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JAGUA JA~ . - Service Bulletin Bulletin 1/ ill.- - - - - - - ISSUE ISSUE NO: NO:JD 04/92 APRIL 1992 SHEET: SHEET: 1 OF 1 S.R.O: 82-25-13 82-25-14 MODEL : XJ6/ S.111 V12 (AIR (AIR CONDITIONED MODELS) MODELS) XJ61 XJS I/ 5.111 SUBJECT : BLOWER MOTOR MOTOR ASSEMBLIES CUSTOMER CONCERN squeak. : Brush Brush gear noisy operation, ie: low speed ticking I/squeak. ADVICE TO CUSTOMER : Installation Installation of revised revised blower motor assemblies incorporating rating a new'P35' motor will overcome the noise concerns. New blower motors have been been introduced from the follow· following ing VINs: VINs: XJ6 (Air Con) Con) -- 657163 657163 -- 183290 183290 XJS 5.111 -- 486002 S.III 486002 DEALER ACT1 ACTION 0N : Yes REPAIR REPAIR METHOD : Blower Assemblies incorporating incorporating the new motor are interinterchangeable on on vehicles prior to t o the above VINs VlNs (see (see Parts Information Information below for model model year variations). should be be carcarReplacement of blower motor assemblies should ried with ried out in in accordance w i t h the following Service Manual Manual instructions: XJ6 -- Volume 4, Section 82, Page 82-38/82-39 82-38/82-39 XJS -- Volume 4, Section 82, 82, Page 82-62/82-63 82-62/82-63 S.III S.Ill -- Section 80-82, 80-82, Page 82-39/82-40 82-39182-40 SERVICE TOOLS PARTS PARTS INFORMATION N/A : Owing Owing to the introduction of 'PM5' 'PMS' harness connectors connectors on blower motor assemblies fitted fitted to XJ6 and XJS models from VINs: XJ6-629286 XJ6 - 629286 XJS -- 179737 179737 Part Numbers for replacement units on on vehicles PRIOR to the abovl3 above ViNs VlNs are as follows: follows; XJ6 XJS RH RH eBC CBC 8966 8966 CCC 5546 cee Jaguar Cars Limited Limited Jaguar LH LH CBe CBC 8967 8967 cce CCC 5547 Jaguar Cars Limited 2005 JA~ JAGUAR % JD 04/92 04 192 Part Numbers for replacement units on on vehicles FROM FROM the above VI Vl Ns are as follows: fol lows: RH RH XJ6 XJS lH LH 5400 CCC 5400 5544 CCC eee eee CCC 5401 5401 eee 5545 CCC S.III V12 v12 The harness connector on on Series III Ill blower motors motors has not changed. For replacement units units incorporating the new motor, the following Part Numbers apply: RH RH 5.111 ADMINISTRATION INFORMATION INFORMATION eee CCC 5546 lH LH eee CCC 5547 : WARRANTY CODES CODES XJ6 )) 7TA (RH) 7TAIRH) XJS )1 7TB (LH) ILHI S.III 5.111 754 REPAIR OPERATION OPERATION CODES XJ6/ XJ6 / XJS MODELS: MODELS: SRO 82-25-14 SRO 82-25-13 82-25-14 (RHI (RH) 82-25-13 (LHI ILH) (SRO (SRO (SRO 82-25-14/09 82-25-1 4/09 (SRO 82-25-13/09 82-25-13/09 LESS ALLOWANCE) LESS JDS ALLOWANCE) LESS LESS JDS ALLOWANCE) 5.111: SRO 82-25-14 (RH) SRO 82-25-13 (lH) Jaguar Cars Limited 2005 A - III Service Bulletin I 1[----. .. . . - --.. . -- -. -. .- DATE: OCTOBER 1991 1991 DATE: 1 of 7 PAGE: 1 REF: JD 08/91 08/91 REF: ITEM: 49 49 ITEM: XJS WARRANTY WARRANTY CODES In In the latest latest edition of the the XJS Warranty Code Code book, book, codes codes for the battery battery and and spare wheel wheel covers covers have have been been duplicated. duplicated. To To rectify rectify this situation situation and a n d prevent prevent further confusion confusion when submitting submitting claims, claims, the the following codes have been removed from the warranty system:following codes have been removed from the system:- CODE CODE DESCRIPTION DESCRIPTION 90S Spare Wheel Wheel Cover Battery Battery Cover Cover Boot Boot 8PZ with immediate immediate effect, effect, Dealers Dealers shou should NOTsubrnitfurtherctaimsforthese Therefore, with Id NOT subm it fu rther cIa i ms fa r these codes. codes. All future future claims claims for for the the above above parts parts should should be be submitted, submitted, using using the the following following codes codes All only:only:9DO 9DR 8NU Battery Battery Cover Cover Battery Battery Cover Cover Support Support Panel Panel Spare Spare Wheel Wheel Cover Cover ITEM: 50 50 ITEM: XJS XJS (FACELlFT) {FACELIFT) WARRANTY WARRANTY CODES CODES The The following following new new warranty warranty complaint complaint:code code has has been been allocated allocated to to cover cover the the fuel fuel gauge gauge "anti-slosh "anti-slosh module", module", introduced introduced on on XJS XJS Facelift Facelift models. models. Code Code Description Description SRO SRO 7JU 7J U Anti-Slosh Module Module Anti-Slosh 88.25.25 88.25.25 JaguarCars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 -h?= JAGUAR JA~ JD JO 08/91 08 / 91 ITEM:51 51 ITEM: ALL ALL MODELS MODELS 12 12 CYLINDER CYLINDER PRESSURE PRESSURE CHECK CHECK WARNING: WARNING: Would Would all alltechnicians technicians please please note notethat that before beforeperforming performingaacylinder cylinderprespresfrom the sure surecheck, check, Repair RepairOperation Operation No. No.12.25.01, 12.25.01,all allfuel fuel should should be bepurged purgedfrom thefuel fuel rail. rail. Purging Purging of of the the fuel fuel rail rail may may be be achieved achieved by by disconnecting disconnecting the the fuel fuel pump pump relay relay and and then then cranking crankingthe the engine enginefor for ten ten seconds. seconds. XJ6 ALL ALL MODELS MODELS&& XJS XJS 3.6/4.0 3.6 1 4.0 XJ6 ITEM:52 52 ITEM: 19 19 CRUISE CRUISE CONTROL CONTROL ACTUATOR ACTUATOR LINKAGE LINKAGE ADJUSTMENT ADJUSTMENT Shou I d customer plai nts be ncrease in se control Should customercom complaints bereceived receivedof ofani an increase inthe thecrui cruise controlresponse response time timeand andaadegree degreeof of hunting huntingof ofthe the set setspeed, speed,the thecruise cruise control controlactuator actuator linkage linkageadadjustment justment should should be bechecked checked in inaccordance accordance with withthe thefollowing following procedure, procedure,before beforetaktaking ingany anyfurther further action. action. Dealers Dealers should should ensure ensurethat that the theclearance clearance between betweenthe the end endof of the theactuator actuator to to throttle throttle link linkslot slot:(A (AFig Fig 1) 1)and and the the shoulder shoulder bolt bolt (8 ( 0Fig Fig 1) 1 )isisO.5mm 0.5mmto to lmm I m m {C {CFig Fig 1). 1). S.R.O. S.R.O. Allowance Allowance Complaint Code Complaint Code 19.75.11 19.75.11 0.10 0.10 hrs hrs 7VCP 7VCP - cQ~)} x FIG 11 FIG 2 Jaguar Cars Limited 2005 % JAGUAR JA~ JD 08/91 XJS V12 V12 XJS ITEM: ITEM:53 53 44 TRANSMISSION TRANSMISSION OIL OIL COOLER COOLER CONNECTION CONNECTION 44 There have have been been aa number numberof of oil oil coolers coolers returned returned with with damaged damaged coupling coupling connector connector There bosses, bosses, the the cause cause of of which which can can be be attributed attributed to to poor poor workshop workshop practice practice where where backbacking spanners spanners have have not not been been used used to t o support support the the integral integral hexagon hexagon connector connector of of the the ing in aa fracturing fracturing of of the the connecting connecting tube tube when when torque torque is is applied applied oil cooler. cooler. This This results results in oil upon tightening tightening or or loosening loosening the the connection. connection. upon Technicians should use useaa backing backing spannerto spanner t o hold hold the the integral integral boss boss whilsttightening whilst tightening Techn icians should the cooler cooler pipe pipe connection connection to t o aa torque torque of of 15 15-- 17 17 Nm. Nm. the XJ6 I/ XJS XJS I/ 5.1111 S.llt / LIMOUSINE LIMOUSINE XJ6 ITEM:54 54 ITEM: 60 FRONT FRONT HUB HUB END END FLOAT FLOAT ADJUSTMENT ADJUSTMENT 60 The following following instructions instructions supersede supersede all all previous previous instructions instructions provided provided in in service service The Manuals will will be b e updated updated at at the the next next reprint. reprint. manuals. Manuals manuals. hubend end float float on on the the above above models models should should be be set set between between 0,0254 0,0254 to to 0,0762mm 0,0762mm Front hub Front (0.001 (0.001to to 0.003in). 0.003in). To To achieve achieve this this in i n service service use use the the following following method: method: N2te:: Note: Prior Priorto to adjusting adjustingthe t h e hub hubend end float float an an absorbent absorbentcloth clothshould should be be placed placed around around the brake brake fluid fluid reservoir reservoir cap. cap. the Slacken the the road road wheel wheel nuts nuts 1/ 4 turn Slacken turn each. each. Jack up up the the front front of of the the vehicle vehicle and and support support with with axle axle stands. stands. Jack Removeone onewheel wheel nut, nut, mark markthe the wheel wheel relative relativeto to the the stud stud and and remove removethe theremaining remaining Remove wheel nuts. nuts. wheel the roadwheel roadwheel and and tyre tyre assembly. assembly. Remove the Remove upon model, model, gently gently prise prisethe the brake brake pads padsfree free or or manipulate manipulatethe the brake brakecaliDependent upon Dependent caliper to to ensure ensure tthe h e brake brake pads pads are are free free within within their their mounti mountings, i.e. the the disc disc isis free free to to per ngs, i.e. rotate. rotate. off the the hub h u b grease grease cap cap (1 (1Fig. Fig. 1) 1). Prise off . Prise Fit . 2). Fit aa Dial Dial Test Test Indicator Indicator (DTI) (DTI)to t o the the hub hub (Fig (Fig. 2). Graspthe hub hub unit. unit. Firmly Firmly pull pult and and push pushthe the unit, unit, oscillating oscillating atthe atthesametime,todeGraspthe same time, to determine termine the the OTI DTI end endfloat float reading. reading. the reading reading is iswithin within the the specification specification quoted quoted there there is isno no need needto tocarry carryout outthe the adjustadjustIfIfthe ment. IfIf not, not, remove remove the the hub hub nut nut split split pin pin and and cover cover (2, (2, 33 Fig. Fig. 1). 1). ment. D', 'C. Fig.2 Fig. 2 Fig. Fig. 11 3 Jaguar Cars Limited 2005 -& JAGUAR JA~ JD 08/91 08 191 Note: Note: For For identification identification purposes purposes only, only, Fig.1 Fig. 1 shows XJS, S III Ill & & limo. Limo. type hub. hub. Fig. Fig. 2 shows XJ6 hub. Adjust the the nut, nut, as necessary, necessary, to to give give a reading reading of O,OS08mm 0,0508mm ++ /I- O,0254mm 0,0254mm (O.002in (0.002in + + / -- 0.001in). 0.001in). Always try to t o achieve achieve the the mid-point mid-point of the the tolerance tolerance i.e., i.e., O,0508mm 0,0508mm (O.002in). (0.002in). Align the the hub hub nut nut cover and and secure secure with with a new new split pin. pin. When When the the newsplit new split pin pin is is fitted, ensure ensure the the end end float is is re-checked re-checkedusingthe using the DTI DTIgauge gauge (Fig. (Fig. 2). 