JAGUAR 3.4 and 3.8 Litre S Type 1963-1968 Factory Workshop & Spare Parts Manual | PDF Download

JAGUAR 3.4 and 3.8 Litre S Type 1963-1968 Factory Workshop & Spare Parts Manual | PDF Download

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 in this Jaguar Service Manual.

• 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, Refitting
• 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 Universal Joints - Examine and check 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, 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
• 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 warning 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 Batteries for 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

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