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1I I -- - -. -- - -- -- ... 1 - Service Service Bulletin Bulletin I1 -- ~AGUAR~ - DATE: DATE:MARCH MARCH1993 1993 PAGE: PAGE: 11of of 99 REF~ REF: JD JD05/93 05/93 ERRATA ERRATA WITH REFERENCE REFERENCETO TO SERVICE SERVICE BULLETIN BULLETINJD JD 17/92, 17192,PLEASE PLEASE NOTE NOTETHAT THATTHE WARWITH THE WARR A N PCOMPLAINT COMPLAINTCODE CODESHOWN SHOWN ON ONPAGE PAGE22AS LBKIS ISINCORRECT. INCORRECT. THIS THISCODE CODE RANTY AS 1ILBK SHOULD READ READ 1'ILKB LKB SHOULD V12 AND AND AJ6 AJ6 ENGINES ENGINES V12 ITEM: ITEM: 01 01 12 INTRODUCTION INTRODUCTION OF OF GRADED GRADED CRANKSHAFT CRANKSHAFT BEARINGS BEARINGS 12 As part part of of Jaguar's Jaguar's on-going on-going commitment commitment to to improving improving quality, quality, three three grades grades (sizes) (sizes) As ofcrank crank pin pinand andjournal journal bearings bearings have havebeen beenintroduced introduced on onall all production productionV12and V12and AJ6 AJ6 of engines. This This will will improve improve engine engine and andvehicle vehicle refinement refinement by by reducing reducingthe the maximum maximum engines. crank running running clearances clearances by by appro)(imately approximately 20%. 20%. crank Graded bearings bearingswere were introduced introduced on on production productionfrom from the thefollowing following engine engine numbers: numbers: Graded V12 XJS: XJS: 8S 8s 86817 86817 V12 V12 1112 Series Series Ill: Ill: 7P 7P 76912 7691 2 6.0 JaguarSport: Jaguarsport: TBA TBA ** 6.0 3.2: 98 111574 4.0: 9E/9W 164637 .* 6.0 6.0 litre litre JaguarSport Jaguarsport engines engines will will use use the the grading grading system system when when aa common common crank crank shaft shaft is is used used for for both both JaguarSport Jaguarsport and and Jaguar Jaguar 6.0 6.0 litre litre engines. engines. The The three three different different grade grade diameters diameters of the the journals and and pins pins are are represented represented by by a letter letter which which corresponds corresponds to to aa colour. colour, i.e. i.e. "P" "P" equals equals Pink, Pink, "R" "R" equals equals Red, Red, etc. etc. The The grade grade of each each individual individual journal journal and and pin pin on on each each crankshaft crankshaft is is identified identified by by having having the the grading grading diameter colour stamped stamped on on the the No No 1 balance balance weight, weight, indicating indicating the the grade grade shell to to be be fitted. fitted. as as follows: follows: of shell Jaguar Cars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 JA~ JD 05193 V12 AJ6 A: F Indicates front B: Journals 1 to 7 7 C: C: Pins 11 to 6 A: F Indicates A: lndicates front B: 8: Journals 11to to 7 C: C: Pins Pins 1 to 66 The bearing sheil sheil is identified by having having the colour on one of ofits edges. letter and colour for each diameter are as follows: follows: The grade lener V12 JOURNALS GRADE LETTER LElTER GRADE COLOUR GRADE DIAMETER p P PINK 3.0005 3.0008 W WHITE G GREEN 3.0009 INS INS (76.222MM) (76.222MM) 3.0009 3.0012 INS (76.230MMI (76.230MM) 3.0013 INS (76.233MMI (78.233MM) 3.001SINS 3.001 6 INS (76.240MM) I76.240MM) INS INS (76.212MM) (76.212MM) INS 1 NS (76.220M (76.220MM) M1 PINS PINS GRADE LETTER LElTER GRADE COLOUR COLOUR R RED yY YELLOW B 6 BLUE BLUE 2 GRADE GRADE DIAMETER 2.2993 INS INS (58.402MM) (58.402MM) 2.2996 INS INS (58.409MM) (58.409MM) 2.2997 INS INS (58.412MMI I58.412MM) 1 2.3000 2.3000 INS (58.420MM) (58.420MM) 2.3001 2.3001 INS (58.422MM) (58.422MM) 2.3004 INS (58.430MM) (58.430MM) Jaguar Cars Limited 2005 JAGUAR % JA~ JD JD 05/93 05 / 93 AJ6 JOURNALS JOURNALS GRADE GRADE LETIER LElTER GRADE GRADE COLOUR COLOUR GRADE ETER GRADE DIAM DIAMETER pP PINK PINK 3.0002 3.0002 INS INS (76.207MM) (76.207MM) 3.0006 INS (76.216MM) 3.0006 INS (76.216MM) W W WHITE WHITE 3.0006 3.0006 INS INS (76.217MM) I76.217MM) 3.0010 3.00t0 INS INS (76.226MM) I76.226MM) G G GREEN GREEN 3.0010 3.0010 INS INS (76.227MM) 176.227MM) 3.0014 3.0014 INS INS (76.236MM) (76.236MM) PINS PINS GRADE GRADE LETTER LETER GRADE ETER GRADE DIAM DIAMETER GRADE GRADE COLOUR COLOUR A R RED RED 2.0852 2.0852 INS INS (52.966MM~ (52.966MM) 2.0856 INS INS (52.975MM} (52.975MM) Y V YELLOW YELLOW 2.0856 2.0856 INS INS (52.976MM} (52.976MM) 2.0860 2.0860 INS INS (52.985MM) I52.985MM) B BLUE BLUE 2.0860 INS INS (52.986MM} (52.986MM) 2.0864 INS INS (52.99SMM) (52.995MM) New Part Part Numbers Numbers for the the graded graded bearing bearing shells shells are are as as follows: follows: New V12 GRADED GRADED BEARING BEARING SHELLS SHELLS (S.3 (5.3 & & 6.0 6.0 LITRE) LITRE) V12 PART NUMBERS NUMBERS PART PARTNO PART NO CONN ROD ROD BEARING BEARING CONN NO N O PPER ER ENGINE ENGINE SIZE1 JLM 11138/01 11138/01 SIZE 1 JLM SIZE 2 JLM SIZE2 JLM 11138/02 11138102 SIZE3 JLM 11138/03 11138103 SIZE 3 JLM 12 12 