2). If If necessary, necessary, re-adjust using using the the same same method, method, until until the the end end float is is correct. correct. Alwavs by checking checking with with a DTI DTI gauge. gauge. Always finish finish the the adjustment by Always ensure ensure the the end end float is is within within the the limits limits quoted. Refit Refit the the grease grease cap. cap. Refit Refit the the road road wheel. wheel. Carry out the adjustment procedure out the adjustment procedure on on the the opposite opposite front hub. hub. Carry When When finished, finished, lower lower the the vehicle vehicle from from the the stands. stands. Ensure Ensure the the wheel wheel nuts nuts are are tightened tightened to to the the specified specified torque. torque. Remove fluid reservoir Remove the the absorbent absorbent cloth cloth from from around around the the brake brakefjuid reservoir cap, cap, ensuring ensuring the the area area is is clean clean and and dry. dry. Before the vehicle, pump pump the the brake brake pedal pedal to to centralise centralise the the pads. pads. Before moving moving the ITEM: 55 55 ITEM: ALL ALL MODELS MODELS 77 77 BODY BODY REPAIR REPAIR To To avoid avoid the the risk risk of causing causing permanent permanent damage damage to to vehicle vehicle ECUs ECUs during during body body repairs, repairs, the following precautions must be observed prior to using any electrical welding the following precautions must be observed prior to using any electrical welding equipment. equipment. 1. Disconnect Disconnect the the vehicle vehicle battery battery and and alternator. alternator. 1. 2. area of any panels 2. Disconnect Disconnect and and removea!1 removeall ECUs ECUs in inthe the immediate immediatearea ofany panelsto to beelectri· beelectrically welded. As As aa general general rule, rule, all all ECUs ECUs within within 22 feet feet of of the the area area to to be be welded welded cally welded. should be removed; removed; for for more more detailed detailed information, information, refer refer to to the the relevant relevant Service Service should be Manual. Manual. 3. 3. When When using using welding welding equipment, equipment, the the earth earth return return clamp clamp should should be be located located as as close as as possible possible to t o the the area area of of repair. repair. close XJ6 XJ6 ALL ALL MODELS MODELS ITEM: ITEM: 56 56 82 82 DRIVER'S DRIVER'S BLOWER BLOWER MOTOR MOTOR ASSEMBLY ASSEMBLY The The repair repair operation operation time time for for renewing renewing the the driver's driver's side side blower blower motor motor assembly assembly has has changed changed on on all all XJ6 XJ6 Vehicles Vehicles from from VIN VIN 629286. 629286. The The repair repair operation operation times times are are now now as as follows:follows:- 4 Jaguar Cars Limited 2005 -k JA~ JAGUAR JD 08/91 08 191 Left Hand Hand Drive Drive Vehicles: 82.25.13 82.25.13 Blower assembly -- Left Hand Hand -- Renew 82.25.13/09 82.25.13109 As 82.25.13 82.25.13 (Less (Less J.D.S. Allowance) 01.25 Hours 00.90 Hours Hours Right Hand Hand Drive Vehicles: 82.25.14 Right Hand Hand -- Renew Blower Assembly -- Right 01.25 Hours Hours 82.25.14/09 82.25.14109 As 82.25.14 82.25.1 4 (Less (Less J.D.S. J.D.S. Allowance) 00.90 Hours Hours Please Please amend your repair time schedules accordingly. No No other repair times are affected. To achieve these times in i n service, adhere to the following procedure:procedure:REMOVE REMOVE Open the bonnet and disconnect the battery earth earth lead. Remove Remove the driver's side dash dash liner. Remove Remove the retaining retaining clip from the air conditioning unit's pliable pliable trunking. Displace the pliable trunking from the air conditioning unit. unit. Displace the relay bases from their mounting mounting brackets. Displace Cut and remove remove the ratchet straps securing the brake switch switch harness. Disconnect the vacuum hose from the blower motor assembly servo unit. Disconnect the blower motor mUlti-way multi-way connectors. Undo and remove remove the steering column lower mounting mounting securing nuts. nuts. Undo and and remove remove the steering column upper mounting securing nuts. Lower the steering column column assembly. Retrieve Retrieve the column upper packing shims. Remove Remove the washer bracket from the column. Manoeuvre the steering column column towards the centre of the vehicle for access. Undo and remove remove the steering column column outer stabilizer bar's upper and lower securing nuts. nuts. Displace and rem ove the steering column remove column stabilizer bar (Fig. (Fig. 1). 1). Reposition Reposition the vehicle harness connectorsto connectors to gain access to t o the blower motorassembly securing bolts. Undo and and remove the blower motor assembly securing bolts. Displace remove the blower motor assembly. Displace and remove Remove Remove and discard the unit intake gasket. Remove Remove the pliable trunking to t o assembly securing tape. Remove the trunking from the unit. Remove REFIT REFIT Fit and align align trunking trunking to t o the new blower motor assembly. tape. Secure the trunking to the assembly with tape. Smear the new intake gasket with a suitable adhesive. Fit the gasket to t o the blower motor assembly intake. and align align the blower motor assembly into its mounting mounting position. position. Fit and Connect the pliable trunking to t o the air conditioning unit. unit. Refit and tighten the blower motor assembly securing bolts. Fit F i t and and align align the trunking retaining retaining clip. Connect the blower motor multi-way multi-way connectors. Connect the vacuum hose to t o the blower motor assembly servo unit. 5 Jaguar Cars Limited 2005 % JAGUAR JA~ JD 08/91 08 1 97 Fit and align the steering steering column stabilizer bar and tighten the securing bolts bolts (10 -14 - 14 Nm). Nm). Fit and align the washer bracket to the column. Loosely fit the steering column column upper mounting mounting securing nuts. Fit the steering column column packing packing shims as necessary. Fit and tighten the steering column column lower mounting securing securing nuts nuts (20 (20 - 22 Nm). Nm). Fully tighten the steering column column upper mounting securing nuts (20 (20-- 22 Nm). Nm). Reposition Reposition the brake switch harness harness to the blower motor assembly. Secure the brake switch harness to the unit with ratchet straps. Fully seat the relay bases bases to their mounting brackets. brackets. driver's dash liner assembly. Refit the driver's Reconnect the battery earth lead and close the bonnet. bonnet. - Fig. 1 Fig. ITEM: ITEM: 57 S.III, S.111, XJS & & XJ6 UP UP TO VINs:VINs:506664 -- USA 506448 506448 -- CANADA 507471 - R.O.W. R.O.W. 507471 - 82 82 AIR CONDITIONING COMPRESSOR (GM (GM A6 TYPE) TYPE) Investigations have confirmed the unnecessary replacement of compressors for noise and leaks. leaks. If excessive excessive compressor noise exists, check the following items:items:- . Compressor drive belt tension. Compressor mountings. . , AlC routing (ensure N C refrigerant refrigerant hose routing (ensure that hoses are not in in contact with other components). . ponents), refrigerant charge weight is correct (referto Section 82 of the SerEnsure that the refrigerant vice Manual for additional additional information). information). 6 Jaguar Cars Limited 2005 - JA~ JAGUAR 08/91 JD 08 / 91 . Ensure that the compressor is filled to the correct level with oil. A MAXIMUM of ee) of refrigerant oil can be added to the compressor without discharg4 ozs ((114 114 cc) (such as 'Snap-on' 'Snap-on' oil injector tool ing the refrigerant. Using an oil injector tool (such 111), (57 ccc} c } increments. (Refer to the procedure detailed ACT 11 11, add oil in 2 oz (57 below). below). NOTE: LOW lOW OR EXCESSIVE CHARGE WEIGHT OR A LOW lOW OIL Oil LEVEL WILL CAUSE COMPRESSOR NOISE. NOISE. . Clutch drag or bearing noise (refer to the clutch replacement procedure, Section 82 of the Service Manual). . replaced in accordance Compressors which leak oil or Freon must have the seals replaced with the procedure detailed in Section 82 of the Service Manual. above-mentioned items. Replace the compressor only after checking all of the above-mentioned NOTE: All returned compressors must be complete and sealed, using the blanking NOTE: plate provided on the replacement unit. Procedure for compressor oil injector tool usage:usage:Ale system. Make sure that the system is full of Freon. Referto SecOperate the A/C Refer t o SetManual for the test procedure. tion 82 of the Service Manual . Remove the sealing gaps from the high and low pressure A/C Ale charging points. . closed. Check that the valve on the oil injector tool is closed Remove Remove the threaded end cap from the t h e oil injector tool and and add add 2 ozs (57 I57 ee) cc) of compressor oil. Replace Replace the end cap. cap. Attach the short flexible hose on the oil injector to the low pressure fitting of the vehicle A/C AlC system. . AlC system extension hose to the fitting on the side of the Attach one end of an A/C valve ofthe of the oil oil injector tool. Attach the other end oftha of the extension hose to t o the high high pressure AlC pressure fitting of the vehicle N C system. Run Run the engine at a t idle idle with the AIC A/C system system operating. . Slowly open open the oil oil injector tool tool valve until until it is is fully open. Allow the oil oil to t o flow into the compressor for 2 minutes. minutes. . Close Close the oil oil injector tool tool valve. let Let the engine run run an an additional minute, then then switch switch off the ignition. . Carefully remove from the high remove the charging charging hoses hosesfrom high and and low pressure fittings and and install install the sealing caps. . Check the the AlC A/C system system for compressor noise. noise. If noise noise still still exists, repeat repeat the the proprocedure cedure once once more, more, adding adding an an additional 22 ozs ozs (57 (57 ee) cc) of compressor oil. . NOTE: NEVER ADD MORE MORE THAN THAN 4 OZS OZS (114 (11 4 cc) c c ) OF OF Oil OIL TO TO THE THE Ale A/C SYSTEM. SYSTEM. . self-adhesive label label to t o the the AlC PJC hose hose (adjacent (adjacent to the the low pressure pressure hose hose Attach a self-adhesive fitting), stating stating how how much much oil oil was was added added and and the the date. date. 7 Jaguar Cars Limited 2005 IIr1 II I III JA~ Service Bulletin Bulletin DATE: DATE: NOVEMBER NOVEMBER 1991 1991 PAGE: PAGE: 11 of 55 REF: REF: JD JD 09/91 09/91 ERRATA ERRATA Would Dealers Dealers please please note note that that in in Service Service Bu Bulletin JD 05/91, 05/91, Item Item 31 31 "Forged "Forged Alloy Alloy Would Iletin JD t h e Part Part No. No. for the the XJS XJS road road wheels should should be be CSC CBC 6175 6175 (not (not CSC CBC 9175). 