This workshop manual is the most comprehensive manual available for repairing, restoring and maintaining your Jaguar S Type.
Suitable for the home workshop mechanic or professional technician this manual will help you repair and maintain your Jaguar. Very easy step by step instructions with lots of diagrams.
This Jaguar Workshop Manual is for the following Jaguar Cars made between 1963-1968.
- Jaguar 3.4 Litre S Type Saloon
- Jaguar 3.8 Litre S Type Saloon
The following is a detailed list of information contained in this Jaguar Service Manual. All sections show how to remove, repair and replace the parts with full easy to follow descriptions and detailed diagrams.
GENERAL INFORMATION
ENGINE
Air Cleaners
Bottom Chain Tensioner - Removal, Refitting
Camshafts - Removal, Refitting, Overhaul
Compression Pressures
Connecting Rod and Bearings - Removal, Overhaul, Refitting, Big-end bearing replacement
Crankshaft - Removal, Overhaul, Refitting
Crankshaft Damper and Pulley - Removal, Overhaul, Refitting
Crankshaft Rear Oil Seal - Removal, Replacing the Seal, Refiiting
Cylinder Block - Overhaul
Cylinder Head - Removal, Overhaul, Refitting
Data
Decarbonising and Grinding Valves
Engine Details
Engine - Removal and Refitting
Engine - To Dismantle
Engine - To Assemble
Engine Mountings
Front Engine Mountings
Rear Engine Mounting (Standard Transmission and Overdrive Models)
Rear Engine Mounting (Automatic-Transmission)
Engine Stabilisers
Exhaust Manifolds - Removal, Refitting
Flywheel - Removal, Overhaul, Refitting
Ignition Timing
Inlet Manifold - Removal, Refitting
Oil Filter - Removal, Refitting, Element Replacement
Oil Pump - Removal, Dismantling, Overhaul, Re-assembling, Refitting
Oil Sump - Removal, Refitting
Pistons and Gudgeon Pins - Removal, Overhaul, Refitting
Routine Maintenance
Sparking Plugs - Service Procedure, Analysing Service Conditions, Standard Gap Setting, Sparking Plug Inserts
Tappets, Tappet Guides and Adjusting Pads - Removal of Tappets and Adjusting Pads, Overhaul, Tappet Guide Replacement
Timing Gear - Removal, Dismantling, Overhaul, Assembling, Refitting
Valves and Springs - Removal, Overhaul, Valve Clearance Adjustment, Refitting
Valve Guides - Replacement
Valve Seat Inserts - Replacement
Valve Timing
CARBURETTERS AND FUEL SYSTEM
Description
Throttle spindle glands
Idling
Data
Routine Maintenance
Lubricate carburetter piston damper
Checking carburetter slow running
Cleaning carburetter filters
Fuel feed line filter
Carburetters - Removal, Refitting
Cleaning the suction chamber and piston
Carburetter tuning
Float chamber fuel level
Centring the end
Auxiliary Starting Carburetter - Description, Adjustment, Thermostatic switch-removal and refitting
Throttle Control Linkage Setting
THE FUEL SYSTEM
The Petrol Pump - Description, Operation, Removal, Refitting
Replacing the delivery chamber diaphragm
Resetting the armature and diaphragm assembly
Petrol Tanks - Removal, Refitting
Petrol Gauge Tank Units - Removal, Refitting
COOLING SYSTEM
Data
Routine Maintenance
Checking radiator water level
Care of the cooling system
Frost Precautions
Anti-freeze
Engine heater
Radiator - Removal , Cleansing the system, Refitting
Fan - Removal, Refitting
Automatic Fan Belt Tensioner
Fan Belt - Removal, Refitting
Thermostat - Removal, Checking, Refitting,
Data
Water Pump - Removal, Dismantling, Checking, Reassembly, Refitting
Water Temperature Gauge
CLUTCH
Description
Data
Routine Maintenance
Clutch fluid level
Clutch free travel
Recommended hydraulic fluids
Hydraulic system-general instructions
Bleeding the system
Flushing the system
Removing and refitting a flexible hose
The Master Cylinder - Principle of operation, Removal, Refitting
Renewing the master cylinder seals
Master cylinder push-rod-free travel
The Slave Cylinder - Removal, Dismantling, Assembling, Refitting
The Clutch Unit - General Instructions
Clutch cover assembly
Release bearing
Condition of clutch facings
Alignment
Pedal adjustment
Removal of clutch - Dismantling, Assembling, Refitting
Data for clutch lever tip setting
Fault finding
GEARBOX AND OVERDRIVE
Gearbox Ratio Data
Data
Routine Maintenance
Recommended Lubricants