MA1N BEARINGBEAR IN G MAIN FRONT/INTERMEDIATE FRO NT(INTER MEDIATE SIZE1 JLM11139/01 11139/01 SIZE 1 JLM SIZE 2 JLM JLM 11139/02 1 1 'I39102 SIZE SIZE3 JLM 11139/03 11139103 SIZE 3 JLM MAIN BEARING BEARING -- CENTRE CENTRE MAIN MAIN BEARING BEARING -- REAR REAR MAIN REPLACES COLOUR COLOUR REPLACES CODE CODE RED RED YELLOW BLUE BLUE C38933 C 38933 55 PINK PINK WHITE WHITE GREEN GREEN 2931311 C 29313/1 JLM 11140/01 11140/01 SIZE 1 JLM SIZE2 11140102 LM 11140/02 2 JJLM SIZE SIZE 3 JLM SIZE3 JLM 11140/03 1 PINK PINK WHITE WHITE GREEN GREEN C 29314/1 2931 4/1 11141/01 SIZE11 JLM JLM11141101 SIZE JLM 11141102 1 1141 102 SIZE 2 JLM SlZE 33 JLM JLM 11141/03 11141/03 SIZE 1 PINK PINK WHITE WHITE GREEN GREEN EAC EAC 3973 3973 SIZE^ CRANKSHAFT 5.3L 5.3L CRANKSHAFT EBC EBC 10961 10961 CRANKSHAFT 6.0L 6.OL CRANKSHAFT EBC 10992 '10992 EBC 3 Jaguar Cars Limited 2005 JA~ JD 05/93 AJ6 AJ6 GRADED GRADED BEARING BEARING SHELLS SHELLS (3.2 13.2 & & 4.0 4.0 LITRE) LITRE) PART PART NUMBERS NUMBERS PART PART NO NO NO NO PER PER COLOUR COLOUR ENGINE ENGINE CODe CODE SIZE1 JLM JLM 11135/01 11135101 SIZE' SIZE2 SIZE2 JLM JLM 11135/02 11135102 JLM 11135/03 11135103 SIZE 3 JLM SIZE3 66 MAIN SIZE 1 JLM MAIN BEARING BEARING -SIZE1 JLM 11136/01 11136101 FRONT/INTERMEDIATE/AEAR FRONT/INTERMEDIATE/REAR SIZE2 SIZE 2 JLM JLM 11136/02 1 1 136102 JLM 11136/03 11136/03 SIZE3 S E E 3 JLM 66 CONN CONN ROD ROD BEARING BEARING MAIN MAIN BEARING BEARING -- CENTRE CENTRE SIZE JLM 11137/01 I 1 137101 SIZE 11 JLM SIZE2 JLM 11 137102 SIZE 2 JLM11137/02 SIZE SIZE33 JLM JLM 11137/03 1 1137103 CRANKSHAFT 3.2L CRAN KSHAFT 3.2L EBC 10916 10916 ESC CRAN KSHAFT 4.0L CRANKSHAn 4.0L EBC 10915 10915 ESC REPLACES REPLACES RED RED 2502 EAC2502 YELLOW YELLOW EAC BLUE BLUE PINK PINK 11 GREEN GREEN EAC 7957 (red) EAC7957Iredl EAC 7958 (blue) EAC7958(blue) PINK PINK WHITE WHITE GREEN GREEN EAC 7961 ~red) EAC7961Ired) EAC EAC 7962 7962 (blue) (blue1 WHITE WHITE bearing problem problem is is encountered encountered on on engines engines built built prior prior to to the the introintroIf aa crankshaft or bearing duction of graded graded bearings. bearings, the the following following applies: applies: duction If If the the bearing bearing shells shells only only have have to to be be replaced, reptaced, sets sets ofthe of the old old condition condition shells shells will will still still be available available and and should should be be ordered ordered as as before. before. be If the the crankshaft crankshaft needs needs to to be be changed, changed, aa graded graded bearing bearing crankshaft crankshaft will will be be supplied supplied If from Parts Parts Operations Operations and and the the relevant relevant graded graded bearings bearings will will need need to to be be fitted. fitted, from crankshaft or bearing bearingproblem problem is is encountered encountered on on engines engines with with the the graded graded bearbearrfIf a crankshaft ings, the the following following applies: applies: ings, If the the bearing bearingshells shells only have have to to be be replaced, replaced, the the relevant shells, as as noted noted on on the the No.1 No.1 If balance weight (see (see abovel, above), should should be ordered. ordered. balance If the the crankshaft needs needs to to be be replaced, replaced, a graded graded bearing bearing crankshaft crankshaft will wit1 be be supplied supplied by Parts Parts Operations and and the the relevant relevant graded graded bearings bearings should should be be ordered ordered separately. separately. by ALL MODELS MODELS ITEM: ITEM: 02 17 EVAPORATIVE EMISSION EMISSION CONTROL CONTROL SYSTEM SYSTEM 17 In order to to meet meet stricter world-wide world-wide emission emission regulations, regulations, an an Evaporative Evaporative Emission Emission In Control Control System System is is now now fitted fitted to to all al4 Jaguar vehicles. vehicles. Introduction Introduction VIN's are: XJS -- 184907 184907 SERIES SERIES III 111 -- 486831 486831 XJ6 -- 664941 664941 Emission Control Control Systems Systems are are designed to t o prevent prevent fuel fuel vapour, which which Evaporative Emission hydro-carbons, escaping escaping into into the the atmosphere. consists mainly of hydro-carbons, i s a resume resume of major components of the the system system and and the the way in in which which The following is system functions: functions: the system 4 Jaguar Cars Limited 2005 JA~ JD 05/93 MAJOR COMPONENTS: /.