9175). Wheels", the XJ6 MODELS MODELS XJ6 ITEM: ITEM: 58 58 44 44 TRANSMISSION TRANSMISSION FRONT FRONT PUMP PUMP ASSEMBLY A new new front front pump pump assembly assembly has has been been introduced introduced which which cannot cannot be be retro-fitted retro-fitted to to A earlier models models as as the the intermediate intermediate plate plate is is not not compatible. compatible. earlier Should ission unit, Should this this later later type type be be fitted fitted inadvertently inadvertently to t o an an earlier transm transmission unit, the the interinternal pressures pressures created created will will blow-out blow-out the the pump pump seal seal (this {this is is because because the the ventilation ventilation nal channel is is now now in i n a different position). position). channel Part No. No. Part I Qty Q ~ YI Description Description 2.9,3.2 & & 3.6 3.6 Litre Litre Models Models 2.9,3.2 Up to to Gearbox Gearbox Serial Serial No. No. 1158414: 1158414: Up JLM 1957 1957 JLM 11 Front Front Pump Pump Assembly JLM 885 885 JLM 1 Intermediate Plate Plate JLM 2286 2286 JLM 11 Front Pump Pump Assembly Front JLM 10715 10715 JLM 11 Intermediate Intermediate Plate Plate JLM 10441 10441 JlM JLM 10448 10448 JLM 1 Front Front Pump Pump Assembly 11 Intermediate Intermediate Plate From Gearbox Serial Serial No. No. 35366: 35366; From JLM 10716 10716 JLM , 1 Front p Assembly Front Pum Pump JLM 10717 10717 JLM 1'1 Intermediate Intermediate Plate Plate , II From Gearbox Serial No.1 No. 115841 53 From 158415; Litre Models Models 4.0 Litre Up to Gearbox Serial Serial No. No. 35365: Up Jaguar Cars C a n Limited Limited Jaguar Jaguar Cars Limited 2005 IIIII ~ A G U JA~ =Q% Service Service Bulletin Bulletin .,. III DATE: OCTOBER OCTOBER 1992 1992 DATE: PAGE: 11 ofS of 8 PAGE: REF: JD JD 16/92 16/92 REF: ERRATA ERRATA Owing Owing to to revised revised information, information, the the torque torque figure figure far for the the coolant cooiant temperature temperature transtransmitter mitter to to engine, engine, XJS XJS models, models, is is 14,5 14,5 to to 19,5 19,5 Nm. Nm. The The torque torque figure figure given given in in Service Service Bulletin Bulletin JD JD 10/92 10192 and and Section Section 88 88 of of XJS XJS Service Service Manual, Manual, JJM JJM 100406/20, 10 04 06/20,should should be be ignored ignored and and only only the the revised revised figure figure used. used. Service Service Manuals Manuals will will be be amended amended at at the the next next reprint. reprint. ITEM: 44 44 ITEM: XJ6 XJ6 93 93 MY M Y (FROM (FROM VIN VIN 667829) 667829) BATIERY BA-TTERY TRANSIT TRANSIT RELAY RELAY -- REMOVAL REMOVAL Owing Owing to to the the relocation relocation of of the the battery battery into into the the boot boot at a t 93 93 MY, MY, aa revised revised battery batterytransit transit relay relay has has been been introduced, introduced, (see {see Fig Fig 1). 1). FIG 11 FIG The The procedure procedure for for the the removal removal of of this this new new relay relay is is as as follows: follows: WITH THE THE IGNITION IGNITION OFF: OFF: WITH 1. 1. Open Open the the boot boot and and remove remove the the battery battery cover, cover, (see (see Fig Fig 2). 2). 2. 2. Remove Remove the the negative negative lead lead from from the the battery. battery. 3. 3. Disconnect Disconnect the the transit transit relay relay from from the the battery. battery. Jaguar Cars Limited 2005 4. yellow (W/Y) 4. Remove Remove the the white white I/yellow (WN) ignition ignition wire wire from from the the transit transit relay. relay. A JAGUAR JA~ JD 16/92 FIG FIG 2 Remove the the positive positive lead lead from from the the transit relay relay terminal terminal post, post, (A, (A, Fig Fig 3). 3). 5. 5. Remove Fig 6. 6. Reverse Reverse the the positive positive lead lead clamp clamp and and refit refit the the clamp clamp to to the the positive positive lead lead (B, (6, Fig 3). 3). =-=-==='====-::~ J'S117t!ol FIG FIG 33 7. 7. Displace Displace the the battery. battery. 8. yellow (W/Y) 8. Tie Tie back back and and secure secure the the white white I/yellow ( W H ) ignition ignition wire, wire, (see (see Fig Fig 4). 4). FIG 4 J:' .... I~IIDI:' TU AT TUIC I I:'An Cl!I:'MAII\IC C1 Jaguar Cars Limited 2005 n I v 11\1<:111 ATl:n \lI.n.II:::1\I <:I:rl u:u::::n - JAGUAR JA~ JD JD 16/92 16 1 9 2 9. 9. Refit Refit the t h e battery. battery. 10. Refit Refit: and secu.re secu,re the positive positive and and then then negative negative lead lead of the battery. battery. 11. 1 1. Replace Replace the the battery battery cover. cover. NOTE: NOTE: ALL DEALERS MUST CONTINUE TO RETURN THE DISPLACED TRANSIT ALL UK UKOEALERS MUSTCONTINUETORETURNTHE DISPLACEDTRANSlT RELAYS. RELAYS. REMOVAL REMOVAL OF OF THE THE TRANSIT RELAY RELAY SHOULD SHOULD BE BE CARRIED CARRIED OUT OUT NO LONGER THAN 24 HOURS BEFORE THE VEHICLE IS HANDED OVER TO THE LONGER THAN 24 HOURS BEFORE THE VEHICLE IS HANDED OVERTOTHE CUSTOMER. THE THE RADIO RADIO AND AND TIME TIME CLOCK CLOCK MUST BE BE RESET RESET AFTER THE THE RELAY RELAY IS 1s RE· REMOVED. MOVED. IMPORTANT: N O CIRCUMSTANCES CIRCUMSTANCES SHOULD SHOULD THE THE RELAY RELAY BE BE USED USED OR RE· REIMPORTANT: UNDER NO TAINED TAINED AS AS AN AN ISOLATION ISOLATION DEVICE DEVICE FOR FOR ROAD ROAD USE. USE. XJS ITEM: 45 03 03 REPAIR REPAIR OPERATION OPERATION TIMES TIMES Air Conditioning Conditioning Blower Blower Motor Motor Assembly Assembly The The repair repair operation operation times times for for renewing renewing the the air air conditioning conditioning blower blower motor m o t o r assem· assernblies blies have have been been re-studied re-studied on on 1992 1992 MY MY vehicles. vehicles. The The new new operation operation times times for vehicles vehicles from from VIN VIN 179737 179737 are are as as follows: follows: Right-hand drive drive vehicles vehicles Right-hand - 82-25-13 Blower 82-25-13 Blower Assembly -left-Hand Left-Hand -- Renew Renew 82-25-13/09 82-25-1 3/09 As As 82-25-13 82-25-1 3 (Less (Less JDS JDS Allowance) Allowance) 0.95 0.95 Hrs Hrs 0.60 0.60 Hrs Hrs 82-25-14 Blower Assembly - Right-Hand - Renew 82-25-14 BlowerAssembly-Right-Hand-Renew 82-25-14/09 82-25-1 4/09 As As 82-25-14 82-25-1 4 (Less (Less JDS JDS Allowance) Allowance) 1.60 Hrs 1-60Hrs 1.25 1.25 Hrs H rs Left-hand Left-hand drive drive vehicles vehicles Blower Assembly -- Left-Hand Left-Hand -- Renew Renew 82-25-13 Blower 82-25-1 3 82-25--13/09 82-25-1 3/09 As As 82-25-13 82-25-13 (less (Less JDS JDS Allowance) Allowance) 1.60 1.60 Hrs Hrs 1.25 1.25 Hrs Hrs 82-25-1 4 Blower Assembly Assembly -- Right-Hand Right-Hand -- Renew Renew 82-25-14 Blower 82-25-14/09 82-25-24/09 As As 82-25-14 82-25-14 (Less (Less JDS JDS Allowance) Allowance) 0.95 Hrs Hrs 0.95 0.60 0.60 Hrs Hrs Please Please amend amend your your repair repair times times accordingly. accordingly. No No other other repair repair times times are are affected. affected. Jaguar Cars Limited 2005 =+b JA~ JAGUAR JD 116/92 JO 6 1 92 ITEM: 46 46 XJ6/1 XJS XJS XJ6 RECOMMENDATIONS 10 BRAKE SYSTEM SERVICE RECOMMENDAT1ONS This bulletin supersedes supersedes Item 21 21 of of Service Bulletin JD JD 03/92. 03/92. Note: This With the introduction of the ABS brake system, from the following VINs, the brake servicing recommendations have changed: 1. XJ6 from VIN 594576. 2. (5.3 convertible) convertible) from VIN 147269. XJS (5.3 (5.3 coupe) from VIN 148782. 3. XJS (5.3coupe) 4. (3.6 coupe) from VIN V1N 148945. XJS (3.6 necessary. The system and components, No routine replacement of system seals is necessary. which are sealed for life, require no maintenance. Repair is by replacement. inspected for satisfactory operation and condition condition The braking system must still be inspected service intervals. intervals. at the regular service nature, brake fluid must be renewed renewed at 2 year or 30 000 Because of its hygroscopic nature, (48 000 km) km) intervals, intervals, whichever is sooner. mile I48 XJ6 ALL MODELS ITEM: 47 18 18 LAMBDA SENSOR SPLASH-SHIELD SPLASH-SHIELD Following reports reports of the intermittent intermittent display of "Fuel "Fuel Failure failure 44" on on the instrument pack, it was found found that this symptom could could be be caused caused bywater by water penetrating penetrating the lambda sensor. sensor. A A lambda lambda sensor splash-shield splash-shield has has been been introduced introduced from from VIN V1N 664941, 664941, which which can can be be fitted fitted retrospectively and and should should be be installed installed whenever a lambda sensor is is changed. changed. This This will will reduce reduce the possibility possibility of water ingress. ingress. /~ Jaguar Cars Limited 2005 % JA~ JAGUAR JD16/92 JD 16 1 9 2 heat-proof sleeve sleeve is fitted by sliding it over the sensor, prior to its its The six-inch silver heat-proof replacement. After the sensor has been been fined, fitted, Dealers Dealers should ensure thatthe that the sleeve is SOL i s pushed pushed fully back down to cover the whole sen sensor- ALL MODELS MODELS ITEM: 48 18 IGNITION SPARK PLUGS PLUGS Spark plugs plugs have been been returned returned under warranty with a yellow I/ brown brown stain stain visible on the insulator housing. Dealers Dealers have have incorrectly interpreted interpreted this as leakage leakage of comcornbustion bustion gases between between the insulator and and metal metal housing and and the cause cause for for spark plug plug misfire. Thefollowing The following is i s an explanation forthe for the staining and and the more more likely cause for spark plug plug misfire. During mostatmospheric most atmospheric conditions a form of o f static staticdischarge, c o m m o n to high high voltDuring discharge, common conductors, can occur. occur, which IS is commonly known known as "Corona discharge". age conductors, Ignition prone t o this effect during wet weather, when the air Ignition systems are particularly proneto space surrounding surrounding the spark plugs becomes becomes charged with a gas composed composed of elecelectrons, ions and and air particles, particles, forming forming a state of general general ionization. ionization. Too much much ionizionization counteracts the spark plug plug insulation and causes a partial partial discharge, which in in turn gives out a blue blue light. light. in no way affect the running running ofthe of the car, providcircumstances this will in Under normal circumstances ing ing the spark plug plug insulators irlsulators are kept clean. onlyoccur if the spark plug insulators were coated Running Runni n9 problems would normally only occur ifthe in a film of dirt, which would allow high high voltage tracking, known known as "flashover", "Rashover", bein plug terminal stud stud and earth, thus causing causing a misfire. tween the spark plug However, provided against this eventuality by the inclusion inclusion of "ribs" "ribs" However, protection protection is provided body. To identify whether or notthe not the spark plugs have been been subsubalong the insulator body. jected to Corona Corona discharge. discharge, plugs should be examined examined in in daylight for the presence presence brown stain stain at the base of the insulator, next to the metal metal housing. housing. of a yellow I/ brown The actual stain stain is caused caused by oil-contaminated oil-contaminated particles, particles, in in suspension suspension around around the spark plug plug insulator, receiving the electrostatic charge of ionization ionization and and fusing themthemselves to the plug. The stain wiped off easily. stain is quite harmless harmless and can can usually be be wiped Corona discharge discharge will cause cause no deterioration in i n service service or malfunction of the spark Corona plug. plug. Corona discharge does not. Cleanliness Cleanliness Moisture or dirt may cause "flashover" but Corona is is vital, therefore, spark plug plug insulators insulators should should be kept clean clean and and dry at all times. Note: Note: returned under warranty may be rejected rejected as "no fault found" Spark plugs returned for the reasons reasons given given above. XJ6 ALL MODELS MODELS 64 64 REAR SHOCK ABSORBERS ITEM~ 49 Jaguar Cars Limited 2005 From VIN VIN 667829. 