Jaguar 2000-06

Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Lock the steering wheel in the straight-ahead position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Steering column intermediate shaft
     
    Outer tie rod ends
     
    Power steering lines
     
    Steering rack and pinion gear

    Click image to see an enlarged view

    Fig. Steering rack



    Click image to see an enlarged view

    Fig. Steering rack attachment clamps

     

  6.  

To install:

  1. Install or connect the following:

    Steering rack and pinion gear. Tighten the bolts to 30-37 ft. lbs. (40-50 Nm).
     
    Power steering lines
     
    Outer tie rod ends. Tighten the nuts to 52-63 ft. lbs. (71-85 Nm).
     
    Steering column intermediate shaft
     
    Front wheels
     
    Negative battery cable
     

  2.  
  3. Fill the power steering fluid reservoir.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.

    Click image to see an enlarged view

    Fig. Front suspension components-XJ V8

  8.  

  1. Center the steering wheel. Lock in position, remove the ignition key.
  2.  
  3. Remove both tie-rod ends. Remove both tie-rod end lock nuts.
  4.  
  5. Remove the air deflector.
  6.  
  7. Make sure the alignment mark on the steering gear pinion seal protection cover is central to the steering gear pinion casting.
  8.  
  9. Loosen the lower steering column pinch bolt.
  10.  
  11. Vehicles built up to 01/2004, disconnect the power steering control valve actuator electrical connector.
  12.  
  13. Detach the lower steering column.
  14.  
  15. Remove the steering gear shaft pinch bolt.
    NOTE
    Cap the power steering lines to prevent loss of fluid and dirt ingress. If power steering fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water. Drain the fluid into a suitable container.

  16.  
  17. Disconnect the power steering supply and return lines. Remove and discard the O-ring seals.
  18.  
  19. Vehicles built up to 01/2004, remove the steering gear.
  20.  
  21. Vehicles built 02/2004 onwards, remove the steering gear. Disconnect the power steering control valve actuator electrical connector.
  22.  
  23. Remove the steering gear.
  24.  

To install:

  1. Vehicles built 02/2004 onwards, install the steering gear. Connect the power steering control valve actuator electrical connector. Tighten to 74 ft. lbs. (100 Nm).
  2.  
  3. Vehicles built up to 01/2004, install the steering gear. Tighten to 74 ft. lbs. (100 Nm).
  4.  
  5. Install new O-ring seals. Connect the power steering supply and return lines. Tighten to 15 Nm.
  6.  
  7. Install the steering gear shaft pinch bolt. Tighten to 26 ft. lbs. (35 Nm).
  8.  
  9. Vehicles built up to 01/2004, connect the power steering control valve actuator electrical connector.
  10.  
  11. Tighten the lower steering column pinch bolt. Tighten to 26 ft. lbs. (35 Nm).
  12.  
  13. Make sure the alignment mark on the steering gear pinion seal protection cover is central to the steering gear pinion casting.
  14.  
  15. Install the air deflector.
  16.  
  17. Install both tie-rod end lock nuts.
  18.  
  19. Install both tie-rod ends.
  20.  
  21. Install a new power steering fluid reservoir.
  22.  

  1. Center the steering wheel. Lock in position and remove the ignition key.
  2.  
  3. Remove the extension shaft lower retaining bolt.
  4.  
  5. Remove the wheels and tires.
  6.  
  7. Detach the stabilizer bar link arms.
  8.  
  9. Remove the radiator splash shield.
  10.  
  11. Remove the driveshaft.
  12.  
  13. Remove the front muffler.
  14.  
  15. Remove the muffler inlet pipe.
  16.  
  17. Detach the rear of the steering gear heat shield.
  18.  
  19. Detach the right-hand front of the steering gear heat shield.
  20.  
  21. Detach the left-hand front of the steering gear heat shield.
  22.  
  23. Remove the engine roll restrictor.
  24.  
  25. Detach the front of the steering gear cooling pipe.
  26.  
  27. Detach the rear of the steering gear cooling pipe.
  28.  
  29. Remove both tie rod ends from the wheel hub assemblies.
  30.  
  31. Disconnect the actuator electrical connector.
  32.  
  33. Remove the latch plate bolt. Rotate latch plate counter clockwise. Disconnect the high and low pressure pipes.
  34.  
  35. Remove the steering gear.
  36.  

