JAGUAR Mark X 3.8 Litre 1961-1965 Factory Workshop & Spare Parts Manual | PDF Download

JAGUAR Mark X 3.8 Litre 1961-1965 Factory Workshop & Spare Parts Manual | PDF Download. 

This Jaguar Workshop Manual is for the following Jaguar Cars made between 1961-1965.

• Jaguar Mark X 3.8 Litre Saloon

Below is a comprehensive list of information in this Mark X Jaguar Service Manual.

• GENERAL INFORMATION
• Car Identification
• General Data: Dimensions and weights
• Capacities
• Performance Data
• Operating Instructions: Instruments, Controls and accessories, Wheel changing, Starting and driving
• Overdrive Operating Instructions
• Automatic Transmission, Operating and Maintenance
• Summary of Maintenance
• Recommended Lubricants and Multi-grade Engine Oils
• Recommended Hydraulic Fluids
• Service Tools
• Service Departments
• Conversion Tables
• ENGINE
• Air Cleaner
• 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, Refitting
• Cylinder Block: Overhaul
• Cylinder Head: Removal, Overhaul, Refitting
• Decarbonising and Grinding Valves
• Engine-Removal and Refitting
• Engine-To dismantle
• Engine-To assemble
• Engine Mountings
• Engine Stabilizer
• 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, Reassembling, Refitting
• Oil Sump: Removal, Refitting
• Pistons and Gudgeon Pins: Removal, Overhaul, Refitting
• Routine Maintenance
• Sparking Plugs: Service procedure, Analysing service conditions, Standard gap setting
• Special Tools
• Tappets, Tappet Guides and Adjusting Pads: Removal of tappets and adjusting pads, Overhaul
• 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
• Routine Maintenance
• Lubricate carburetter piston damper
• Checking carburetter slow running
• Cleaning carburetter filters
• Fuel pumps
• Fuel feed line filter
• Carburetters: Removal, Refitting
• Cleaning the suction chamber and piston
• Carburetter tuning
• Float chamber fuel level
• Centring the jet
• The auxiliary starting carburetter: Adjustment
• Thermostatic Switch: Removal, Refitting
• Accelerator Linkage: Adjustment
• THE FUEL SYSTEM
• Fuel Pumps: Removal, Refitting, Servicing instructions
• Fuel Tanks: Removal, Refitting
• Fuel Tank Gauge Units: Removal, Refitting
• COOLING SYSTEM
• Routine Maintenance
• Checking the radiator water level
• Care of the cooling system
• Frost Precautions: Anti-freeze
• Engine heater
• Radiator: Removal, Refitting
• Radiator Cowl: Removal, Refitting
• Fan: Removal, Refitting
• Fan Belt: Removal, Refitting
• Thermostat: Removal, Checking, Refitting
• Water Pump: Removal, Dismantling, Checking, Reassembly, Refitting
• Water Temperature Gauge
• Pressure Testing Radiator Cap and Cooling System
• CLUTCH
• Routine Maintenance
• Clutch fluid level
• Clutch pedal free travel
• Hydraulic System-General Instructions
• Bleeding the System
• Flushing the System
• Removing and Refitting a Flexible Hose
• The Master Cylinder: Removal, Renewing the Master Cylinder Seals, Master Cylinder Push-rod-Free Travel, Refitting
• The Slave Cylinder: Removal, Dismantling, Assembling, Refitting
• The Clutch Unit
• Clutch Cover Assembly
• Release Bearing
• Pedal Adjustment
• Removal of Clutch: Dismantling, Assembling
• Adjusting the Release Levers
• 1. Using a Borg and Beck Gauge Plate
• 2. Using the Churchill fixture
• 3. Using the actual Driven Plate
• Refitting
• Data for Clutch Lever Tip Setting
• Fault Finding
• GEARBOX
• Gearbox Ratio Data
• Data
• Routine Maintenance
• Gearbox-To remove and refit
• Gearbox-To dismantle
• Dismantling the mainshaft
• Dismantling the constant pinion shaft
• Gearbox-To reassemble
• Checking layshaft end float
• Assembling the mainshaft
• Assembling the 2nd gear synchro assembly
• Fitting the 2nd gear assembly to the mainshaft
• Assembling the 3rd/top synchro assembly
• Fitting the 3rd/top synchro assembly to the mainshaft
• Assembling the constant pinion shaft
• Assembling the gears to the casing
• Fitting the top cover
• Fitting the rear cover