667829, a new rear shock absorber is fitted to t o all all non-ride-Ievelling non-ride-levelling veFrom interchangeable with all previous previous components when hicles. This new part is fully interchangeable '==-% JA~ JD 16/92 16 / 92 JAGUAR This new part, number CCC 6923, should be be used used in in all cases where rear shock absorbers are replaced, with immediate effect. Under no circumstances should this new part be mixed mixed with old condition parts on on a vehicle axle. When failures are identified identified in in service, single shock absorbers only need need to t o be be changed if the parts have less than 25,000 miles (40,OOOkm} (40,000km) service use. The new units, which have have a black finish, can can be be easily distinguished from the previous parts by a new sealed gaiter, which will reduce dirt ingress. ingress. XJS 6CYl/ GCYL I V12 AND SERIES III 111 V12 ITEM: ITEM: 50 50 82 RECEIVER RECEIVER DRIER BOTTLE BOTTLE When replacing replacing the receiver drier bottle, Part Number CAe CAC 1881, 1881, it is essential that the receiver drier bottle vertical. This is bottle is mounted mounted with w i t h the sight glass glassvertical. is to ensure that the pick-up pick-up tube inside inside the drier bottle is always immersed immersed in in liquid liquid refrigerant. refrigerant. Ifthe If the receiver drier bottle is mounted at angles in excess of +j~ 20 degrees from the vertical, mounted in +1-20 degreesfrom there is a risk, under certain conditions, that vapour rather than liquid liquid may enter the pick-up pick-up tube. Should this occur. occur, erratic air conditioning performance performance may result. result. ITEM: ITEM: 51 51 XJS 4.0l 4.01 I/ V12 86 86 LOW COOLANT WARNING LIGHT LIGHT FAULT FAULT DIAGNOSIS DIAGNOSIS Dealer investigations into low coolant warning light concerns have resulted resulted in in a high high number of low coolant probes probes and control units being being rep/aced replaced unnecessarily, unnecessarily, as most probes probes and and control units tested by the supplier reveal reveal no no faults. In In order to re~ reduce this unnecessary replacement. replacement, the following following electrical checks should be be carried out by Dealers before condemning condemning or replacing components where the cause is found to should include inspection ofthe t o be loweoolant low coolant level. The checks checksshould of the coolant system tern for leaks. leaks, which is best achieved achieved by pressure testing the coolant system to t o locate the source of the leak. Coolant leaks may be caused by: loose hose clip connections, connections, worn or damaged damaged pressure cap seals, or damaged hoses. Lack of coolant recovery from f r o m the atmospheric recovery bottle may be be a further reason reason for low tow coolant level level in in the header tank. Transfer of coolant from f r o m the atmospheric recovery bottle relies relies on the presence of a vacuum, as the coolant contracts when the engine is turned off. Checks should should be be made to ensure that the recovery bottle and and its connections through to the header made tank are leak-free leak-free and and unrestricted. unrestricted. In In addition, the vacuum valve in in the header tank should be be checked checked to t o ensure that it operates correctly and does not stick. ELECTRICAL CHECK PROCEDURE PROCEDURE CIRCUIT I SYSTEM S Y S f EM DETAILS DETAILS Jaguar Cars Limited 2005 The system operates by measuring the t h e resistance resistance of the coolant. coolant. With resistance below 5,000 Ohm, Ohm, the warning light is off. The light will illuminate with the resistance % JAGUAR JA~ JD JD 16/92 16/92 , _ _ _.;..:w'--_-----, W/R w/u II 1--_--..:8=------, 6 2 COMPONENT CIRCUITCODE CODE COMPONENT I/ CIRCUIT WIRING WIRING CODE CODE 11-Ignition - Ignition (lGN) (IGN)supply supply - Lawcoolant coolantcontrol control unit unit 22 -low light (Will (W/L) 33--Warning Warning light Headertank tank 44 --Header Low coolant coolant probe probe 55 --low Headertank tankearth earth via via fixing fixing bolts bolts 66--Header W W W/R W/R W/U W/U BB FAULT FAU LT -- White White White I/ Red Red -- White White I/ Blue Blue -- White -- Black Black ACTION ACT10N CAUSE CAUSE WfLdoes does not notilluminate illuminateat at Blown W/l BlownW/l W/L or or open open circuit circuit aany n y time. time. (Bulb (Bulb check check on onW/L W/L wire wire doesnot notoccur occurLe. i.e.@ @11sec sec does on on following following ign) ign) Earthwire wireat at unit unitopen opencircirEarth cuit cuit Check Check by by shorting shorting white white fI blue (W/U) wire to earthblue (W/U) wire to earth W/l W/L should should come come on. on. Check Check resistance resistance to to good good chassis chassis ground ground-less -less than than 22 Ohm. Ohm. Check supply supply at at unit, unit, Ign cir- Check lgnsupply supplyto tounit unitopen opencirshould cuit cuit should be bebattery batteryvoltage. voltage. Ifthe If the above above checks checks are are satisfactory sarisfactorv replace replace faulty faultv low low coolant coolant unit. unit. W/l Lowcoolant coolant W/L on on all all the the time time with with Low tgn ign Check and 'Check and top top up up as as rerequired quired thecoola coolant level isissatisfactory, satisfactory,the thefollowi following checkwi will determine which partof ofthe the IfIfthe nt level ng check II determ i ne wh ich part circuit isisat at fault. fault. circuit Disconnectthe t h e probe probe wire wire at a tthe the tank tank and and short short to t o ground. ground. IfIfthe the W/L W/L goes goes out, out, proproDisconnect ceed ceed to to (A). (A). IfIf the the W/L W/L stays stays on, on, go go to to (B). (B). (A) Poor Poor connection, connection, body body to to earth earth tank tank Check Check resistance resistance of of tank tank chassis body good body to to good chassis earth -should be beless lessthan than earth-should 20hm. 2 Ohm. Poor Poor connection connection on on Lucar Lucar Visual Visual check check -- clean, clean, rereconnector connector Red Red I/ White White place place as as required. required. wire.. Lucar Lucar rivet rivet loose looseon on wire low low coolant coolant probe probe Low coolant coolant probe probe // platplat- Remove low Removeprobe probefrom from tanktankLimited 2005 ing contaminated contaminated ing clean wire wool -- ifif clean with withJaguar wireCars wool probe probe Lucar Lucar is is damaged damaged : or or loosened loosened durina durina rere- - JA~ JD 16/92 16 1 9 2 (B) IB JAGUAR Short to earth in in W/L wire or W/L bulb-holder bulb-holder pack Unplug Unplug low coolant unit unit. If the W/L goes off, circuit OK-IfW/Lremains OK-If WjL remains illuminated-locate nated-locate short circuit. Short to earth on probe With unit and probe probe diswire White I/ Red (W/R) connected, check the Red White I/ Red Red wire w i r e resistance to good chassis earth earth - should be above 20,000 20,000 Ohm. 0 hrn. - satisfactorv, replace redace faulty faultv low coolant unit. unit. If all of the above checks are satisfactory, WIL flashes on, then goes Low coolant level level W/L off off Check -- top up as requi red. quired. Interrnittent Intermittent open circuit, on on White I/ Red Red (W/R} (W/R) low coolant probe wire Ground probe probe wire at tank -test drive vehicle. -test vehicle. If fault recurs, check harness harness I/ connectors, locate locate open circuit Less Less likely causes but may Bad Bad connection connection tank body in certain certain conditions, with with to earth in ificatio n an out of spec specification unit, cause a fault Check resistance resistance of tank body to good chassis earth-should earth -should be less than 2 Ohm. Poor connection connection on Lucar Visual check -- clean clean rereconnector Red Red I/ White (RI IR/ pl place required. ace as required. , W) W) wire. Lucar rivet loose loose on on low coolant probe Low coola Dt -- probe I/ plat- Remove probe coolant probe from tank, ing contaminated clean with wire wool -- if contaminated probe probe Lucar is damaged or loosened during removal moval replace replace probe. Jaguar Cars Limited 2005 III JA~ Service Bulletin III DATE: DATE: APRIL APRIL 1992 1992 PAGE: PAGE: 11of 4 REF: JD JD 03/92 REF: Owing Owing to to revised revised information information received received from from Engineering, pages pages 11 11 of Service Service Bulletin Bulletin JD JD 01/92,3/4 01/92, 3/4 and and 9/10 9110 of Service Service Bulletin Bulletin JD JD 02/92 02/92 are are being being re-issued and and are are proprovided at the end of this Bulletin, marked" *Issue 2* ". vided the end this marked " '2 ". Existing Existing pages pages ofthe of the above above should shoutd be be removed removed and and discarded discarded to to be be replaced replaced with with the the revised revised version. XJ6 3.2 & 4.0 ITEM: ITEM: 20 20 03 03 ADDITIONAL REPAIR REPAIR OPERATION OPERATION TIME TIME The The following following Repair Repair Operation Operation limes Times are are now n o w available: available: - 12.29.16 -- Cylinder Cylinder Head Head Gasket Gasket Rear Rear Blanking Blanking Plate Plate -- Renew Renew 12.29.16 Gasket Gasket 12.29.17 -- Cylinder Cylinder Head Head Rear Rear Blanking Blanking Plate Plate 12.29.17 1.40 Hrs Hrs 1.40 Renew -- 1.40 1.40 Hrs Hrs -- Renew Please Please amend amend your Repair Repair Operation Operation Time Time Schedule Schedule accordingly. accordingly. No No other other Repair Repair Times nmes are are affected. XJ6/ XJ6 / XJS XJS ITEM: ITEM: 21 21 10 BRAKE BRAKE SYSTEM SYSTEM SERVICE SERVICE RECOMMENDATIONS RECOMMENDATIONS 10 With the the introduction introduction of of new new brake brake components components on on the the above above models, models, the the brake brake With servicing recommendations recommendations have have changed. changed. servicing No routine routine replacement replacement of of system system seals seals is is necessary necessary as as the the seals seals are are designed designed to to last last No for for the the life tife of of the the vehicle. vehicle. The braking braking system system must must still still be be inspected inspected for for satisfactory satisfactory operation operation and and condition condition The at at the the regular regular service service intervals. intervals. Brake fluid fluid to to be be renewed renewed at at 22 years years or or 30 30 000 000 miles miles (48000 (48 000 km) km)intervals, intervals, whichever whichever Brake is the the sooner. sooner. For For North North America America only, only, 18 18 months months or or 30 30 000 000 miles miles (48 (48000 000 km). km). is N.2:te..; N9te; Service Service Manuals Manuals will will be be up-dated up-dated at at the the next next reprint. reprint. Jaguar Cars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 % JAGUAR JA~ JD 03/92 03 / 92 JD ALL AJ~ENGINED AJGENGINED VEHICLES VEHICLES ALL ITEM: ITEM: 22 22 26 WATER WATER PUMPS PUMPS 26 A A revised revised water water pump pump assembly assembly has has been been introduced introduced on on AJ6 AJ6 engines. engines. The The assembly assembly now now has has aa gasket gasket between between the the two two halves, halves, instead instead of of RTV RTV sealant sealant as as previously previously used. used. The The revised revised assembly assembly is is fitted Rtted from from the the following following engine engine numbers: numbers: 4.0: 157275 3.2 : 107696 The part part number number of the the new new assembly assembly is is ESC EBC 8550 8550 and and replaces replaces EBC EBC 4437. 