------------------8 K jSI-la~a 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel Fuel Tank Evaporative Evaporative loss flange PressureNacuum relief valve with vacuum operated operated by-pass by-pass valve PressureNacuum Purge Purge control valve Purge Purge air port (on Ion charcoal charcoal canister) canister) Charcoal Charcoal canister Purge port (on Ion induction induction manifold) manifold) Electrical connection connection to ECU ECU Electrical Induction manifold manifold 5 Jaguar Cars Limited 2005 JA~ JD 05/93 THE SYSTEM SYSTEM FUNCTIONS FUNCTIONS IN IN THE THE FOLLOWING FOLLOWING WAY: WAY THE Fuel Fuel vapour, generated generated in in the the fuel fuel tank, is is passed passed in in aa controlled controlled mannerto manner to aa storage storage device, located located at a t the the front front left-hand left-hand side side of of the the vehicle, in in front front of of the the road road wheel. wheel. device, The canister filled with The storage storage device device is is aaplastic plasticcanisterfilled with charcoal, charcoal, (6, (6, Fig Fig 1). 1). The The charcoal charcoal ababsorbs the the vapour, vapour, enhancing enhancing the the storage storage capacity capacity of of the the canister. canister. sorbs When aa vehicle vehicle is is at at rest rest with with the the engine engine turned turned off, off, the the flow flow of of vapour vapour is is controlled controlled When by by aa pressure/vacuum pressure/vacuurn relief relief valve valve (3. (3,Fig Fig 1), I ) , so so that that aa low low positive positive pressure pressure is is mainmaintained inthefuel in the fuel tank.lfthis tank. Ifthis pressure pressure exceeds exceeds approximately approximately 1.5 1.5 psi. psi, the the pressure/vapressure/vatained cuum relIef relief valve valve opens. opens, to t o allow allow the the excess excess pressure pressure and and fuel fuel vapour to to bleed bleed into into cuum the charcoal charcoal canister, canister, thus thus maintaining maintaining the the low low positive positive pressure. pressure. the be any any blockage blockage of of the the line line between between the the fuel fuel tank tank and and the the charcoal charcoal cancenShould there there be Should ister, there there are are further further pressure pressure relief relief valves, in in both boththe the evaporative evaporative loss loss flange flange and and ister, the fuel fuel filler cap, cap, to t o prevent prevent any any excess excess tank tank pressure. pressure. the When the the engine engine is is running, running, the the pressure{vacuum pressure/vacuum relief relief valve valve is is held heldopen open by by engine engine When vacuum, allowing allowing an an unchecked uncheckedflow Row of of vapourfrom vapourfrom the the fuel fuel tank to to the the canister canister and and vacuum, "zero" pressure pressure in in the the fuel fuel tank tank (i.e. (i.e. atmospheric pressure.) pressure.) "zero" via a purge The The charcoal charcoal canister canister is is connected connectedto t o the the vehicle's induction induction manifold manifoldviaa purge concontrol valve valve (Fig (Fig 1, 1, item item 4), 4), the the operation operation of which which is is controlled controlled by by an an electrical electrical signal signal trol from the the engine engine management management ECU, ECU, according according to to aa pre-determined predetermined map. map. from The The canister canister is is purged purged bydrawing by drawing the the vapour into intothe the induction induction manifold, manifold, the the volume volume of of vapour being being controlled controlled by by the the purge purge valve valve via via the the ECU. ECU. The The vapour is is then then disdisposed of of during during the the combustion combustion process. process. posed 4.OL AUTO AUTO MODELS MODELS ALL 4.0L ITEM: 03 ITEM: 03 18 TRANSMISSION CONTROL CONTROL UNIT UNIT (TCU) (TCU) 18 Should an an automatic transmission transmission failure failure warning warning be be accompanied accompanied by by fault codes codes 17 17 Should and 08 08 (torque (torque control control and and select select -- possible possible open open circuit), technicians may assume assume and the transmission control control unit unit (TCU) (TCU) is is faulty faulty and and erroneously erroneously logging bogging the the fault fault that the codes, particularly particularly if no no fault is is immediately immediately evident with with the the wiring. However, However, itit is is codes. unlikely that the the TCU TCU is is at fault, fault, as as the the most most likely cause cause of the the fault is is in in the the wiring to the the engine engine management management ECU. ECU. to The "pull-up" "pull-up" resistors resistors for the the torque control control and and select select tines tines are are located located in in the the enThe gine management ECU. ECU. tfthe If the supplytothis supply to this ECU ECU is is faulty. faulty, there there will will be be no no pull-up and and gine the voltage voltage on on the the select select and and control control lines lines will will drop. The The TCU TCU will will diagnose this this as as the an open open circuit circuit failure. Therefore, when when fault codes codes 17 17 and and 08 08 are are seen seen together, together, the the an to the the engine engine management management