• Fitting the clutch housing
• OVERDRIVE
• Operation
• Construction
• Operating Instructions
• Dismantling and Reassembling
• Removing the overdrive from the gearbox
• Inspection
• Reassembling the overdrive rear casing
• Pump
• Refitting the overdrive to the gearbox
• The Relief Valve
• The Dashpot
• Rotary Solenoid Valve
• The Pump
• AUTOMATIC TRANSMISSION (Linkage and Controls)
• Description
• Anti-Creep System
• Data
• Automatic Gear Changes
• Recommended Lubricants
• Routine Maintenance
• Operation
• 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
• Routine Maintenance:
• Front Propeller Shaft: Removal, Refitting,
• Rear Propeller Shaft: Removal, Refitting
• Centre Bearing: Removal, Dismantling, Reassembly, Refitting
• Divided Propeller Shaft Alignment
• Checking-in the horizontal plane
• Checking-in the vertical plane
• Adjustment of engine stabilizer
• The Universal Joints: Examine and check for wear, Dismantling, Assembling
• REAR AXLE
• Routine Maintenance:
• Checking the oil level
• Half shaft lubrication
• Rear wheel bearing lubrication
• Changing the rear axle oil
• The Axle Unit: Removal, Refitting
• The Rear Hubs: Removal, Dismantling, Assembling
• Hub bearing end float
• The Half Shafts: Removal, Refitting
• The Universal Joints: Checking for wear, Dismantling, Assembling
• The Differential Unit
• The Output Shafts: Removal, Dismantling, Assembling, Refitting
• Removing the Differential Assembly from the Carrier
• Dismantling the Differential Assembly
• Pinion removal
• Dismantling the differential unit
• Assembling the differential unit
• Checking the differential unit for wear
• Pinion adjustment
• Differential bearing preload and drive gear adjustment
• Final assembly
• Tooth contact
• Ideal contact
• High tooth contact
• Low tooth contact
• Toe contact
• Heel contact
• Backlash
• Drive gear and pinion movement
• Special Tools
• STEERING
• Routine Maintenance
• Checking the reservoir oil level
• Steering tie rods
• Oil reservoir filter
• Steering idler housing
• Recommended Lubricants
• Operation:
• Steering in the straight ahead position
• Steering on lock
• The Steering Unit: Removal, Dismantling, Assembling
• The Top End cover
• The Rocker shaft cover
• Rocker shaft adjustment
• Replacement of top end cover oil seal
• The Reservoir: Dismantling, inspection and reassembling
• Bleeding the System
• The Pressure Pump: Operation, Removal, Dismantling, inspection and assembly, Refitting
• Fault finding
• High steering effort
• Noise
• Oil leaks
• Steering Idler Assembly: Removal, Dismantling, Assembling, Refitting
• Lock Stop Adjustment
• Front Wheel Alignment
• Steering Arm: Removal, Refitting
• Tie Rod: Removal, Refitting
• Track Rod: Removal, Dismantling, Assembling,
• Steering Wheel: Removal, Refitting
• Steering Column: Removal, Dismantling, Assembling, Refitting
• Lower Steering Column: Removal, Refitting
• Accidental Damage
• Special Tools
• FRONT SUSPENSION
• Routine Maintenance: Hydraulic dampers, Wheel bearings
• Front Suspension Assembly: Removal, Refitting
• 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, Refitting
• Upper Wishbone Ball Joint: Removal, Refitting
• Castor Angle Adjustment
• Camber Angle Adjustment
• Anti-Roll Bar: Removal, Fitting the link arm bush, Refitting
• Accidental Damage
• Special Tools
• REAR SUSPENSION
• 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 - Adjustment
• Accidental Damage
• Special Tools
• BRAKES
• Retractor Operation
• Handbrakes
• Routine Maintenance
• Brake fluid level
• Brake fluid warning light
• Footbrake adjustment
• Handbrake cable adjustment
• Examining the friction pads for wear
• Renewing the friction pads
• Recommended brake fluids
• Bleeding the Brake System
• Brake Overhaul-Precautions
• The Brake Pedal Box Assembly: Removal & Refitting
• Brake linkage-dismantling
• Brake linkage-assembling
• Setting the operating lever
• The Master Cylinders: Removal, Renewing the master cylinder seals