4437. The The part part The number of of the the gasket is is ESC EBC 9220. 9220. number Note: Note: THE THE GASKET GASKET CANNOT CANNOT BE BE RETRO-FITTED RETRO-FITTED TO TO RTV-SEALED RTV-SEALED WATER WATER IF A LEAK BETWEEN THE TWO HALVES IS PUMPS. PUMPS. IF LEAK BETWEEN THE TWO HALVES IS APPARENT, APPARENT, THE THE OLD OLD STYLE STYLE PUMP PUMP ASSEMBLY ASSEMBLY MUST MUST BE BE REPLACED REPLACED BY BY EBC EBC 8550. 8550. When ESC EBC 8550 8550 has has been been fitted fitted to to an an engine, engine, the the bolts bolts securing securing the the two two halves halves totoWhen gether must must be be re-torqued re-torqued to to 21.5 Nm Nm -- 28.5 28.5 Nm, Nm, to t o overcome overcome the the possibility possibility of gasket relaxation. relaxation. XJ6 // XJ-S XJ-S I/ 5.111 S.III XJ6 ITEM: ITEM: 23 23 80 80 AIR AIR CONDITIONING/HEATER CONDITIONING/!-IEATER MICROPROCESSOR MICROPROCESSOR 82 82 Refe[ Refer to t o Service Service Bulletin Bulletin JD JD 09/91, Item Item 62. To improve improve the the retention retention of the the air air conditioning/heater conditioning/heater servo servo drive drive motor motor les ICs (inte(inteTo grated circuits) circuits) secured secured to· to'the microprocessor unit unit heatsink, the the supplier has has now now grated the microprocessor changed the the process process to t o "Rivscrews". "Rivscrews". changed This modification modification commenced commenced during during mid-November mid-Novem ber 1991 1991 and and .raplaced the previpreviThis replaced the ous bolt-type bolt-type fixings. fixings. ous units fitted fitted with w i t h revised revised microprocessors were were progressively progressively Air conditioning/heater units from VINs: introduced from introduced XJ6 - 659029 659029 XJS XJS - 183501 183501 S.III S.l1I - 486299 486299 ITEM: 24 ITEM: XJ6 84 WINDSCREEN WIPER WIPER ARM ARM AND BLADE BLADE 84 FromVIN VlN 657725, 657725, all all XJ6vehicies XJ6 vehicles have have been been fitted fitted with with a revised revised wiper arm arm and and blade blade From assembly. assembly. These new new parts parts are are interchangeable with with cars cars built built prior to this VIN. VIN, when when changed changed as as an an assembly only. only. Dimensional Dimensional changes prevent prevent the the fitment fitrnent of a mixed mixed condition condition arm and and blades. of arm Dealers are are reminded reminded that wiper blade blade replacement replacement remains remains a part part of the the 7500 7500 mile mile Dealers (12000km) km) service schedule for all all vehicles. (12000 2 Jaguar Cars Limited 2005 JD03 / 92 JD 03/92 JAGUAR % JA~ XJS XJS ITEM:25 25 ITEM: 86 STOP STOP LIGHT LIGHT FAILURE FAILURE SENSOR SENSOR MODULE MODULE -- LOCATION LOCATlON 86 FromVIN VlN 179737 179737(92MY (92MY Facelift Facelift XJS). XJS),the the stop stop light lightfailure failure sensor sensor module moduleisislocated located From inthe the boot boot ofthe of the vehicle, vehicle, attached attachedto to the the inside insideof of the the boot bootside side reinforcement reinforcementpanel panel in (drainage channel) channel) L.H. L.H. (Fig. (Fig. 1). 1). (drainage FIG. 11 FIG. Prior to t o VIN VIN 179737 179737 (90MY (90MYXJSJ, XJS), the the module module isis located located beneath beneath the the centre centre console console Prior veneer finisher, finisher, attached attached to to aa bracket bracket in in front front of of the the stowa stowage compartment (Fig. ( F i g . 2). 2). veneer ge compartment FIG. 22 FIG. 3 Jaguar Cars Limited 2005 JD JD 03/92 03 192 =h+ JAGUAR JA~ - ITEM: 26 ITEM: XJ6 88 EXTERNAL EXTERNAL SPEED SPEED SENSOR BRACKETS BRACKETS -- IDENTIFICATION 1DENTlFlCATlON Two extern a I speed are avai lable for use Twoexternal speed sensor brackets bracketsareavailablefor use on on XJ6 models. models, To To avoid avoid any confusion, confusion, they are are identified identified as as follows: fojlows: Bracket Bracket Part Part No No Description Description Of Use Use For For all all Drive Drive Units Units prior prior to to the the introduction introduction of EBC EBC 9750 9750 and and ESC EBC 9751 9751 (no (no colour identification). identification). EBC For all all Drive Drive Units Units from from the the introduction introduction of EBC EBC 9750 and and ESC EBC 9751 9751 EBC 9820 9820 For (identified (identified by by a "spot" "spot"of blue blue paint). paint). CAC CAC 9884 9884 4 Jaguar Cars Limited 2005 Ii- -- - -- - - - ... ..... -- - . .. . -. .- - -. -. · JA~l - .-. Service Bulletin Bulletin I I ~~~~==~~~~~~~~~~~~~ DATE: DATE: SEPTEMBER SEPTEMBER 1993 1993 PAGE: 5 PAGE: 11 of of5 REF: REF: JD JD 26/93 26/93 00 ERRATA PLEASE NOTE THE FOLLOWING ERRATA IN RECENT SERVICE BULLETINS: 17/93 dated August 1993 I1.. JD 17/93 Page 6 FOURTH DIGITS duplicated . The Fourth Digit codes J and V have been duplicated. Please deletecode delete code J, so that iin future only code V will be used for "Thread "Th read Damn V age" . age". 17/93 dated August 1993 2. JD 17/93 Page 7 Lines 21 21 & 22 The entry 9YV is duplicated on these lines. read: 9YU gyU - Engine Compartment The first entry should read: 3. JD 24/93 dated September 1993 Page 2 Line 12 12 read: 44-1539/09 (Less JDS .... etc) etc) This line should read: 44-'~39/09 As 44-1539 44-1~39 (Less ITEM: 26 ITEM: XJ6 AND XJ12 XJ12 1994 1994 MY MY ALL VARIANTS VARIANTS 00 00 INFORMATION INFORMATION ADDITIONAL ADDlTlONAL TO THE THE 94 94 MY MY TECHNICAL GUIDE GUIDE The The 1994 1994 Model Model Year specificatron specification is is enhanced enhanced by by the the Inclusion inclusion of two two new new features features designed designed to to refine refine both both the the handling handling and and cosmetic cosmetic qualities qualities of Jaguar saloons. saloons. INTRODUCTION OF THE THE ZF ZF PHASE PHASE 22 STEERING STEERING RACK RACK INTRODUCTION OF FIG. FIG. 11 JaguarCars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 =+% JAGUAR JA~ JD 26/ 93 The The ZF ZF Phase Phase 2 Steering Steering Rack (Fig. (Fig. 1) 1) is is added added to the the 1994 1994 MY M Y specification. specification. The The rack rack body body consists of two two aluminium aluminium pressure pressure diecastings; diecastings; the the rack rack mounting mounting is Is ununchanged. changed. The The pinion pinion height (1, (1, Fig. Fig. 1) 1) is is increased increased by by 7mm; 7mm; the the steering steering column column is is altered change. The valve block altered toaccommodatethis toaccommodate thischange. The fluid fluid pipe pipe union union positions positions in in the thevalve are are also also altered. altered, with with the the fluid fluid pipes pipes being being modified modified accordingly. The The steering steering raci< rack assembly assembly is is a non-serviceable non-serviceable item. item. INTRODUCTION OF OF REAR REAR WHEEL WHEEL ALIGNMENT ADJUSTMENT ADJUSTMENT INTRODUCTION A system of rear Asystern rear wheel wheel alignment adjustment is is now now incorporated incorporated in in the the rearsuspenrearsuspensian sion assembly. assembly. The The lower lower suspension arm arm has has a plate, plate, with with a rectangular recess recess machined machined in i n the the centre, added added to to the the rear rear pivot pivot eye eye (1, (1, Fig. Fig. 2), 2 ) . The The suspension arm arm pivot pivot bolt bolt hole hole (2, (2, Fig. Fig. 2) 2)is is elongated, horizontaly. horizontaly, at this this point. The The pivot pivot bolt bolt has has an an integral integral eccentric eccentric (3, (3, Fig. Fig. 2) 2) below below the the bolt bolt head, which. which, when when in in position position in in the the plate, plate, has has a slight clearance clearance at a t the the sides sides but but full clearance clearance at the the top top and and bottom. bottom. Rotation Rotation of the the bolt bolt head, head, with with the the eccentric constrained constrained between between the the vertical thusdisplacvertical faces, faces, causes causes the the bolt bolt shank to to be be moved moved in in the the horizontal horizontal plane. plane,thusdisplacing ing the the hub hub carrier carrier and and effecting effecting wheel wheel alignment alignment adjustment. FIG. FIG. 2 XJS XJS FROM FROM VIN VIN 187900 187900 ITEM: ITEM: 27 27 - 30 EXHAUST SYSTEM SYSTEM - DETAIL DETAIL CHANGES CHANGES 30 EXHAUST From From the the above above VIN VIN a number number of changes, mainly mainly to to dimensions, have have been been introintroduced duced to t o exhaust exhaust systems. The The object object of the the changes changes is is to to improve improve clearance clearance bebetween tween exhaust exhaust system system components, components, the the seat seat pan pan heat heat shield shield and and the the rear rear axle, axle, thus thus giving giving less less possibility possibility of offouling. fouling. The The items items affected affected are: are: 1. Intermediate Intermediate pipe pipe -- shortened shortened by by 10mm. 10mm. 1. - 2. 2. New New 'Tarca' 'Torca' clamp clamp-tack-welded tack-welded in in production production (for (for ease ease of ofassembly) assembly) to to the the rear rear catalytic catalytic convertor, convertor, to to clamp clamp to to the the intermediate intermediate pipe. pipe. Note Note that that in in service service the the tack-welds tack-welds may may be be cut cut away away with with aa chisel, chisel, enabling enabling the the clampto clamp to be bediscarded. discarded. Newclamps New clampsshould should always always be beused usedwhen when the the exhaust exhaust syssystem tem is is being being re-assembled. re-assembled. 3. 3. The The rear rear catalytic catalytic convertors convertors (with (with attached attached clamps, clamps, as as above) above) have have aa longer longer outlet outlet pipe. pipe. The The convertors convertors fit fit lower lower in in the the vehicle vehicle than than previously, previously, improving improving clearance clearance between between convertors convertors and and the the seat seat pan pan heat heat shield. shield. 