ECU ECU should should be be checked. checked. supply to is also also possible possible that this this fault may may be be caused caused by by any any non- approved approved security/alarm security/alarm ItIt is which immobilise irnmobi lise the engine engine management management system system by by cutting cutting its its power power supsystems, which ply. ply. 6 Jaguar Cars Limited 2005 JA~ JD 05/93 ALL MODELS ITEM: ITEM: 04 26 DELETION DELETION OF BARRS BARRS LEAK When draining and refilling refilling the cooling cooling system during vehicle maintenance, it is no no longer necessary to add add 'Barrs Leak' radiator leak sealer. Process Process improvements and improved component quality now render the continued continued use use of 'Barrs Leak' unnecessary. On vehicles prior to t o the following VIN's VINJs'Barrs Leak' radiator leak sealer should Note: On 'Barrs Leak' still be used. Models -- VIN. 670522 XJ6 Models 186210 XJS Models -- VIN. 186210 ITEM: ITEM: 05 XJ692 MY 51 51 FINAL DRIVE UNIT UNIT range 665838 to 667716 VIN range A number of vehicles within the above VIN range range have been been fitted with an alternative final drive unit, unit. The current and and alternative units can can be distinguished by the number of bolts bolts in in the output shaft seal housing, five in in the current final drive unit and and three in in the alternative. The alternative alternative final drive will not be supported with spare parts until until mid-1993, mid-1993, therefore, should there be any service concerns, Jaguar Parts Operations will only supply the current final drive units. To complete the repair it will be t o fit the appropriate speed sensor bracket. bracket. necessary to Forfinal For final drive unit part numbers EBC EBC 10910/1/2/3 and and ESC EBC 10911/1/2/3, 10911/1/2/3, fit speed sensor bracket EBC 9820 (identified (identified by a blue paint spot). Fo Forr all other final drive unit part numbers, numbers, fit speed sensor bracket CAe CAC 9884. ::n.. ,.,. 11:2.. Lt.-"- ,-NCf'/ (J h .. ote:::: JI...-r"'f'_ll'-.4-/l LC{c... ITEM: ITEM: 06 XJ6 1991 MY - 1993 MY 86 86 BATIERY BATTERY QUIESCENT DRAIN DRAIN INFORMATION To enable Jaguar Dealers Dealers and their technicians to t o keep keep abreast of both both past and and presinformation covers the thevehicle range vehicle range ent quiescent drain specifications, the following information over the last three years. METHOD METHOD OF MEASUREMENT In order to correctly measure measure quiescent current, technicians MUST adhere to the following lowing procedure: -- Disconnect the battery negative lead. negative lead. lead. -- Connect ammeter between the battery negative post and negative high meter range range (ie: Iie: equal to or more than 10 10 amps) amps) -- Select high Switch the ignition "on" then ""off", remove the key. key. (Do (Do notcranktheengine) not crank theengine) -- Switch off", then remove record the measurements obtained overthe over the time scales identified in in -- Observe and record this Bulletin. 7 Jaguar Cars Limited 2005 JA~ JD05/93 Note: Whilst testing is being carried out. no vehicle systems must be activated. For this reason, on 1993 Model Year vehicles, the boot light should be disabled and its lock latched shut. QUIESCENT DRAIN FIGURES (Approximate values in milliamps) COMPONENT VEHICLE MODEL YEARS iUMY azMY :llMY XJ6 XJ6 XJ6 Air con/heater 0.5 Ride level 1.0 0.6 0.6 Transmission control 1.3 2.0 2.0 Central processor 3.3 8.0 8.0 Instrument pack 2.5 2.5 2.5 Alternator 0.5 3.0 3.0 Radio head unit 2.6 2.6 2.6 CD Autochanger 2.5 3.5 3.5 Clock 0.3 0.7 0.7 Air bag module 0.3 Engine ECU 3.5 3.7 3.7 Infra-red locking 1.0 1.5 1.5 Seat memory modules 7.0 1.0 1.0 1.5 1.5 Facia switch panel 1.0 1.0 Wipe logic 1.0 1.0 1.0 I Gearshift interlock contro l module Passive ECU Door lock EeU 1.0 F/R/H Bulb fail unit 0.6 0.6 0.6 F/R/H Bulb fail unit (UK) 1.5 1.5 1.5 F/LJH Bulb fail unit 0.6 0.6 0.6 F/ LJH Bulb fail unit (UK) 1.5 1.5 1.5 R/ RtH Bulb fail unit 0.4 0.4 0.4 R/l/H Bulb fail un it 0.4 0.4 0.4 TYPICAL QUIESCENT CURRENT LOADS FOB 1993 MY XJ63.2 XJ64.0 SOV 3.2 SOV 4.0 DAIM 4.0 20.0 28.6 27.3 28.6 28.6 10 10 10 10 10 TOTAL DRAIN CURRENT 30.0 38.6 37.3 38.6 38.6 VEHICLE STANOING TIME IN DAYS (INC ALARM) 53.3 42.4 43.8 42.4 42.4 SPECIFICATION TOTAL (NOMINAL VALUEI BASE RF ALARM (DISARMED) 8 Jaguar Cars Limited 2005 =+% JA~ JAGUAR JD 05/93 05 193 Note: -- These figures were calculated for a new battery. battery, discharging from 80% Note: charged charged to 20% 20% charged. between markets. -- The base quiescent drain figures will vary between - Accessory parts will reduce reduce the vehicle stand stand time. Non-approved accessories are likely to reduce reduce considerably the vehicle -- Non-approved stand stand time. - IMPORTANT: -- Vehicle drain figures should be be calculated according to t o their indiIMPORTANT: vidual specifications. This