Gearbox - remove and refit
Gearbox - dismantle
Dismantling the mainshaft
Dismantling the constant pinion shaft
Gearbox - re-assemble
Checking layshaft end float
Assembling the mainshaft
Assembling the second gear synchro assembly
Fitting the second gear assembly to the mainshaft
Assembling the third/top synchro assembly
Fitting the third/top synchro assembly to the mainshaft
Assembling the constant pinion shaft
Assembling the gears to the casing
Fitting the top cover
Fitting the extension
Fitting the clutch housing
OVERDRIVE
Description
Method of operation
Routine Maintenance
Recommended Lubricants
Dismantling and re-assembling - Removing the overdrive from the gearbox
Dismantling the overdrive - Inspection, Re-assembling the overdrive
Refitting the overdrive to the gearbox
Components
The operating valve
The hydraulic system
The pump valve
The Pump - Dismantling, Assembly
Hydraulic Pressure
The Accumulator Piston and Spring - Removal
The Control System
Wiring Circuit
Operating solenoid
Data
Operating Instructions
Fault Finding
Service Tools
AUTOMATIC TRANSMISSION (Linkage and Controls)
Description
Anti-creep System
Data
Routine Maintenance
Operation
Selector
To release transmission from P (Park) when facing UP HILL
To release transmission from P (Park) when facing DOWN HILL
Service Adjustments:
Accelerator to governor lever adjustment
Starter cut-out and reverse light switch
Manual selector cable adjustment
Anti-creep throttle switch adjustment
PROPELLER SHAFT
Description
Routine Maintenance
Propeller Shaft (Standard Transmission Models) - Removal, Refitting
Propeller Shaft (Overdrive and Automatic Transmission Models) - Removal
Refitting
The Umversal Joints - Examine and Gheck for wear, dismantle, AssemblIng
REAR AXLE
Description
Data
Axle Ratios
Recommended Lubricants
Routine Maintenance
Checking rear axle oil level
Changing the rear axle oil
The Axle Unit - Removal, Refitting
The Rear Hubs - Removal, Dismantling, Assembling, Refitting
The Halfshafts - Removal, Refitting
The universal joints
The Differential Unit - Description
Principle of operation
The output shafts
Removing the differential assembly from the carrier
Dismantling the differential unit
Assembling the differential unit
Pinion adjustment
Differential bearing pre-load and drive gear adjustment
Final assembly
Tooth contact
Special Tools
STEERING
Description
Data
Routine Maintenance:
Steering Box (Standard Steering)
Steering Idle Lever Housing
Steering Tie-Rods
Wheel Swivels
Front Wheel Alignment
Recommended Lubricants
Steering Unit - Removal, Dismantling, Assembling, Refitting
Wormshaft End Float
Rocker Shaft End Float
Steering Wheel - Removal, Refitting
Steering Column - Removal, Dismantling, Re-assembling, Refitting
Lower Steering Column - Removal, Dismantling and Re-assembly, Refitting
Steering Idler Assembly - Removal, Dismantling, Assembling, Refitting
Steering Arm - Removal, Refitting
Tie Rod - Removal, Refitting
Track Rod - Removal, Dismantling, Assembling
Front Wheel Alignment
Lock Stop Adjustment
Accidental Damage
POWER-ASSISTED STEERING - FIRST TYPE
Description
The Steering Unit
Data
The Valve
The Rocker Shaft
Routine Maintenance
Checking the Steering Reservoir Oil Level
Steering Idle Lever Housing
Steering Tie-Rods
Recommended Lubricants
Operation
(a) Steering in straight ahead position
(b) Steering on lock
The Steering Unit - Removal, Dismantling, Assembling
The End Cover
Rocker Shaft Adjustment
Rocker Shaft Assembly
Replacement of Top End Plate Oil Seal
The Reservoir
Bleeding the System
Steering Idler Assembly - Removal, Dismantling, Assembling
Refitting
Fault Finding
1. High Steering Effort
2. Noise (the installation is noisy at engine idling speed)
3. Oil Leaks
POWER-ASSISTED STEERING - SECOND TYPE
Description
The Steering Unit
Data
The Valve
The Rocker Shaft
Routine Maintenance
Checking the Steering Reservoir Oil Level
Steering Idle Lever Housing
Steering Tie-Rods
Recommended Lubricants
Operation
(a) Steering in straight ahead position
(b) Steering on lock
The Steering Unit (Second Type) - Removal, Dismantling, Assembling
The Top Cover
The Rocker Shaft Cover
Rocker Shaft Adjustment