2 Jaguar Cars Limited 2005 JA~ JD 26/93 New Part Part Nos. Nos. New Description Description Market Application Application Market NMB NMB 6740AA 6740AA Intermediate pipe pipe Intermediate All markets markets All EBC EBC 9257n 925717 Clamp Clamp All All markets markets EBC EBC 11122 11122 Catalytic Catalytic Convertor Convertor RH RH EEC EEC (inc. (inc. GB), GB),Middle Middle East, East, EBC EBC 11123 11123 Catalytic Catalytic Convertor Convertor lH LH Malta, Malta, Cyprus, Cyprus, Poland. Poland. EBC EBC 11128 11128 Catalytic Catalytic Convertor Convertor RH RH All All other other markets markets EBC EBC 11129 11129 Catalytic Catalvtic Convertor Convertor lH LH All All other other markets markets XJ6 XJ6 AND AND XJ12 XJ12 ITEM:28 28 ITEM: IDENTIFICATION OF OF FINAL FINAL DRIVE DRIVE UNITS UNITS I/ LIMITED LIMlTED SLIP SLIP DIFFERENTIALS DIFFERENTIALS 51 IDENTIFICATION 51 Dea lers may certa i n owners, Jarly those who maya Iso drive ig h-perDealers mayfind findthat thatcertain owners, particu particularly thosewho may also drivehhigh-performance vehicles vehicles under under sporting sporting or or competition competition conditions, conditions, express express concern concern that that formance theirsaloon saloonvehicle vehicleappears appearsto tohave haveaadefective defectiveor or inoperative inoperativelim limited slip differential differentiat their ited slip unit, unit, or or that that the the final final drive drive appears appears to to be be of of aa "plain" "plain" or or conventional conventional type. type. Someclarification clarification isistherefore therefore necessary necessaryconcerning concerningthe theperformance performancecharacteristics characteristics Some aflimited limitedslip slip differential differential units. units. and identification identification of and Powr-Lok differential differential essentially essentiallyvaries variesfrom fromaaconventional conventional bevel bevelgear gear unit unit in in havhavAA Powr-Lok ingthe theaddition additionof offriction friction plates platesbetween betweenthe the output output bevel bevelgears gearsand anddifferential differential cascasing ing; the the friction friction plates plates are are loaded loaded by by input input torque torque to to the the differential differential unit, unit, in in addition addition ing; t oaa static staticpre-load. p r e l o a d .The Themode modeof ofoperation operationof ofsuch suchaa unit unitisisthat thatthe the speed speedof of rotation rotation to of aa slipping slipping road road wheel wheel isis limited limited by by the the braking braking action action of of the the friction friction plates, plates, and and of greatertorque torque isisapplied appliedtothe to the road roadwheel wheel having havingthe the better bettergripon g r i p o nthe theroad roadsurface. surface. greater This principle principle isiscommon comrnon~to all friction friction plate plate differential differential units. units. This ,to all Thecapacity capacityto totra transfer torque isisexpressed expressed as asthe the "Bias "Bias Ratio", Ratio", which which can can be bemodimodiThe nsfer torque fiedto tosuitthevehicle suitthevehicleapplication. application. Theselection Theselectionofl/Bias of "Bias Ratio" Ratio" isisaacomplex complex process, process, fied being aa compromise compromise between between vehicle vehicle handling, handling, refinement, refinement, and and traction. traction. AA HIGH being HIGH "Bias Ratio" Ratio" will will tend tend towards towards aa locked lockeddifferential differential condition, condition, as as may may be besuited suited to to aa "Bias hig h-performance vehicle vehicle tuned tuned for for competition competition purposes; purposes; aa vehicle vehicle so so fitted fitted will will high-performance from greater greatertraction traction capabilities capabilitiesthan than one onefitted fittedwith withaa low low "Bias "Bias Ratio" Ratio" unit, unit, benefitfrom benefit but but at atthe the expense expenseof of refinement refinement and andease ease of of handling. handtjng. basicallyin inthe the interests interests of of refinement refinementthat that the the Powr-Lok Powr-Lok differential differential units unitsfitted fitted ItIt isisbasically t o current currentJaguar Jaguar Saloon Saloon models models isisof of the the LOW LOW "Bias "Bias Ratio" Ratio" type, type, whilst whilst still still conferconferto ring the the benefit benefit of of partial partial locking locking between betweenthe the rear rear wheels wheels under under conditions conditions of of low low ring tyre tyre adhesion. adhesion. mayconfirm confirmthat thataa Powr-Lok Powr-Lok differential differential isisfitted fittedto to aa particular particularvehicle vehicle by byaa Dealers may Dealers BLACKCROSS CROSSon onthe theidentification identificationlabel labelon onthe therear rearcover coverof ofthe thedifferential differential housing. housing. BLACK In addition, addition, from from VIN VIN 684618, 684618, all all Powr-Lok Powr-Lok differentials differentials have have aa metal metal tag, tag, stamped stamped In "P/l", "P/L", attached attachedto to one oneof ofthe the bolts boltssecuring securingthe the fear rear cover. cover. XJS MODELS MODELS XJS ITEM:29 29 ITEM: 57 57 STEERING STEERING RACK RACK ASSEMBLY ASSEMBLY Commencingat at VIN VtN 188105 188105aa revised revisedpattern patternof ofsteering steering rack rackassembly assembly has hasbeen been ininCommencing troduced on on all allXJS XJS models. models. troduced 3 Jaguar Cars Limited 2005 JA~ JD 26/93 These units with the steering units (identified (identified below) below) are fully interchangeable interchangeablewith sreering rackassemrackassemblies on on all earlier XJS derivatives. derivatives. In In common common with the XJ6IXJ12 XJGDCJ12 steering steering racks racks supplied supplied through through Jaguar Parts Parts Operations, the racks racks will be be supplied supplied with a Centralising Centralising Pin Pin installed. installed. Upon Upon fitment of the rack assembly to the vehicle, this pin pin must be be removed removed and and replaced replaced by a screw and and special washer, as listed listed below. below. an Exchange Exchange Programme Programme of rack assemblies assemblies will be be introduced, initial initial units units Whilst an be new. The appropriate suffix, N N or E, E l should be be used. will all be NEW Part No. No. REPLACES Part Nos. eec CCC 6012 eee CCC 5660 5660 & & cee CCC 5666 CCC 6013 eee CCC 5861 5661 & & cee CCC 5667 eec CCC 6014 eee CCC 5662 & & eec CCC 5668 eee CCC 6015 eee CCC 5663 & & eec CCC 5669 5669 " ,., JZS 100046 100046 JZW J Z W 100019 Screw Washer Appl icatians Applications RHO V12 Sportspack RHD & & 3.6/4.0 3.614.0 Litre Litre Coupe RHO RHD & V12 Sportspack LHD & 3.8/4.0 3.614.0 Litre Litre Coupe LHD LHD V12 (Standard (Standard Spec.) Spec.) RHD RHD & & 4.0 litre Litre Convertible RHD RHD V12 (Standard (Standard Spec.) Spec.) LHD LHD & & 4.0 Litre Litre Convertible LHD LHD All above applications All above applications common with XJ6 and and XJ12 models, the above assemblies can can not be be serviced. In common reTo assist identification where warranty claims are submitted for the fitment of reshould be be utilised: urilised: placement units, the following NEW warranty codes should 5PA 5PD 5PF 5PG 5PH 5PJ 5PK 5PL 5PM 5PN 5PO 5PR 5PS 5PT Power Steering Steering Rack & Pinion Pinion Rubber Gaiter Rack Pipes Pipes Rack Pipe Pipe Unions Unions Track Rod Rod LH LH Track Rod RH RH Rack Mou Mounting nting Bush Bush LH LH Rack Mounting Bush Bush RH RH Rack Mounting Mounting Bracket Bracket LH tH Rack Mounting Mounting Bracket RH RH Front Wheel Tracking Tracking Outer Track Rod Rod Ball Ball Joint LH LH Rod Ball Ball Joint RH RH Outer Track Rod Mounting Bracket Fixings Fixings Rack Mounting XJ61993 MY ITEM: ITEM: 30 74 7 4 HUB HUB CAP DAMAGE DAMAGE To prevent distortion distortion to the hub caps, arising from from over-tightening over-tightening of the securing screw, a new plastic "snap on" on'' pattern pattern of hub cap has been been introduced introduced from VIN VIN 684705. The road wheels wheels affected are the 'Roullet' 'Roullet' alloy (Part (Part No. eee CCC 2708) 2708) and the 'Radial' alloy wheel (Part (Part No. No. CCC 3524). 35241. The new pattern pattern of hub hub cap is available as a s Part No. No. eee CCC 5281. 5281. 4 Jaguar Cars Limited 2005 JA~ JD 26/93 MODELS ALL XJ6, XJ12, XJS MODELS FROM VIN VIN 673299 673299 XJ12, XJ12,676725 XJ6,188105 FROM 676725 XJ6, 188105 XJS ITEM: ITEM: 31 31 74 16 INCH INCH ALLOY WHEELS 74 A A new new surface surface finish finish is is now now being being applied applied to to 16 16 inch inch Alloy wheels which which will will provide provide increased increased protection protection against against corrosion corrosion and and pitting pitting arising arising from from brake brake dust. dust. Dealers Dealers should should bring bring to to the the attention attention of owners owners concerned concerned that ONLY ONLY the the Jaguar-approved wheel cleaner should be used; acid-based cleaning products may proved wheel cleaner should be cleaning products may lead lead to to disdiscoloration coloration of alloy alloy wheels. wheels. The revised+ondition wheels wheels are are available available through through Jaguar Parts Parts Operations Operations under under The revised--condition Part Part Number MHB MHB 6115AA. 61 15AA. XJS XJS FROM FROM VIN VtN 187645 187645 ITEM: ITEM: 32 32 76 DOOR ARM ARM REST REST ESCUTCHEON ESCUTCHEON 76 A re-designed chrome chrome escutcheon escutcheon (securing (securing screw screw concealer) concealer)for the the door arm arm rests rests has has been been introduced introduced from from VIN VIN 187645. 187645. This This revised revised item item (Part (Part No. No. BEC BEC 23781) 23781) provides provides an an increased increasedclearance clearance between between the the escutcheon escutcheon and and the the trim trim cover cover of of the the arm arm rest, rest, compared compared to to the the previous previous condition. condition. XJ6 4.0 & & 3.2, 3.2,XJ12 XJ12 XJ6 ITEM: 33 33 ITEM: HEATER MATRIX MATRIX -- COOLANT COOLANT LEAKS LEAKS 80 HEATER 80 Investigations into into heater heater matrix matrix units units returned returned with with the the complaint complaint of of coolant coolant leakage leakage Investigations have resulted resulted in in design design changes. changes. Modifications Modifications to to the the top top and and bottom bottom tanks tanks and and colcolhave lector plates plates have have been been introduced introduced to to correct correct this this concern. concern. lector Heater Heater units units incorporating incorporating the the modified modified matrix matrix assemblies assemblies were were introduced introduced at a t VIN VIN 680591. 68059 1. All current current stock stock held held by by Jaguar Parts Parts Operations Operations is is to to the the revised revised condition. condition. All XJ6 1 XJ12 XJl2 SERVICE SERVICE MANUAL MANUAL XJ6/ ITEM: ITEM: 34 34 82 82 ERRATUM ERRATUM -- SECTION SECTION 82 82 PAGE PAGE 82-23 82-23 Your attention attention is isdrawn drawn to to an an error error in inthe the text text on on the the above above page, page, in inIssue Issue 2, 2,dated datedJanJanYour uary uary 1993. 1993. The The correct correct version version ofthe of the text text is is included included below; below; aa revision revision bar bar is is placed placed to the the left left of of the the changed changed text, text, which which is is also also underlined. underlined. Until Untilthis this section sectionis is re-issued, re-issued, to please please amend amend the the Service Service Manual Manual page page concerned. concerned. • See See 82.10.20.82.10.08 82.10.20. 