information information must be be passed passed on to the appropriate workshop technicians_ techniciansSTAGES OF QUIESCENT QUIESCENT DRAIN DFIAlN IMPORTANT -- The current figures used used here are only examples_ examples. The time scales IMPORTANT: shown are, however, accurate. VEHICLE QUIESCENT DRAIN DRAIN FIGURES FIGURES 0-5 0-5 minutes minutes 6-21 6-21 minutes 22 minutes onward 500 milliamps milliamps (example) (example) 75 milliamps milliamps (example) (example) 25 milliamps rnilliamps (example) (example) The above example highlights the significant drop in in current demand. demand, which can can be measured measured after the vehicle has been been left for a few minutes. Note: t o this final value if the keys keys are left in in the Note: -- The current drain will not drop to ignition, even if the ignition is not switched switched on. ignition, ALARM QUIESCENT ORAl N FIGURES (R ALARM DRAIN ( R F Alarm with ultra-sonic ultra-sonic intrusion sensors). 1-3 1-3 days 16 milliamps milliarnps 10 10 milliamps milliarnps 6 milliamps milliarnps 4-28 4-28 days 29 days onward onward Note: The current drain will only drop to t o this final value if the alarm is armed. Ifthe If the alarm is left disarmed, then there will be be a constant drain of 10 10 milliamps milliarnps for as long as the vehicle is left. left. For general current measurement and battery charging procedures, procedures, please ptease refer to the Battery Care Manual. 9 Jaguar Cars Limited 2005 r;;;::::=-- ..... ..-. . . .- Service Bulletin Bulletin l_~_~- __ -____-_ .-.... =+% JA~ll jAGuA7 ------------------------~~1~= ISSUE ISSUE NJ: NO: JD JD 42/93 DECEMBER DECDTWR PAGE PAm 1993 1993 11 OF 22 SRO: SRO: 44-15-32 44-15-32 : XJ6 4.0 LITRE LITRE AND XJS X3S 4.0 4.0 LITRE LITRE vrn SUBJECT AlJITlvlATIC GEARSHIIT ClUALITY : ADVICE ~ ~ T t ro l Ca.JSTQYlER W K M XJ6 629286 TO 667829 XJS 179737 TO 185820 RAN3E: Harsh Harsh upshift upshift lll1der under light ltght throttle throttle at at 50 50 MPH Mm3: (80 (80 KPH) KPH) E R: A A nrx:lified d f i e d transmission transmission control cmtrol unit unit (TaI) (TCLT) is is TICM nclw available which which gives gives aa significant significant irrproverrent impmvemmt in in available gearshift quality quality when w h m the the gearOOx g e a r b x m:d.e r d e switch switch is is gearshift in the the IDRMAL M3WlL p:lsition. position. In In S:PORT SPORT m::x:l.e, M e , there there is is aa in q i n a l improvem::nt impmvmmt in in shift shift quality. quality. rrarginal DEALER D m ACTION ACI'ICN : Yes Yes REPAIR REPAIR MEIHOD r4mmD ; 1, R w L m I m w m r:::ealers Cealers should shmld canplaint ccmplaint is is ensure that t h a t the the custCllEr custm ensure caused by any any of of the W caused. not not following: following: a. a. b. b. c. c. d. d. Engine w i n e tune tune Gearb::Jx. oil Geoil level level Selector cable cable adjustrrent adju s t m t Selector Rotary Rotary switch switch setting setting Use JIB to Use t o interrcgate interrqate the the 'IUJ K U for for fault fault cedes. ccdes. 2. \i'EruFI(~TI{N Dealers Balers mlSt rrarst verify verify that t h a t the the correct correct parts parts are are fitted: fitted : Transmission -- Part Part No. No. EBC EBC 4409 4409 Transmission Transmission Transmission Control Unit Unit -- Part Part No. No. DBC DBC 10110 10110 Control Jaguar JaguarCars Cars Limited Limited Jaguar Cars Limited 2005 3• RESJllJI'ICE Where the the custarer c u s t m r catplaint ccmplaint persists persists after after the the Where a b v e checks checks, replace the the existing &sting TClJ W by by the the al:ove I replace rrdified unit. m::xii f ied unit. PARTS INFORMATICN IMFDRMATIm PARTS : The m:dified r r d i f ied TC.U K U is is available available through t h g h Jaguar Jaguar Parts Parts 'The Operations : q:erations: Part N:>. rJo. I.MA LMA 2400AA. 2 4 0 m . Transmission Transrmissirm Control Cbntml Unit. Unit. Part ACMINISIRATION rnFORMATION : Control Control will will be k exercised mid concerning the the return return of of TCUs. All All displaced displaced tmi units must be be acccrnpani.ed acccmpanid by by an an TCUs. ts must Informtion Label Label (JJM (J3M10 10 59 59 99) 9 9 ) as asdetailed detailed in in Em Information UK Policy Policy letter Letter JHSC W C 239 239 or or Export b p r t Policy Policy letter Letter UK mth Policy k l i c y letters Letters were were dated dated M3.rch Mzch Both 1993. 1993. JosC 137. 