To install:

  1. Install the steering gear. Tighten to 98 ft. lbs. (133 Nm).
  2.  
  3. Attach the left-hand front of the steering gear heat shield. Tighten to 62 inch lbs. (7 Nm).
  4.  
  5. Attach the right-hand front of the steering gear heat shield. Tighten to 62 inch lbs. (7Nm).
  6.  
  7. Attach the rear of the steering gear heat shield. Tighten to 62 inch lbs. (7 Nm).
  8.  
  9. Install the engine roll restrictor. Tighten to 59 ft. lbs. (80 Nm).
  10.  
  11. Attach the rear of the steering gear cooling pipe. Tighten to 62 inch lbs. (7 Nm).
  12.  
  13. Attach the front of the steering gear cooling pipe. Tighten to 62 inch lbs. (7 Nm).
  14.  
  15. Install the muffler inlet pipe.
  16.  
  17. Install the front muffler.
  18.  
  19. Install the driveshaft.
  20.  
  21. Install the radiator splash shield.
  22.  
  23. Attach the stabilizer bar link arms. Tighten to 36 ft. lbs. (48 Nm).
  24.  
  25. Install the wheels and tires.
  26.  
  27. Install new O-ring seals. Connect the power steering lines. Tighten the latch plate bolt to 89 inch lbs. (10 Nm).
  28.  
  29. Tighten the pinch bolt to 18 ft. lbs. (25 Nm).
  30.  
  31. Install a new power steering reservoir.
  32.  

XJ Range Through VIN F59525; Xk Range



  1. Centralize steering the wheel.
  2.  
  3. Raise and support the vehicle on a hoist.
  4.  
  5. Place a suitable drain pan under the steering gear.
  6.  
  7. From below the vehicle, check that steering gear is centralized by aligning the centralizing notch on the dirt protection cover with the location hole in the pinion housing casting.
  8.  
  9. Remove and discard both tie rod end nuts. Detach both of the tie rod ends.
  10.  
  11. Loosen the steering column lower shaft retaining bolt.
  12.  
  13. Remove and discard the steering column lower shaft retaining bolt.
  14.  
  15. Detach the steering column lower shaft.
  16.  
  17. Disconnect the steering gear transducer electrical connector.
  18.  
  19. Cut and discard the power steering return pipe tie-strap.
  20.  
  21. Detach the power steering return pipe from the mounting rubber.
  22.  
  23. Remove the power steering supply and return pipe retaining plate bolt and withdraw the plate.
  24.  
  25. Drain the power steering fluid.
  26.  
  27. Disconnect the power steering supply and return pipes and allow the fluid to drain.
  28.  
  29. Remove and discard the O-ring seals from the pipe connectors.
  30.  
  31. Install caps to the pipe connectors and pinion housing ports.
  32.  


NOTE
The steering gear mounting bushings must be replaced as a pair.

  1. Remove the steering gear mounting bracket bushings.
  2.  


NOTE
When removing the steering gear, maneuver the power steering return pipe past the pinion housing to steering gear pipes.

  1. Remove the steering gear.
  2.  
  3. Using a tap (M10 x 1.5 mm), clean the steering gear to crossbeam bolt hole threads.
  4.  

To install:


NOTE
If a new steering gear assembly is to be fitted, make sure steering gear is centralized before installation. A new steering gear assembly is supplied with a dirt protection cover/centralizing cap fitted.

  1. Position the steering gear to vehicle.
  2.  
  3. Install the steering gear mounting bracket bushings. Torque to 33 ft. lbs. (45 Nm).
  4.  
  5. Connect the power steering supply and return pipes to the pinion housing.
  6.  
  7. Install new O-ring seals in pipe connectors. Lubricate the O-ring seals with clean power steering fluid.
  8.  
  9. Position the power steering supply and return pipes to the pinion ports and seat O-rings. Attach the power steering supply and return pipes to the pinion housing.
  10.  
  11. Ensure the power steering supply and return pipes and the retaining plate are correctly seated. Install the bolt. Tighten to 9 ft. lbs. (12 Nm).
  12.  
  13. Attach the power steering return pipe to the steering gear.
  14.  
  15. Attach the rubber support to the power steering return pipe.
  16.  
  17. Install a new power steering return pipe tie-strap.
  18.  
  19. Install a new steering gear transducer harness tie-strap.
  20.  
  21. Connect the steering gear transducer electrical connector.
  22.  
  23. Locate the tie rod end into the steering arm. Install a new nut. Tighten the nut to 21 ft. lbs. (28 Nm).
  24.  


NOTE
Make sure the steering wheel and wheel and tire assemblies are in the straight ahead position before fitting the steering column lower shaft.