Replacement of Top Cover Oil Seal
The Reservoir
Bleeding the System
Steering Idler Assembly - Removal, Dismantling, Assembling
Lock Stop Adjustment
Fault Finding:
1. High Steering Effort
2. Noise
3. Oil Leaks
Accidental Damage
The Pressure Pump - Operation, Removal, Dismantling, Inspection and Assembly, Refitting
FRONT SUSPENSION
Description
Data
Routine Maintenance
Front suspension
Front shock absorbers
Wheel swivels
Front wheel alignment
Front Suspension Assembly - Removal, Refitting,
Suspension Bump Stop
Hydraulic Dampers - Removal, Refitting
Coil Springs - Removal, Refitting
Coil spring packing pieces
Wheel Hubs - Removal, Dismantling, Refitting
Bearing end-float adjustment
Stub Axle Carriers - Removal, Refitting
Lower Wishbone - Removal, Fitting the rubber/steel bushes, Refitting
Lower Wishbone Ball Joint - Removal, Dismantling, Reassembling
Adjustment of the ball joint, Refitting
Upper Wishbone - Removal, Dismantling, Fitting the rubber/steel bushes , Reassembling, Refittmg
Upper Wishbone Ball Joint - Removal, Refitting
Castor Angle Adjustment
Camber Angle Adjustment
Anti-Roll Bar - Removal, Fitting the link arm bush, Refitting
Accidental Damage
REAR SUSPENSION
Description
Data
Routine Maintenance
Recommended lubricants
Rear Suspension - Removal, Refitting
Road Spring and Hydraulic Damper Assembly - Removal, Refitting
Hydraulic Dampers - Removal, Refitting
Radius Arm - Removal, Refitting
Wishbone - Removal, Refitting
Wishbone Outer Pivot - Removal, Dismantling, Reassembly, Bearing adjustment, Refitting
Inner Fulcrum Wishbone Mounting Bracket - Removal Refitting
Rear Wheel Camber Angle-Adjustment
Accidental Damage
Special Tools
BRAKES
Description
Handbrake
Data
Routine Maintenance
Brake fluid level
Brake fluid level wJlrning light
Friction pads-examination for wear
Friction pads-renewal
Brake servo air cleaner
Bleeding the brake hydraulic system
Brake overhaul-precautions
The Master Cylinder - Operation, Removal
Renewing the master cylinder seals
Master cylinder push-rod-free travel
The Brake Assembly - Assembling
Renewing the friction pads
Renewing cylinder seals
Handbrake - Operation, Friction pad carriers-removal, Dismantling, Friction pad carriers-refitting
Handbrake cable adjustment
Handbrake friction pads-renewing
Handbrake cable - removal, Refitting
The Brake Fluid Level and Handbrake Warning Light - Description
Handbrake warning light switch-setting
The Vacuum Reservoir and Check Valve - Description, Removal, Refitting
Lockheed 6i" Vacuum Servo Unit
Booster Piston
Slave cylinder
Control valve
Service Tools
WHEELS AND TYRES
Description
Data
Road Wheels
Wheel Alignment and its Association with Road Camber
Tyee and Wheel Balance
Tyee Replacement and Wheel Interchanging
Wire Spoke Wheels, Description, Removal and Dismantling, Rebuilding, Trueing
BODY AND EXHAUST SYSTEM
The Instrument Panel - Opening, Removal, Refitting
The Screen Rail - Removal, Refitting
The Side Facia Panel - Removal, Refitting
The Glovebox - Removal, Refitting
The Console - Removal, Refitting
Bonnet - Removal, Refitting
Bonnet Lock - Removal, Adjustment of the Bonnet Lock, Refitting
Chrome Strips on Bonnet - Removal, Refitting
Radiator Grille - Removal, Dismantling, Re-assembling, Refitting
Mascot - Removal, Refitting
luggage Compartment Lid and Hinges - Removal, Refitting
Boot Lock Adjustment
Petrol Filler Lids - Removal, Refitting
Front Bumper - Removal, Refitting
Front Bumper Over-riders - Removal, Refitting
Rear Bumper - Removal, Refitting
Rear Bumper Over-riders - Removal, Refitting
Windscreen - Removal, Refitting
Rear Glass - Removal, Refitting
Front Doors and Hinges - Removal, Refitting
Rear Doors and Hinges - Removal, Refitting
Front and Rear Door Trim Casing - Removal, Refitting
Front and Rear Door Window Frames and Glass - Removal, Refitting
Front No Draught Ventilator - Removal, Refitting
Rear No Draught Ventilator - Removal, Refitting
Front Window Regulator - Removal, Refitting
Rear Window Regulator - Removal, Refitting
Front Seats and Seat Runners - Removal, Refitting
Rear Seat and Squab - Removal, Refitting
Polished Wood Cappings - Removal and Refit of Upper and Lower Capping on Door Pillar