• Master cylinder push-rod-adjustment
• The Front Calipers: Removal, Refitting
• The Rear Calipers: Removal, Refitting
• The Front Brake Discs: Removal, Refitting
• The Rear Brake Discs: Removal, Refitting
• Brake Disc "Run-out"
• Renewing the Friction Pads
• Renewing the Brake Piston Seals
• The Handbrake: Operation
• Friction pad carriers-removal
• Friction pad carriers-dismantling
• Friction pad carriers-assembling
• Friction pad carriers-refitting
• Handbrake Cable Adjustment
• Renewing the handbrake friction pads
• Removal and refitting the handbrake cable
• Removing and refitting the handbrake control
• The Brake Fluid Level and Handbrake Warning Light
• Handbrake warning light switch-setting
• The Bellows Type Vacuum Servo
• Dismantling the unit
• Reassembling the unit
• Fault finding
• Checking the servo unit for vacuum
• The vacuum reservoir and check valve
• Special Tools
• WHEELS AND TYRES
• Road Wheels
• Tyres
• Inflation Pressures
• Tyres - General Information
• Construction of the Tyre
• Removing and Fitting of Tyres
• Tyre Examination
• Wheel Alignment and Its Association with Road Camber
• Tyre and Wheel Balance
• Static Balance
• Dynamic Balance
• Tyre Replacement and Wheel Interchanging
• BODY AND EXHAUST SYSTEM
• Side Facia Panel: Removal, Refitting
• Glove Box: Removal, Refitting
• Screen Rail; Removal Refitting
• Bonnet: Removal Refitting
• Bonnet Hinge Assembly: Removal Refitting
• Bonnet Lock: Removal of the right-hand lock Refitting the right-hand lock
• Removal of the left-hand lock Refitting the left-hand lock
• Removing the bonnet release lever Refitting the bonnet release lever
• Removing the bonnet lock striker pegs Adjustment of the striker pegs
• Chrome Strip on Bonnet: Removal Refitting
• Mascot: Removal Refitting
• Radiator Grille and Surround: Removal Refitting
• Luggage Compartment Lid and Hinges: Removal Refitting
• Luggage Compartment Locks: Removal Adjusting the locks Refitting
• 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
• Front Door and Hinges: Removal Refitting
• Rear Door and Hinges: Removal Refitting
• Adjusting the door torsion spring
• Front and Rear Door Trim Casings: Removal Refitting
• Front Door Window Frame and Glass: Removal Refitting
• Rear Door Window Frame and Glass: Removal Refitting
• Front No Draught Ventilator: Removal Refitting
• Rear No Draught Ventilator: Removal Refitting
• Front Window Regulator (Manually Operated): Removal Refitting
• Rear Window Regulator (Manually Operated): Removal Refitting
• Front Window Regulator (Electrically Operated)
• Rear Window Regulator (Electrically Operated)
• Front Seats and Runners: Removal Refitting
• Rear Seat and Squab: Removal Refitting
• Polished Wood Cappings: Removal of centre pillar capping Refitting
• Removal of screen capping
• Removal of screen pillar capping
• Removal of rear quarter cant rail capping
• Removal of rear cant rail capping
• Removal of courtesy light and capping
• Removal of front cant rail
• Transmission Tunnel Cover and Console: Removal Refitting
• Parcel Tray: Removal
• Heater Duct Control: Removal Refitting
• Door Lock Mechanism: Removal of lock mechanism
• Removing the remote control unit
• Removing the lock unit
• Removing the outside handle base plate assembly
• Removing the outside handle
• Removing the striker unit
• Refitting the lock mechanism
• Refitting the remote control unit
• Aligning the lock assembly
• Refitting the outside handle base plate assembly
• Connecting the push button mechanism
• Fitting and adjusting the striker unit
• Master check for correct alignment
• Front doors
• Rear doors
• Lubrication
• Accidental Damage: Replacing the body panels
• Checking the Body Underframe Alignment
• Checking for distortion in the horizontal plane
• Checking for distortion in the vertical plane
• 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
• EARLY TYPE
• Heater controls
• Fan Switch
• Air Distribution
