Jaguar Mark X 420 420G S-Type (1960-1970) - Repair, Service and Maintenance Manual

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JAGUAR MK X 1960-1970 (INCLUDING 420-420G) & 'S' TYPE


- English Service Manual to Jaguar Mark X 420 420G S-Type (1960-1970)



CONTENTS:


JAGUAR MKX 1960-1970 SERVICE MANUAL

01 GENERAL INFORMATION
General Information
Index to Sections
Index
Car Identification
Car Number
Engine Number
Gearbox Number
Body Number
Key Number
General Data
Dimensions & Weights
Capacities
Performance Data
Fig. 5 Instruments & Controls-RHD
Fig. 6 Instruments & Controls-LHD
Instruments
Ammeter
Oil Pressure Guage
Water Temperature Guage
Fuel Level Guage
Electric Clock
Revolution Counter
Speedometer
Headlight Warning Light
Ignition Warning Light
Flashing Direction Indicators-Warning Lights
Brake Fluid Level & Handbrake Warning Light
Controls & Accessories
Accelerator Pedal
Brake Pedal
Clutch Pedal
Headlight Dipper
Gear Lever (Overdrive & Standard Transmission)
Overdrive Switch Lever
Automatic Tansmission Selector Lever
Handbrake Control
Seat Adjustment
Steering Wheel Adjustment
Rear Door Locks
Horn
Ignition Switch
Starter Switch
Front Door Locks
Map/Interior Light Switch
Lighting Switch
Panel Light Switch
Flashing Direction Indicators
Headlight Flasher
Glovebox Light
Braking Lights
Reversing Lights
Luggage Compartment Illumination
Cigar Lighter
Windscreen Wipers
Windscreen Washer
Heating & Ventilating Equipment
Scuttle Ventilator
Bonnet Lock Control
Two Pin Plug Socket
Spare Wheel & Jacking Equipment
Tools
No Draught Ventilation
Fuel Tank Fillers
Luggage Compartment
Interior Driving Mirror
Ash Trays
Wheel Changing
Picnic Tables
Seatbelts
Electrically Heated Backlight
Starting & Driving
Prior to Starting
Starting from Cold
Warming Up
Driving
"Running-In" Instructions
Overdrive
Operation
Automatic Transmission
Data
Automatic Gear Changes
Driving Instructions
Maintenance
Check Transmission Fluid Level
Drain & Refill Transmission
Summary of Maintenance
Daily
Weekly
Monthly
Every 1,250 miles (2,000 km)
Every 2,500 miles (4,000 km)
Every 5,000 miles (8,000 km)
Every 10,000 miles (16,000 km)
Every 20,000 miles (32,000 km)
Recommended Lubricants
Recommended Hydraulic Fluids
Special Sevice Tools
Service Departments
Conversion Tables

02 ENGINE
Engine
Index
Data
Camshaft
Connecting Rod
Crankshaft
Cylinder Block
Cylinder Head
Gudgeon Pin
Lubricating System
Piston & Piston Rings
Compression Height
Sparking Plugs
Tappet & Tappet Guides
Timing Chain & Sprockets
Valve Timing
Valve & Valve Springs
Valve Guide & Valve Seat Insert
Routine Maintenance
Checking Engine Oil Level
Changing Engine Oil
Distributot Contact Breaker Poins
Sparking Plugs
Fan Belt Tension
Oil Filter Element
Top Timing Chain Tension
Air Cleaner
Recommended Lubricants
Capacity
Fig. 9 Engine
Engine - Removal & Refitting
Fig.10 Removing the Engine
Engine - Dismantle
Engine - Assemble
Decarbonising & Grinding Valves
Compression Pressures
Connecting Rod & Bearings
Big End Bearing Repacement
Camshafts
Crankshaft
Crankshaft Rear Oil Seal
Crankshaft Damper & Pulley
Cylinder Block
Fig. 30 Cylinder Block Assembly
Fig. 31 Cylinder Head Assembly
Cylinder Head
Exhaust Manifolds
Flywheel
Ignition Timing
Oil Filter
Fig. 35 Oil Filter
Inlet Manifold
Oil Pump
Fig. 40 Oil Pump
Oil Sump
Pistons & Gudgeon Pins
Sparking Plugs
Sparking Plug Inserts
Tappets, Tappet Guides & Adjusting Pads
Timing Gear
Fig. 55 Timing Gear
Bottom Chain Tensioner
Valves & Springs
Valve Guides
Valve Seat Inserts
Valve Timing
Engine Mountings
Engine Stabiliser
Air Cleaner
Special Tools
Modified Pistons
Reduced Big End Bearing Clearances