Capping Rail at the Side of the Windscreen - Remove, Refitting
Courtesy Light and Capping - Removal, Refitting
Removal of Lock Mechanism - Front Doors, Rear Doors
Remote Opening Control - Removing and Refitting
Turn-Button Locking Control - Removing and Refitting
Lock Unit - Removing and Refitting
Outside Handle Base-Plate - Removing and Refitting
Striker Unit - Removing and Refitting
Outside Handle - Removing and Refitting
Master Check for Correct Alignment - Front Doors, Rear Doors
Replacement Body Panels
Checking Body Underframe Alignment:
Checking for Distortion in the Horizontal Plane
Checking for Distortion in the Vertical Plane
Body Alignment Jig
Welding Methods:
Spot Welding
Breaking Spot Welds
Gas Welding
Breaking Gas Welds
EXHAUST SYSTEM
Removal
Refitting
HEATING AND WINDSCREEN WASHING EQUIPMENT
CAR HEATING AND VENTILATING SYSTEM
Description
Fan Switch
Air distribution
Cold weather
Hot weather
Vacuum Servo System
Scuttle Ventilator Servo Unit - Removal, Refitting
Heater Tap Servo Unit - Removal, Refitting
Vacuum Supply Tank - Removal, Refitting
Heater Unit - Removal, Refitting
Heater Matrix - Removal, Refitting
Fan Motor - Removal, Refitting
Fan Switch - Removal, Refitting
Air Temperature Control Panel - Removal, Refitting
Heater Control Lever - Removal, Refitting
Front Air Direction Vents - Removal, Refitting
Direction Vent Control Cables - Removal, Refitting
WINDSCREEN WASHING EQUIPMENT
Operation
Filling-up
Cold weather
Adjusting the jets
Jet nozzles
Lubrication
ELECTRICAL AND INSTRUMENTS
BATTERY
Routine Maintenance
Removal
Refitting
Data
Persistent Low State of Charge
Recharging from an External Supply
Preparing New Unfilled, Uncharged Batteriesfor Service
Preparing New "Dry Charged" Batteries for Service
DISTRIBUTOR
Removal
Refitting
Routine Maintenance
Servicing
Data
Distributor Test Data
FLASHER UNITS
Information
FUSE UNITS
Information
Circuits
GENERATOR-MODEL C42
General
Routine Maintenance
Performance Data
Removal
Refitting
Servicing
GENERATOR-MODEL C48
General
Routine Maintenance
Performance Data
Removal
Refitting
Servicing
CURRENT VOLTAGE REGULATOR-MODEL RB 340
General
Voltage Regulator
Current Regulator
Cut-out Relay
Adjustment of Air Gap Settings
Cleaning Contacts
STARTER MOTOR
Performance Data
General
Removal
Refitting
Routine Maintenance
Servicing
To Dismantle
Reassembly
STARTER DRIVE
General
Routine Maintenance
Dismantling and Reassembly
LAMPS
Lamp Bulbs
Headlights
Headlight Beam Setting
Headlight Unit-Replacement
Sidelight Bulb-Replacement
Sidelight Warning Light Bulb-Replacement (Italian)
Front Flasher Bulb-Replacement
Rear Flasher Bulb-Replacement
Flashing Indicator Bulb-Replacement
Rear/Brake Light Bulb-Replacement
Number Plate Light Bulb-Replacement
Luggage Compartment Light Bulb-Replacement
Reversing Light Bulb-Replacement
Interior Light Bulbs-Replacement
Glovebox Light Bulb-Replacement
Map Light BUlb-Replacement
Indicator Strip Bulbs-Replacement
Automatic Selector Bulb-Replacement
Fog-Light Unit-Replacement
Fog Lamp Bulb-Replacement (Switzerland)
Fog Lamp Bulb-Replacement (France)
Adjusting Fog Lamp Beams
HORNS-MODEL 9H
Description
Maintenance
Adjustment
Service Replacements
Horn Relay-Checking
WINDSCREEN WIPER
Data
Description
Maintenance
Removal of Wiper Motor and Cable
Refitting
Removal of Wheelboxes
Refitting
Fault Diagnosis
Testing
WIRING HARNESS REPLACEMENT
MISCELLANEOUS
Electric Clock
Brake Fluid and Handbrake Warning Light
Flashing Indicator Control
THE INSTRUMENTS
The Instrument Panel
The Screen Rail
The Side Facia Panel
The Glovebox
The Speedometer
The Revolution Counter and Clock
Testing Operation of Revolution Counter
The Revolution Counter Drive
Removal of the Instrument Panel Components
The Bi-Metal Resistance Instrumentation
Operation of the engine temperature gauge
Operation of the fuel tanks gauge
Analysis of the engine temperature and petrol tank gauge faults
Analysis of the oil pressure gauge faults
Operation of the oil pressure gauge
The Speedo Drive Cable
Speedometer Cable
Speedometer
Radio
Radio Unit and Front Loudspeaker Mounting
Rear Speaker Fitting
Electrically Heated Backlight
Fault diagnosis |
