrical diagnostics, and suspension system overhauls.
๐ Manual Specifications
File Format
Quality:
High-resolution PDF, allowing for clear viewing and printing of all diagrams and text.
Print Quality
Printability:
Fully printable, allowing users to create physical copies of sections or the entire manual.
Multi-point fuel injection (MPFI) or sequential multi-port fuel injection (MPI).
๐ง Transmission
Standard
Transmission Type:
6-speed automatic (ZF 6HP26) for most V8 models, 6-speed automatic for 3.0L V6.
Optional
Drive Type:
Rear-wheel drive (RWD) standard. All-wheel drive (AWD) available on select models/years.
Features
Shift Modes:
Includes Jaguar Sequential Shift (JSS) allowing manual gear selection via gear selector or steering wheel-mounted paddles on some models.
๐ Dimensions
Exterior
Wheelbase:
Approx. 124.3 inches (3157 mm)
Length:
Approx. 200.1 inches (5083 mm)
Weights
Curb Weight Range:
Approx. 3700 - 4200 lbs (1680 - 1905 kg) depending on engine and configuration.
๐ก๏ธ Safety Features
Ratings
NHTSA Ratings:
General safety ratings were good for its class; specific year-by-year ratings vary. Expected good performance in frontal and side impacts due to robust construction.
Active Features
Driver Assistance:
Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD), Traction Control System (TCS), Dynamic Stability Control (DSC).
Passive Features
Airbags:
Front airbags, front side-impact airbags, curtain airbags.
๐ก Technology Features
Infotainment
Touchscreen Interface:
Central touchscreen for climate control, audio, navigation, and vehicle settings.
Audio Systems:
Premium audio options from brands like Alpine or Bowers & Wilkins, with CD changer and auxiliary inputs.
Driver Assistance
Adaptive Cruise Control:
Optional Adaptive Cruise Control (ACC) that maintains a set distance from the vehicle ahead.
Parking Sensors:
Front and rear parking sensors, often accompanied by a rearview camera on later models.
Connectivity
Bluetooth:
Bluetooth connectivity for hands-free phone calls and audio streaming on many models.
๐ง Maintenance
Service Intervals
Oil Change:
Typically every 10,000 miles or 12 months, whichever comes first. Consult manual for specific engine requirements.
Transmission Fluid Change:
ZF recommends fluid changes at intervals around 60,000 miles for optimal transmission longevity. Check manual for specific recommendations.
Fluid Specifications
Engine Oil:
Specific synthetic oil grades (e.g., 5W-30 or 0W-30) compliant with Jaguar specifications (e.g., STJLR.51.5126 or similar). Capacity varies by engine.
Coolant:
Jaguar approved long-life coolant (e.g., OAT-based coolant, typically orange or pink). Capacity approx. 9.0-10.0 liters.
Transmission Fluid:
Specific ATF fluid compatible with ZF 6HP26 transmission, such as Shell M-1375.4 or an equivalent meeting the specification. Capacity approx. 9-10 liters for a full drain and fill.
Known Issues
Air Suspension:
Potential for leaking air springs (air struts/bags), compressor failure, or valve block issues leading to uneven ride height or a harsh ride.
Thermostat Housing:
Plastic thermostat housings can become brittle and crack, leading to coolant leaks.
Timing Chain Tensioners:
Early V8 engines (pre-2005/2006 depending on VIN) can have plastic timing chain tensioners that may degrade and fail, causing significant engine damage. Replacement with updated metal tensioners is recommended.
Water Pump:
The water pump, often with a plastic impeller, can fail, leading to coolant leaks and overheating.
๐ Vehicle History
Brand Heritage
Jaguar Legacy:
Jaguar has a long-standing reputation for producing luxurious, sporting sedans with a focus on performance and craftsmanship.
Model Evolution
X350 Introduction:
The X350 generation debuted in 2003, marking a significant departure with its all-aluminum body structure, replacing the steel unibody of previous XJ models.
X358 Facelift:
A significant facelift in 2007 (designated X358) introduced updated styling, including a more prominent grille, revised bumpers, and interior enhancements.
Production
Manufacturing Location:
Castle Bromwich Assembly, Birmingham, England.
๐ Awards & Recognition
Recognitions
Design Awards:
The X350 generation received acclaim for its elegant and timeless design, often cited as one of the most beautiful modern Jaguars.
Ratings
Automotive Journalism Reviews:
Consistently praised for its comfortable ride, refined interior, and powerful performance, particularly the supercharged variants.