137. JOSe It is is essential. e i a l that that Dealers Dealers replacing replacing TCUs Ws supply supply It the following follaJing additional a d d i t i d information i n f o m t i o n on on the the ab::we ahme the label, attached attached to to the the displaced displaced 'IUJ: XU: lal::::el, * #1/ VDJ and and gearl:::cx gear& serial serial nurnl:;er m m k r (instead (insteadof of JDS JS VIN ** Reference to: to : IBulletin ' Bulletin JD JD 42/93 42/931 ' Reference * For UK UK market: tllarket: For identified codes) axles). . identified thf;Warranty Warranty Return Return Ref Ref No. m. the For E>Q;:ort mrt rrarkets: m r k e t s : the the Claim C l a i m Number Nmkr and and Dealer Baler For code. Cede. DGmMATTION EAILURE TO TO SUPPLY !SUPPLYALL ALL OF OF mE THEN:JJVE ABOVE INF'ORMATION FAILURE (CLEARLY&& I...EGIBLY) LEGIBLY) WIlL WILL RESULT RESUET ill INClAIMS CLAD% BElNG B E E (CLEARLY FduEcrED. REJECI'ED. WARRANIY CODE'S: XJ6 and XJS 4CGE REPAIR OPERATION OPERATIrn CODES: CDDES: REPAIR SRO: 44-15-32 Transmission Control Unit-renew 0.75 hours. - 2 - Jaguar Cars Limited 2005 r -- - jAGVAq JA~ .- -- Service Bulletin Bulletin Service I I l DM'E: FHRJARY 1994 PAGE 1 OF 7 REF: JD 07/94 00 ERRATUM PLEASENOTE?HE F O m mRATOM: EFzRAmIN SERVIcE B l m m T NJD J D 43/93 43/93 PLEASE NOI'E 'IHE FOII.CMING IN SERVICE BULLETIN JD 43/93 43/93 dated dated December 1993, 1993, Page Page 2, 2, line l h 16: 16: JD This line line SHOULD SHOULD read: read: 'Ihis ( P a r t Nos. Nos. CC 224JA 2243A to to CC ~243X). 2243x1. (Part Pla w d the the original original service Sewice Bulletin Bulletin accordingly. accordirqly. Please arrend XJ6 " XJl2 FlU! V1N 593884 03 03 A - REPAIR OPERATION OPERATION TIMES TIMES - ADDITIONAL AWITIONAL REPAIR The following f o l l w h g Service Service Repair Repair Operation Operation is is nCM now available available for for r.Ihe replacing the vehicle set of wishbone bushes and is applicable to replacing the vehicle set of wishbone b..lshes ani is applicable to vehicles fram 593884: vehicles fram VIN 593884: 60-35-29 60-35-29 - - Qxx & & Lower Law- Wishbones Wishbones - Vehicle Vehicle Set Set - Strip Strip & & Rebuild Relxlild Upper 4.85 Hours Ho4.85 Please amend amend your your Repair Repair Time T h Schedule Schedule ao:::nrd.irgly. accordingly. Please No other other Repair Repair Times T b are are affected. affected. No ITDt: 05 12 T3MING CHAIN CfIllIN TENSIONER TENSIONER ACCESS ACCESS GRrnMEr GRXMET TIMING Whenethe access access grommet g n m m ~ to tto the the t.im.i.n;J timing chain chain tensioner tensioner of of aa VI2 V12 Whenever the engine is is refitted., refitted, both both the the gromrret grommet and and its its location location in in the the t.imi.n3 timing engine caver should should be b cleaned, cleaned, to to rert'K)ve r m v e all a l l traces traces of of oil. oil. rover bead of of RIV RTV sealant sealant should should be be applied applied between between the theridges ridges of of the the AA bead grcmmgt, which which will will prevent prevent any any possibility possibility of of an an oil oil weep weep from fran the the grommet, grcmrmet area. area. grommet JaguarCars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 JD 07/94 AIL U I2 wrm: ITEM: 06 AJ6 JHiINE AJ6 ENGINE pr..u::; -- REVISED ENGINE SUMP DRAIN PLW REVISED 'TORQUE TORQUE SEITING S m The torque torque setti..rg settirq for the the stmtp sump drain plug on AIL AJ6 engines engines has has l:een been 'Ihe reduced redhzced from frm 65 - 79 Nrn Nm to: to: - -vised torgue t o m e settincJ: settinq: Revised 48 - 63 Nm. 'Ibis This revised setting should be use:l used whenever ~ m e v e raa sump swrp drain plug is is refitted. refitted. Ensure m e that the the latest latest pattern of washer, incotp:).rnting incorprating aa rubber rubber sealing aa drain plug. (Part No. ESC sealing ring, ring, is is used when whm refittin:;J ref it(Part No. IBZ 9044 available available via Jaguar Jaguar Parts P a r t s Operations) OpeYations) . . In p r a c t i o n ,I engines engines assembled with w i t h the the revised torque setting are In production fitted fitted fram f m approximately VIN rn 684700 (XJ6) (XJ6) and VIM V I N 189150 189150 (XJS). (X3S). :rJ»tI: 07 AIL WTIH AT6 EKi::JBE3 :PRIm. 'ID VIN 677386 (XJ6) HUm 'ID VIN 18Tl54 (XJS) 12 12 CYLINDER HEAD HEAD EROSION WSION 'lHIS SERVICE Illll~ SUPERSEDES 'DIE ENTIRE aNl'ENI'S OF SERVICE H1UEPDI .JD 08/92 lTEH 31 Where the the cylind.er cylinder head of of an an AJ6 en;Jine w i n e has teen been remove:i removed in in the the Where course caurse of aa Service S e n i c e Repair Operation, Operation, it may m y be noticed that t h a t aa certain certain amount of erosion to to the the cylirrler cylinder head face face has occurred ~ x u r r e daround a r m the aI1DW1t coolant passages passages of the cylinder head, f0rmh-q irregular irregular cavities. cavities. coolant h~d, forming Provided that NO!' exterx:l that the eroded area (coooition (condition C, Fig. F i g . 1. 1. ) does does NCrr extend into into the the area occupied o x u p i d by any firirg rin:;J ring,I (Item (Item I'A AI 1I , Fig F i g 1.), I.), of the the head gasket, gasket, using aa head gasket as as aa template; aa repair repair can be effected. effected and there is is no need n e d to to replace replam the cylirrler cylinder head. head- firm Where Where erosion has has resulted in in the the formation of cavities cavities in in less less critical areas passages, (con::lition areas around a r 0 the coolant pssages, (condition D, D, Fig. F i g . 