03 FUEL
Carburetters & Fuel System
Carburetters
Index - Carburetters
Description
Throttle Spindle Glands
Idling
Data
Routine Maintenance
Lubricate Carburetter Piston Damper
Checking Carburetter Slow Running
Cleaning Filters
Fuel Pump
Fuel Feed Line Filter
Removal & Refitting
Cleaning the Suction Chamber & Piston
Carburetter Tuning
Float Chamber Fuel Level
Centring the Jet
The Auxiliary Starting Carburetter
Adjustment
Thermostatic Switch
Removal & Refitting
Accelerator Linkage Adjustment
Fig.16 Accelerator Linkage RHD
Fig 17 Accelerator Linkage LHD
Fuel System
Index- The Fuel Systen
Description
Fuel Pumps
Removal
Refitting
Servicing Instructions
Fuel Tanks
Removal
Fig. 26 Fuel System
Refitting
Fuel Tank Guage Units
Removal & Refitting
Modified Petrol Tank & Nylon Breather Tube
Modified Petrol Filler Box Drain Tube
Introduction of Baffles in Petrol Tank Vent Pipes
Modified Petrol Tanks & Pipes
Introduction of 'Delrin' Float Chamber Needle

04 COOLING
Cooling
Index
Data
Routine Maintenance
Checking 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
Fig. 14 Water Pump
Checking
Reassembling
Refitting
Water Temperature Guage
Pressure Testing Radiator Cap & Cooling System
'Quick-Lift' Thermostat
Modified Radiator

05 CLUTCH, GEARBOX & OVERDRIVE
Clutch
Index
Description
Data
Routine Maintenance
Clutch Fluid Level
Clutch Pedal Free Travel
Recommended Hydraulic Fluids
Hydraulic System - General Instructions
Fig. 5 Clutch Operating System
Bleeding the System
Flushing the System
Removal & 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
Fig. 9 Clutch Assembly
General Instructions
Clutch Cover Assembly
Relaese Bearing
Condition of Clutch Facings
Alignment



Pedal Adjustment
Removal
Dismantling
Assembling
Adjusting the Release Levers
(1) Using a Borg & Beck Guage Plate
(2) Using the Churchill Feature
(3) Using the Actual Driven Plate
Refitting
Data for Clutch Lever Tip Setting
Fault Finding
Gearbox & Overdrive.pdf
Gearbox
Index
Gearbox Ratios
Data
Routine Maintenance
Gearbox Oil Level
Overdrive Oil Level
Changing the Gearbox Oil
Overdrive-Oil Changing
Recommended Lubricants
Gearbox & Overdrive Oil Capacities

Fig. 4 Gear Train
Fig. 5 Gearbox Casing & Top Cover
Gearbox-Remove & Refit
Gearbox-Dismantle
Dismantling the Mainshaft
Dismantling the Constant Pinion Shaft
Gearbox-Reassemble
Checking Layshaft End-Float
Assembling the Mainshaft
Assembling 2nd Gear Synchro Assembly
Fitting 2nd Gear Assembly to Mainshaft
Assembling 3rd/Top Synchro Assembly
Fitting the 3rd/Top Synchro Assembly to Mainshaft
Assembling the Constant Pinion Shaft
Assembling the Gears to the Casing
Fitting the Top Cover
Fitting the Extension
Fitting the Clutch Housing
Fig. 22 Gearbox & Overdrive
Overdrive
Operation
Construction
Fig. 24 Overdrive
Operating Instructions
Axle Ratio
Dismantling & Reassembling
Removing Overdrive from Gearbox
Dismantling the Overdrive
Inspection
Reassembling the Overdrive
Pump
Refitting the Overdrive to the Gearbox
Relief Valve
Dashpot
Rotary Solenoid Valve
The Pump
Hydraulic Pressure
Electrically Operated Control System
Fault Finding
Special Tools

11 WHEELS & TYRES
Wheels & Tyres
Index
Data
General Information
Construction of Tyre
Removal & Refitting
Inflating
Inflation Pressures
Effect of Temperature
Nylon Tyres
Tyre Examination
Wheel Alignment-Road Camber

Tyre & Wheel Balance
Tyre Replacement & Wheel Interchanging

12 BODY & EXHAUST
Body
Index
Side Facia Panel
Glove Box
Screen Rail
Bonnet
Bonnet Hinge Assembly
Bonnet Lock
Chrome Strip on Bonnet
Radiator Grille & Surround
Luggage Compartment
Petrol Filler Lids
Front Bumper
Bumper Over-Riders
Windscreen
Rear Glass
Door & Hinges
Door Trim Casings
Door Window Frame & Glass
No Draught Ventilator
Window Regulator
Front Seats & Seat Runners
Rear Seat & Squab
Polished Wood Cappings
Transmission Tunnel Cover & Console
Parcel Tray
Rear Heater Duct Control
Rear Door Lock Mechanism
Fig.50 Body Panels
Fig.51 Underframe Components
Accidental Damage
Body Underframe Alignment
Fig. 53 Underframe Alignment Diagram
Key to Alignment Diagram
Welding Methods
Exhaust

13 HEATING & WINDSCREEN WASHERS
Heating & Windscreen Washing
Index
Heating & Ventilation
Windscreen Washing Equipment
Heating & Ventilation-Early Type
Heater Controls
Fan Switch
Air Distribution
Vacuum Servo System
Fig. 4 Heater Components
Cold Weather
Hot Weather
Heater Unit
Heater Matrix

AND MORE.....