  1. Attach the steering column lower shaft.
  2.  
  3. Attach the steering column lower shaft.
  4.  
  5. Install the steering column lower shaft retaining bolt. Tighten to 25 ft. lbs. (34 Nm).
  6.  
  7. Install a new power steering fluid reservoir, refill with new power steering fluid and bleed air from the system.
  8.  
  9. Check and adjust the front toe.
  10.  


    Click image to see an enlarged view

    Fig. Centering the steering shaft


From VIN G00442



  1. Center the steering wheel. Lock in position, remove the ignition key.
  2.  
  3. Remove both tie-rod ends. Remove both tie-rod end lock nuts.
  4.  
  5. Remove the air deflector.
  6.  
  7. Disconnect the power steering control valve actuator electrical connector.
  8.  
  9. Remove the steering gear shaft pinch bolt.
  10.  
  11. Cap the power steering lines to prevent loss of fluid and prevent dirt ingress.
    NOTE
    If power steering fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water.

  12.  
  13. Disconnect the power steering supply and return lines. Remove and discard the O-ring seals.
  14.  
  15. Remove the steering gear.
  16.  

To install:

  1. Install the steering gear. Tighten to 100 Nm.
  2.  
  3. Install new O-ring seals. Connect the power steering supply and return lines. Tighten to 15 Nm.
  4.  
  5. Attach the lower steering column. Install the steering gear shaft pinch bolt. Tighten to 35 Nm.
  6.  
  7. Connect the power steering control valve actuator electrical connector.
  8.  
  9. Install the air deflector.
  10.  
  11. Install both tie-rod ends.
  12.  
  13. Install both tie-rod end lock nuts.
  14.  
  15. Install a new Power Steering Fluid Reservoir.
  16.  

Through VIN M45254



  1. Disconnect the battery ground cable.
    NOTE
    Install the special tool to the lower steering column to maintain a straight ahead steering wheel position. Failure to do so may cause damage to the steering wheel clock-spring.

  2.  
  3. Install the special tool to the lower steering column.

    Click image to see an enlarged view

    Fig. Steering wheel locking tool installed-2002 S-Type through VIN M45254

  4.  
  5. Loosen the lower steering column slider pinch bolt.
  6.  
  7. Remove both front wheels and tires.
  8.  
  9. Disconnect the actuator electrical connector.
  10.  
  11. Detach the lower steering column.
  12.  
  13. Remove the steering gear shaft pinch bolt.
    NOTE
    Whenever the steering gear unions and hoses are disconnected the steering gear valve body ports and hoses should be plugged to prevent dirt ingress. Failure to follow this instruction may result in damage to the vehicle.

  14.  
  15. Disconnect the power steering supply and return tubes.
  16.  
  17. Drain the fluid into a suitable container.
  18.  
  19. Remove and discard the O-ring seals.
  20.  
  21. Prevent the tie-rod end ball joint ball pin hexagon from rotating. Failure to do so may result in damage to the tie-rod end ball joint boot.
  22.  
  23. Detach both of the tie rod ends. Remove and discard the retaining nuts.
  24.  
  25. Vehicles with 4.0L engine, detach the steering gear supply and return tubes.
  26.  
  27. Remove the steering gear.
  28.  

To install:

Click image to see an enlarged view

Fig. Steering gear mounting points-S-Type

  1. Install the steering gear. Tighten to 76 ft. lbs. (103 Nm).
  2.  
  3. Vehicles with 4.0L engine, attach the steering gear supply and return tubes.
    NOTE
    Prevent the tie-rod end ball joint ball pin from rotating. Failure to do so may result in damage to the tie-rod end ball joint boot. Make sure the mating surfaces are free from dirt and lubricant. Failure to do so may result in damage to the vehicle.

  4.  
  5. Attach both of the tie-rod ends to the wheel knuckles. Install new retaining nuts. Tighten to 56 ft. lbs. (75 Nm).
  6.  
  7. Install new O-ring seals. Connect the power steering supply and return tubes. Tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Install the steering gear shaft pinch bolt. Tighten to 26 ft. lbs. (35 Nm).
  10.  
  11. Connect the actuator electrical connector.
  12.  
  13. Install both front wheels and tires.
  14.  
  15. Tighten the lower steering column slider pinch bolt. Tighten to 26 ft. lbs. (35 Nm).
  16.  
  17. Remove the special tool from the lower steering column.
    NOTE
    When the battery has been disconnected and reconnected, some abnormal driving conditions may occur while the vehicle relearns its driving strategy.

  18.  
  19. Connect the battery ground cable.
  20.  
  21. Install a new power steering fluid reservoir.
  22.  
  23. Check and adjust front wheel alignment.
  24.  

 
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