1.) I.),I repair of the cylirrler q l i n d e r head should te be urrlertaken. Ulkdertaken. Careful Careful filll..m' filling of the cavities to to restore restore the cyli.rrler cylinder head face face to to its its original surface urrlertaken by means of profile may be undertaken of aa proprietary 'Plastic ' Plastic Metal I' Ceq r) • A proouct be available (q 'BELZONA 'BELZONAt). A suitable p r a c t will b available shortly from Jaguar No. JIM Jaguar Parts P a r t s Operations Operations under Part P a r t No, JLM 11719. 11719. CYLINDER HEADS NO!' n : HEADS SHOUID SHOULD NOT :IM[{RI'ANl': BE REMJVED REMOVED 'ID TO LOOK LDOK FOR 'IHIS THIS THE ?HE ABOVE AcrION ACTION SHOUlD SEDXD ONLY m Y BE NNECESSARY I E I E S A R Y WHEN '!HE IS NOITCED ON REM)VAL THE CONDITION -ITION IS NOTICED REMCRJAI; OF A CYLINDER CYIJNDER HEAD HERD FOR Umm REPAIR R E P m toc>RK. WE. CfIHER CONDITION. CONDITLON. - 2 - Jaguar Cars Limited 2005 .JD 07/94 TEXliNICAL BACKGROUND On engines engines prior prior to to VIN VIN on 677386 (XJ6) (XS6) and and VIN VIN 187554 187554 (XJS) (XJS) the the foundry foundry 677386 practices involved involved in in the the manufacture manufacture of of the the cylinder cylinder head head arrl and the the practices cylinder block b l d resulted resulted in in elongated elongated cored cared coolant coolant passages passages at at the the cylinder upper face face of of the the cylinder cylinder block, bl&, facing small small diatneter diameter drilled drilled upper facing passages in in the the cylinder cylirder head, head, separated seprated by by the the gasket. gasket. Coolant Coolant flCM flow passages between cyli..rrler cylh-der block block and an3 cylWer cylinder head is is controlled controlled by by the the diameter diameter between of of the the holes holes in in the the cylinder cylinder head head gasket gasket (Item (Item B, B, Fig. Fig. 1.) 1.) o D ~~ o Ii I_---r-A c o )5] 1131 Fig. Fig. 1. 1. In service, service, the the material of of the the head head gasket gasket 'collapses' wllapses' into into the the In larger leaving larger cored cored passage passage of of the the cylir'rler cylinaer block, bl&, leaving aa gap gap between between the the cylinder cylinder head aM ;ukd the the gasket, gasket, surrounding surrounding one one or or more more coolant cmlant passages. coolant Cmlant in in this this gap gap tnay may,I in in certain certain circumstances circmstances,I boil boil passages. l m l l y and and cause cause erosion erosion of of the the cylinder cylinder head head material. material. locally From mom the above h v e VINs, VTNs, the the coolant coolant apertures a p r h r e s in in the cylinder cylbder head have have been enlarged enlarged to to correspond correspond with w i t h the the apertures apertures in in the the cylirrler cylinder block; b l e ; hence coolant cmlant: can can no longer longer be trapped between the the cylinder cylinder head hence gasket an:i and cylinder head face. fa m , gasket REPAIR REPAIR MElliOD MEIHOD on On aa cylinder head on on which i h i c h erosion, erosion, within w i t h i n the the aboVe above permissible permissible limits, limits, has has occurred, camred, the the cavities cavities should should be be fille::i filled with w i t h aa suitable suitable J'Plastic should P l a s t i c Metal'. Metal ' It It is is desirable desirable that such such infilling infillshould restore restore the ercd.ed eroded area area to to be bs flush flush with with the machined mchined face, face, such that t h a t any any re-machining re-mchinirq of of the face face is is unnecessary. urmeoz,sary. However, Hawever, should it it tecome t3ecome ilnp:lssilile kpssible to to maintain mintah the required required surface surface finish finish and and dimensions dimensions without machining, should machinirq, reference refershould be made to to Service Senice BUlletin Bulletin JD JD 02/93 02/93 (Issued (Issued Janucuy January 1993) 1993) for for full full details details of af sizes, sizes, limits, limits, surface surface finish finish etc. etc. . - 3 - Jaguar Cars Limited 2005 JD 07/94 lMPORI'ANT : EXCESSIVE REMJVAL F'R.C:M 'IHE EX-SIVE RE3DVAL OF MATERIAL MATHE C'iLINDER CYLLNDER HEAD HEAD FACE FACE MAY LEAD I;E;AD 'ill TO PmKlNG/DEIONATION P ~ / D ~ T I PIDBLEMS. mx>BLEMS. O N Note: On On reJ:::uilding the ensure that that the the cooling cool* r-ldiq the engine, engine, ensure system system contains contains the the correct come& mixture mixture of of Jaguar Jaguar AntiFreeze/Coolant/Corrosion Inhibitor (See relevant Freeze/Wlant/Cmrosion (See Service Service Manual, Manual, Section 26, 26, 'Description *&?scription and and AntiAntiFreeze') Freeze' ) . . XJ6 & XIS 4.0 :r.rmE l.994 ItDEL YEAR XJ6 3.2 