82.10.08 for for removal removal ..... ..... etc etc.. ... bly and .., Reassem Reassembly and fitting fitting is is the the reversal reversal of of this this procedure procedure noting noting that that special special tool tool JD JD 164 164 must must be be placed placedover over the the compressor compressor shaft shaft for for seal seai installation installation and and that that the the replacement replacement seal seal must must be be fitted fitted with with the the aid aid of 197. of JD JD. 5 Jaguar Cars Limited 2005 F-II~~ '--~ ---~ --' ~"~~ '~ - ~~~ -~-~ 7 - I U_.__ Service Bulletin -_-~~s~e-r-Vi-C-e-B-U-lle-t~in~~~~JAGUAR DATE: DECEMBER DATE: 1993 1993 PAGE: 11 of of 6 PAGE: FEF: JD JD 44/93 REF: XJS IUS 4.0 LrTRE IZIRE 1994 1994 MY FROM VIN VIN 190528 190528 30 30 I'I'EM: 46 EXHAUsr EXHAUST SYsrEM SYSTl3l -- DETAIL DETAIL CHANGES, CHANGES, USA USA && CANADA CANADA ONLY ONLY for the the USA USA and and canada Canada markets markets ONLY, ONLY, the the Prior Prior to to the the alxJve above VIN V I N I, for exhaust exhaust system system basically b s i c a l l y consisted consisted of: of: -- downpipe dmpipe -- plain ('Y') p l a i n intermediate int-iate ('Y') pipe pipe -- twin twin catalytic catalflic convertors convertors -- over-axle over-axle pipes pipes -- rear rear silencer silencer assemblies assemblies the exhaust exhaust system system layout layout becomes: -: commencing C m c i n g at at the t h e above a b v e VIN, LEN, the -- -- downpipe downpip i n t d i a t e ('('Y') pipe with w i t h integral i n t e g r a l single s b l e catalytic catalytic - intermediate Y') pipe convertor convertor -- twin min plain plain silencers silencers -- over-axle over-axle pipes pipes -- rear rear silencer silencer assemblies assemblies '!be The following following part p a r t numbers n u n b x s are are applicable applicable to to the t h e later later condition, condition, from from VIN V I N 190528: 190528: NEW NEW PARr PART NOs NOS DESCRIPTION MARKEl' MARKFT APPLICATION APPLICATION EBC 10144 Intermediate I n t d i a t e (''i') ( ' Y ' ) pipe pipe with with integral intqral catalytic catalytic convertor convertor USA && CANADA CANAIXl USA me 9782 Intermediate Intermediate silencer silencer assembly assembly RH RH USA && CANADA CANADA USA me 9783 Intennediate Intermediate silencer silencer assembly assembly LH UI USA && CANADA (omw!A USA Jaguar JaguarCars Carslimited Limited Jaguar Cars Limited 2005 -~ m ClJ1\NGE alAra2 XJS 1993.5 -93-5 KDEL m m YEAR YEAR XJS 76 ITEM: 47 OONNEI' BONNET RELEASE RELEwE MECHANISM MECWlNISM Coinciding approximate.ly approximately with with the the intred.uction i n t r d u c t i o n of of XJS XSS 1993.5 1993.5 Mcx:lel Mdel Coinciding Year Year vehicles, vehicles, aa revised revised pattern pattern of of oonnet bonnet release release catch catch has has been been introduced introduced as as aa rurming m F n q charge. change. In I n the the course course of of development developrent of of the the new type type of of catch, catch, aa methed. m e t h d of of gaining gaining access access to to the the engine engine new (mrprbmt has has been been established establish& to to overcome overcome the the problem problem which mich would would compartment arise in in the the rare rare event event of of release release cable cable failure. failure. arise 'This This rnethcd method allows allows the the oonnet bonnet to to be be released released and and opened o p e d without without panel panel or paintwork paintwork damage damage to to the the oonnet bonnet itself itself or or adjacent adjacent panels.'Ihe panels.The oonnet hnnet or release release problem problem may nay then then be be traced t r a c d and and rectified. rectified. Strict observance o b s m c e of of the t h e following following method rraethod is is essential essential to to avoid avoid strict cosmetic m s e t i c damage: damage: 1. Ensure m e that t h a t the the radio radio code code is is known known prior prior to to disconnection dismnnedion of of the the battery. Open Open the the toot. boot. Remove Remove the t h e battery battery cover cover and and disconnect disconnect battery. the tattery. battery. the 2. Apply masking masking tape tape to to the the outside outside edges edges of of the the bonnet b n n e t and and Apply adjacent panels, panels, 'WTapping wrapping the t h e tape tape as as far far as as possible possible around around the the adjacent panel edges. edges. Fit F i t wing wing covers. covers. panel 3. F?m-ovethe the front f r o n t grille. grille. Remove 4. 4. Remove the the bolts bolts retaining retain* the t h e bonnet bnnet hinges. hinges. Remove Have Have an an assistant assistant ready ready to to prevent prevent the the front f r o n t end end n : Thp:n:t.ant : of the the bonnet bonnet being being raised r a i d by by the the action action of of the the of gas struts struts as as the t h e 1::01 bolts are removed. removed, gas ts are 5. 5. Allow the the front front end end of of the t h e bonnet bannet to to be be raised raised through through aa short short Allow distance by by the t h e gas gas struts, struts, the the rear rear end end meanwhile meanwhile pivoting pivoting on on distance the strikers strikers still still engaged engaged to to the the catches. catches. the Continue to to raise raise the the front front end end slowly slowly and and carefully carefully until until access access Continue is available available to to the the bonnet bnnet ball-joint k l l - j o i n t of of each each gas gas strut. strut. is Carefully release release each each ball ball joint joint from from its its pivot pivot ball. ball. carefully Wure that t h a t the the assistant assistant holding holding the the bonnet bonnet Ensure appreciates that that as as each each strut s t r u t is is released released (and (and appreciates allow& to to extend), extend), there there will w i l l be k aa change change from from allowed holding the the ronnet bonnet down down to to the the need need to to sUPp:Jrt support the the holding bmet bonnet. . 6. Have the the assistant assistant raise raise the t h e front front end end of of the the bonnet bonnet aa short short Have distance further further, until access access is is available available to to the t h e catches. catches. care Care distance I until is required required that t h a t the the rear rear corners comers of of the the tx:>rmet bonnet do do not not contact contact is the plenum plenum panel panel below. below. the - :2 Jaguar Cars Limited 2005 Release the theRHS RXS c a t c h by operating the latch arm directly by Release catch by operating the latch ann directly by hand. hand. 7. Us- the thelocally-made lccally-maderelease releasetool tmlillustrated illustratedininFig. Fig.1.1.belcw, below, Using the 1 l 1 5 catch may k e released a f t e r passing the release tool the lHS catch may be released after passing the release tool across t h e top of t h e engine. The notch on the end face of the across the top of the engine. The notch on the end face of the toolprevents preventsslippage slippagefrom fromthe thecatch. catch. tool 8. R w a v e the the bonnet bonnet byby lifting l i f t i n g itit upup and and away away from from the t h e engine erqine Remove c m p r b e n t aperture. compartment apert1..l.Te. 9. 10. 10. Traceand andrectify rectifythe t h erelease releaseproblem. problem. Trace 11. Refit Refitand andadjust adjustthe thebonnet bnnettotothe theaperture. aperture. 11. 12. Refit Refitthe t h efront frontgrille. grille. 12. 13. R e m n n e c tthe t h ebattery batteryand andref refit t h ebattery batterycover. cover. 13 . Reconnect it the 14. Re-code Re-codethe theradio; radio;re-set re-setthe theclock. clmk. 14. A--~ ~~;=-----------~ J t ~ ,., ______________190 1000 Fig. 1.1. Fig. I h e tool illustrated a b v e should be locally m u f a r t u r d frcm a 'llle tool illustrated abJve should l::e locally manufactured from a lengthofofsteel steelrod, rcd,6.0Omrn 6.00mn diameter, approximately lOOOrrm long. ?he length diameter, approximately lOOOmm long. The overall length, however, n o t critical, critical, provided provided that thatthe +hetool tool is1s overall length, hOHever, isisnot sufficiently long to provide access across t h e engine c o n p x b e n t . sufficiently long to provide access across the engine compartment. - 3 Jaguar Cars Limited 2005 I'l'fH: 48 76 ' USE OF OF LISTED LCSTED 'PIASTIe PIASTIC PADDTh'G PADDINGI ' BODY W D Y REPAIR REPAIR PRODUCTS PRODUCTS USE Being widely widely available available through through Body Body Refinishing ~ e f i n i s h i r qtrade trade suppliers, suppliers, Being Jaguar Jaguar make make the the following followinq recommendations reconrmendations as as aa result result of of laboratory laboratory lxzsts carried carried out out on on the the two two prcducts prcducts concerned:concerned:tests ' P l a s t i c Padding' Padding' 'Plastic WB2000 Stonechip Plastic Padding' Paddhq 'Plastic 'ULTIMA' ' U L m ' Universal Universal Body Body Filler Filler WE S'roNECHIP This is is aa sill-coat sill-coat repair repair product, p r d u c t , spray spray applied applied as as aa water-based water-based '!his emulsion. m l s i o n . Though Though prin:arily p r k i l y an an air a i r dried dried prrouct, product, it it rroay m y be be force force dried dried if if necessary. necessary. It It is is confirmed confkrmd that t h a t this this material mterial MAY MAY be be employed employed as as aa repair repair product procIuct on on Jaguar Jaguar and and Daimler IXimler vehicles, vehicles, where where the the repair repair will will be be the the subject subject: of warranty. Warranty. of Tests indicate, indicate, however, however, that that the the procluct product will w i l l give give aa coarser coarser finish finish Tests than t h a n that that given given by by the the original original factory factory finish f i n i s h sill-coating. s i l l - c o a t i q . 'TWo Ttm coats coats of to of the the product product are are recommended reco-ed to give give aa minimum mininun dry-film dry-film thickness thiclmess of of 400 microns. microns. 400 Colour mlour finishing finishing by by the the conventional convesltional 2K 2K process prmess should should be be force-dried forcedried at fine-roil' effects.) at 60"C 6O0C rrrudmum. mimum. (LoW (Low bake bake at at 90°C 90°C may may procluce produce I 'fine-boil' effects.) It should should be bs noted noted that t h a t repairs repairs adjacent adjacent to to clear clear coat coat must must be be It preceded by by thorough thorough flatting flatting of of the the clear clear coat m a t (360 (360 grit g r i t paper) paper] to to preceded achieve satisfactory satisfactory adhesion adhesion and and anti-chip anti-chip performance. performance. achieve 'ULTIMA t UNIVERSAL BODY FIlLER This This is is aa filler filler product, product, to to be be knife-applied knife-applied over over etch-primed etch-primed metal metal surfaces. After After appropriate appropriate sanding, sanding, aa conventional conventional 2K 2K colour colour process process surfaces. may be k applied. applid. may This product product is is Nor NOI' APPROVED APPROW for for J::cdy m y repairs repairs which which carry carry Wan-anty. Warranty. 