• Vacuum Servo Unit: Description
• Heater Unit: Removal Refitting
• Heater Matrix: Removal Refitting
• Vacuum Supply Tank: Removal Refitting
• Vacuum Servo Unit (Scuttle Ventilator): Removal Refitting
• Vacuum Servo Unit (Heater Flaps): Removal Refitting
• Fan Motor: Removal Refitting
• Heater Water Control Valve: Removal Refitting
• Fan Switch: Removal Refitting
• Air Temperature Control Panel: Removal Refitting
• LATER TYPE
• Heater Controls
• Off
• Heat
• Air
• Vacuum System
• WINDSCREEN WASHING EQUIPMENT
• Operation
• Warning
• Filling-up
• Cold Weather
• Adjusting the Jets
• Jet Nozzles: Cleaning
• Lubrication
• ELECTRICAL AND INSTRUMENTS
• Battery
• Data
• Routine Maintenance
• Removal
• Refitting
• Persistent Low State of Charge
• Recharging from an External Supply
• Preparing New Unfilled, Uncharged Batteries for Service
• Preparing New "Dry Charged" Batteries for Service
• Distributor
• Removal
• Refitting
• Ignition Timing
• Routine Maintenance
• Servicing: Dismantling, Bearing replacement, Reassembly
• Distributor Test Data
• Flasher Units
• Information
• Fuse Unit
• Information
• Generator Model C.48
• General
• Routine Maintenance
• Removal
• Refitting
• Performance Data
• Servicing
• Horns
• Removal
• Adjustment
• Refitting
• Lamps
• Light Bulbs
• Headlights: Description
• Beam Setting
• Outer Headlight Replacement
• Inner Headlight Replacement
• Sidelight Bulb-Replacement
• Front Flasher Bulb-Replacement
• Rear Flasher Bulb-Replacement
• Rear/Brake Light Bulb-Replacement
• Number Plate Light Bulb-Replacement
• Reversing Light Bulb-Replacement
• Interior Light Bulbs-Replacement
• Glovebox Light Bulb-Replacement
• Flashing Indicator Bulb-Replacement
• Overdrive/Automatic Selector Bulb-Replacement
• Map Light Bulb-Replacement
• Indicator Strip Bulbs-Replacement
• RB 340 Current and Voltage Regulator
• Preliminary Checking of Charging Circuit
• Voltage Regulator Adjustment
• Current Regulator Adjustment
• Cut-out Adjustment
• Cleaning Regulator Contacts
• Cleaning Cut-out Contacts
• Starter Motor
• Removal
• Refitting
• Routine Maintenance
• Performance Data
• Servicing
• Starter Drive
• Routine Maintenance
• Dismantling and Reassembling
• Windscreen Wiper
• Maintenance
• Removal of Wiper Motor and Cable
• Disconnecting the Cable
• Refitting
• Removal of Wheelboxes
• Refitting
• Fault Diagnosis
• Testing
• ELECTRICALLY OPERATED WINDOWS:
• Removal of Window Regulator
• Refitting of Window Regulator
• System Employed on Early cars
• System Employed after Later cars
• Driver's Control Switches
• Rear Passenger's Control Switches
• Miscellaneous
• Intermediate Speed Hold Switch: Removal Refitting
• Electric Clock: Removal Adjustment Refitting
• Brake Fluid and Handbrake Warning Light: Renewing the Bulb
• Flashing Indicator Control: Removal Refitting
• Overdrive Switch: Removal Refitting
• Wiring Diagram
• Wiring Diagram
• Instruments
• Screen Rail: Removal Refitting
• The Instrument Panel: Opening Removal Refitting Closing
• The Glove Box: Removal Refitting
• Side Facia Panel: Removal Refitting
• Speedometer: Removal Refitting
• Revolution Counter and Clock: Removal Refitting
• Revolution Counter Drive: Removal Refitting
• Removal of the Instrument Panel Components:
• Ignition Switch
• Cigar Lighter Element
• Cigar Lighter Unit
• Starter Push Button
• Head and Side Light Switch
• Tumbler Switches
• Ammeter and Oil Pressure Gauges
• Fuel and Water Temperature Gauges
• Voltage Regulator
• Switch Indicator Strip
• Engine Temperature, Fuel Tank Contents and Oil Pressure Gauges
• Operation of the engine temperature gauge
• Operation of the fuel tanks gauge
• Operation of the oil pressure gauge
• Analysis of faults (Engine Temperature and Petrol Gauge)
• Analysis of faults (Oil Pressure Gauge)
• Speedometer Cable: Removal Refitting
• Speedometer Cable-General Instructions
• Speedometer-General Instructions

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