'Ihis to other other similar similar materials' materials' of of '!he equivalent to The prcduct product is is assessed assessed as as r'equivalent the the catalysed catalysed polyester polyester type, type, and and shares shares with w i t h them them the the tendency tendency to to prcxiuce m c e micro-blistering micro-blistering around around the the interface interface between between the the repair repair and and original materials, materials, particularly particularly in in high high humidity humidity conditions. conditions. Hence, Hence, original on Jaguar Jaguar and and Daimler DaimLer vehicles vehicles its its use use must must J:e be confined c o n f h d to to repairs repairs on which do do not n o t carry carry Warranty. Warranty. W'hich - 4 Jaguar Cars Limited 2005 ITEM: 49 AIL KDELS Fl'lTED WTIH AIR a::tIDrrIctflNG 82 82 BIANKING B~G PLIKS FOR M R REFRIGERATION REFRIGERATION CIRCUITS CIRCUITS PUX;S ~ttentionis is drawn dram to to the the neoo need for for connections connections on on Refrigeration ~efrigeration Attention Circuit conpnents to b blanked o f f , whenever the circuit is is Circuit components to l::e blanked off, whenever the circuit disturbed for servicing or component replacement, in order to prevent disturbed for servicing or component replacement, in order to prevent contamination of of the t h e circuit circuit by by the the ingress ingress of of rroisture mistwe and and I 'foreign' contamination foreign I material. As well as k i n g necessary f o r on-vehicle a m p n e n t sI , this this material. As well as l::eing necessary for on-vehicle components also applies to components being returned u n d e r W a r r a n t y , since also applies to components being returned Wlder Warranty, since suk;sequent investigation investigation of of these these components components is is often often compromised cdmprclmis& by by sutsequent c o n ~ t i o of n their interior before receipt a t Jaguar. contamination of their interior before receipt at Jaguar. Components being being returned returned to to Jaguar Jaguar should should l::e k blanked blanked off off using using the the Components blanks installed on the r e p l a m t part. Compnmts on the vehicle blanks installed on the replacement part. Components on the vehicle should be be blanked blank& off off using using suitable s u i t a b l e internal internal line line plugs plugs and and external external should line caps. line caps. set of of plugs plugs and and caps caps found found suitable suitable for for most mst of of the the corrqxlJ1ents components in in AA set the Refrigeration C i r c u i t is the V a c u u m and Fuel Line Plug Set, the Refrigeration Circuit is the Vacuum and Fuel Line Plug Set, available from from Snap-on Snap-on Tools, T m l s , under under their their Part Part No. No. THX THX 312. 312. It It is is available recmmwxled t h a t Dealers should obtain sets of these, or their recommended that Dealers should obtain sets of these, or their equivalent, from from their their lCX2l 1-1 distributors. distributors. equivalent, In addition, addition, certain c e r t a i n connections connections can can be k blanked blanked off off using using aa Bonnet Bonnet In Stop, P a r t No. BD 10224, available via Jaguar P a r t s Oprations. stop, Part No. BD 10224, available via Jaguar Parts Operations. It is is important important to to note note that t h a t plugs plugs and and caps caps kept kept for for repetitive repetitive use use on on It ~ e f r i g e r a t i o n circuits should be kept segreqatd from those used f o Refrigeration Circuits should be kept segregated from those used forr other purposes, purposes, such such as as blanking blanking off off fuel fuel or or hydraulic hydraulic components. wmponenb. other ITEM: 50 50 I'lDI: 82 82 R E l X I E R DRIER DRIERASSEMBLY ASSEMBLY RECEIVER Current instructions instructions require rquire that that the t h e Receiver Receiver Drier D r i e r Assembly Assembly be be OJrrent r e p l a c d whenever whenever the the Refrigeration Refrigeration circuit circuit is is opened, o p e n d , even even though though replaced theremay m y 00 be no no reasons reasons to to suspect suspect the t h e serviceability serviceability of of the the Drier. Drier. there T h i s Service Service Bulletin Bulletin revises revises that that requirement requirement and and permits permits the the Drier Drier This to remain ramin in i n service service provided:provided:to blanks are are installed installed on on component c o p n e n t and and refrigerant refrigerant line line blanks connections immediately after disconnection. connections immediately after disconnection. blanks are are only only removed r m v d from from conponent compnent and and refrigerant refrigerant 1line blanks ine connections immediately W i a t e l y prior prior to to reconnection. reconnection. connections 1. 1. Refer to to Item Item 49 49 al:ove above of of this this service Service Bulletin Bulletin Refer f o r details details of of the t h e blanking blanking plugs plugs and and caps caps for rquired. required. - 5 Jaguar Cars Limited 2005 2. Refer Refer to to service service Bulletin Bulletin JD JD 45/93 45/93 for for details details of of the the latest latest standard standard lOr '0' ring ring seals seals for for R134A EU34A systems systems on on XJ6 X J G and and XJ12 XJ12 models. models. 3. \Vhen \hen reconnecting reconnecting the the refrigerant refrigerant line, line, new new '0' '0' ring ring seals, seals, lubricated lubricated with w i t h the the recarrunended recmmmmded refrigerant refrigerant oil, oil, must must be be used. used. However, However, the the Receiver Receiver Drier Drier Assembly Assanbly must m u s t still still be be replaced replaced if:if:it it is is suspected suspected that that there there is is swarf, marf, or or some some other other contaminant, con-t, in in the the Drier Drier as as aa result r e s u l t of of aa component compnent failure failure in in the the RefrigerRefrigerant ant Circuit. Circuit. the the Drier Drier is is blocked, blccked, damaged damaged or or leaking. leaking. there is is corrosion corrosion in in the the Drier Drier or or in in the t h e Refrigerant Refrigerant lines lines there (indicating (indicating the the presence presence of of moisture moisture in in the t h e system). system). - 6 - Jaguar Cars Limited 2005 - Service Service Bulletin Bulletin . . .- --.- -. . DATE: DATE: HAROi MARCH 1994 1994 PAGE; PAGE: 11of of 22 REF: REF: JD JD 26/94 26/94 ITaI: ITm: 22 22 XJ6 & XJ12 VIN ~ 50747~ 'ID 667578 XJS VIN RAtI;E lOOOO~ 'ID 190527 SERIES III 1985 MY 'ID VIN 487641 82 82 CONVERSION TO TO HFe W C 134A 134A REFRIGErWfI' REFRIGERANT FRCM l%XM CFC CFC Rl2 X 2 CONVERSION refrigerant R12 R12 l:ecornes bcornes increasingly increasingly less less available available 'dorld-'...;ide, vorld-wide, in in refrigerant favour of of refrigerant refrigerant HFe HFC 134A 134A ".mich which is is more mre environmentally e n v i r o m t a l l y friendly friendly, favour I it '...;il1 will become become necessary necessary to to convert convert the the refrigeration refrigeration systems systems of of it certain vehicles, vehicles, 'Which which '..Jere were originally originally manufactured manufactured \-lith with aa refrigrefrigcertain ation system s y s t m filled filled with w i t h Rl2 FU2 refrigerant, refriqerant, to to accept accept HFC HFC 134A 134A ation refrigerant. ref r iqerant . As As the above above situation situation may m y arise arise following following component component damage damage due due to to the collision, or or from from component component failure failure, Dealers :nay m y also also :te be requested requested by by collision, Dealers l customers to to change charqe their their vehicle vehicle to to the the later later refrigerant. refrigerant. Apart Apart from from customers these situations, situations, vehicles vehicles equipped equipped 'with w i t h CFC CFC Rl2 R12 systems systems should should these continue to to be k e serviced serviced using u s w Rl2 R12 refrigerant, refrigerant, and and only only retro-fitted retro-fitted continue to HFC HFC 1J4A 134A standards standards ',men when R12 R12 is is no no longer lorqer available available or or costmstto effective. effective. While ~~ile The principal principal change change involved involved is is the the replace.'T\ent r e p l a m m t of of the the existin:J existing The corrrpressor lubricating lubricating oil oil (compatible (coryatible CIilli C N X '..Jith with R12 R12 refrigerant) refrigerant) by by compressor an oil oil. corcqJatihle catpzkible with w i t h roth b t h HFC HFC 134A 134A refrigerant refrigerant and and \vith with residues residues of of an the earlier earlier lubricating lubricating oil, oil, which which it it is is not not fXJssible possible to to eliminate eliminate the completely from fron the the refrigerant refrigerant system. systm. In In addition, addition, it it is is also also completely necessary to to replace replace the t h e input input shaft shaft seal seal of of the the compressor carpressor by by aa seal seal necesscuy compatible \.,i w ith t h the the later later refrigerant. refrigerant. compatible Full details d e t a i l s are are contained contained in in aa Technical T e c h n i c a l Guide, Guide, '..;hich which is is l::eing being issued issued full at the the same he time t h as as this this bulletin. bulletin. at 'The The necessary necessary Parts P a r t s for for the the al:xJve a b v e conversions conversions are are available available from from Jaguar Parts P a r t s Operations Operations in in kit k i t form: form: Jaguar IaT KIT PARI' PARr NO. NO. MODEL MODEL All All XJ6 XJ6 & & XJ12 XJlZ JLM 11610 11610 JIM i I All XJS XJS All JLM 11611 11611 JIM I Series Swles III T I 1 rocrlels models I I/ I I APPLICATION APPLICATION up up to to vrn VIN 667578 667576 , I 1 up up to to \TIN V I N 190527 190527 I1 Post Post 1984 1984 MY MY I I i JaguarCars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 JD 26/94 service S e r v i c e Operation m a t i o n arrl and I..al:::our W u r Time T i m Allowance Allmce 'The The following following Fitting Fitting Operation Times apply: vrn V l l RANGE RANGE }i)DEL ImI3EL SANDEN SANDEN 810 810 593884 SANDEN 709 709 3.6L 3.6L 112586 112586 -- 179739 179739 HARRISON HARRlSON 3.00 3.00 hours XIS XSS 4.0L 4.OL 179740 179740 -- 190527 190527 SANDElf SANDEN 709 3 . 3 5 hours 3.35 XJS XSS 5.3L 5.3L 100001 100001 - 188104 188104 HARRISON HARRISON 3.10 hours 188105 ~ ~ 1 --0 190527 190527 5 SANDEN' SANDEN 709 709 PRIOR 'TO M 487641 487641 HARRISON 6.0L 6 . OL - , 1 1 I 3.10 3.10 hours 667578 667578 )oS XSS XJS US I -- 507471 507471 - 593883 593883 XJ6, XT6, XJ12 XSl2 R.O.T. R.O.T. Cll1PRESSOR CCNPRESSOR SERIFS SERIES III 111 LITRE urn 1 5.3 5.3 1 3.45 3 . 4 5 hours !1 3.10 3 . 1 0 hours I I I Details of the retro-fit pro:::ed.ure retro-fit p r d u r e are contained. contained in in the the Technical Technical Guide, Guide, flAir "Air Conditioning system System -- HFC Refrigerant Retrofit". Retrofit". - 2 Jaguar Cars Limited 2005