LI'lRE 1994 KDEL YEAR 44 44 ITEM: 08 TRANSMISSION TRANSMISSION FIXING BOLTS BOLTS aa number arrl numkr of of the the above above models, d e l s , manufactured. mufactured during November NOV& and December December 1993, 1993, four four of of the the ten ten bolts which fix fix the the automatic automatic transtransmission mission convertor convertor housi.n:;J housing to to the the intermediate intermediate plate have have l::een been fOUIXl found to to On On of of incorrect incomect material material specification. specifimtion. '!he The l:olts bolts concen1E!d conindicated by by arrCMS mms in in the the illustration illustration below. kelaw. indicated be are are 'llie bolts The suspect susbolts are are black black in in colour; colour; if if refitte::l r e f i t w in in the the course course of of aa service virv;J the sewice repair repair operation operation mvol invalvhq the separation separation of of the the transmission transmission from frm the the engine, engine, they they would would be be likely likely to to suffer suffer thread thread stripping stripping when when tightened torque. tightened to to the the upper upper limit limit of of recommended r-ed toque. Should Should the the occasion axasion arise arise to to separate separate the the transmission transmission from from the the engine engine in in the the course course of of aa service service repair repair operation, operation, the the affecte::i affected tolts bolts should should be be replaced replaced by by bolts bolts of of correct correct specification. specification. Tests Tests have have indicate::1 indicated that tolts that there there is is little little likelihoo::l likelihood of of the the affected affbolts failing failing in in service. service. - 4 - Jaguar Cars Limited 2005 .JI) 07/94 IMWRTANT: IMFORI'ANT: TRANSMISSION UNITS UNITS SHOUlD SHOULD NOr NOT BE BE REMOVED RIX)VED 'ro ?r) IOOK LROK FOR !>NY. ANY TRANSMISSION CONCERN. CONCERN. REPLACEMENT REPIACEENT OF OF 'IHE TFE BOLTS BOLTS <X>NCERNill WCEF!NED IS IS ONLY ONLY ~ A S A P RAS B 2AA PRECAUI'ION ~ O N I P J T Hill E E'lEE V E E.VENI' K T O FOF M RMAJOR S O R SSERVICE EKVICE REQUIRED REPAIRS. REPAIRS. Vehicles Vehicles affected affected may m y only only be be recognised recognised by by Engine mine Number, M m h r , within w i t h i n the the ranges: rqes: Engine wine No. No. 9E 9E 185496 185496 to to 9E 9E 186799 186799 Engine Engine No. No. 9B 9B 116832 116832 to to 9B 9B 117005 117005 XJ6 XJ6 & & XJS XJS 4.0 4.0 Litre: Litre: XJ6 XJ6 3.2 3.2 Litre: Litre: Replacarmt oolts blts should should be be orderej ordered via via Jaguar Jaguar Parts P a r t s Operations: Gprations: Replacement Washer-faced Washer-faced bolt. Part P a r t No. NO. FB FB 110125 110125 J. J. Qty jVelllcle 4. ANY DISPLACED DISPLACED PARI'S PAKPS SHOUlD SHOULD BE BE RElURNED 'IQ JAGUAR JAGUAR WARAANIY WlRRANTY REl'URNS RETURNS AT ANY BAGIFEON, 'llffiOU3H m I X ; H '!HE 'ISIE NORMAL NO= UFNNES. FAIUJRE BAGINIDN, OIANNEI..S. FAILURE 'ro TO 00 DO SO SO MAY MAY RESULT RFsULT IN IN ?HE CLAIM cIAIr4 FOR 'IHE T m ABOVE ABOVE PARI'S P m s BElliG BEING DEBITED. DEBrn. THE Torque T o m e Setting: Bolt, Convertor Convertor Housing Housing to to Intermediate Intermediate Plate: Bolt, .DGI:IAR & mD( 76 ~ XJ"6 AND XJl2 1994 MY AU. VARIANI'S 49 49 -- 54 54 NIn Nm.• rI'tM: 09 VIN 687219 FRONT FCOIWEf...L CARPErS - FI'l'l'ING PROCEDURE Additional tto the information in in Service Service Bulletin Eulletin JD JD 38/93 38/93 Item Itern 40, 4 0 , aa Additional o the f u r t h e r .i.nq:>rovement hprovmmt to to the the method method of of retention retention of of front f r o n t footwell footwell ftu:ther mtp?tS on on 1994 1994 MY saloon Saloon rnod.els models has has been intrcx:luced. intrduced. carpets Ebth versions versions are are described descriixd and and illustrated illustrated in in this this Service Bulletin. Both In of the carpet In roth both cases, cases, correct c o r r e fitment fi-t carpet within w i t h i n the footwell fmtwell is is essential essential to to eliminate elinhate the possibility subsequent displacement displa-t of the the cart;:et. carpet. subsequent of Note: F1UI vm of of 687219 'lU VIN 697999 Introduced as 1n-d as aa first first improvement improvement for for 1994 1994 Medel Model Year Y e a r vehicles, vehicles, the the rear edge rBdge of of both the the Driver's Driver' s and passeJ"X3'er's Passenger1s footwell f mtmell carpet carpet (Item 'B', J I section (1'B1, Fig.l.) Figel.) has has aa I'J1 seztion plastic strip s t r i p (Item (Itan 'A', ' A t , Fig.l.), Fig-l.), l which section (Item I Fig. 1. ) fixed which erl3"ages engages with w i t h aa corresporrling mrrespond~ -ion ( I t e m 'e 'C', Fig-1.) fixed to to on the the front front of of the the Seat ECU Ecv cover. cover. aa bracket on - CARPEr I S SIDE W E T FITMENT FI?MENT PRlXEDURE PRXEDURE - DRIVER DRIVER'S In In aa new new vehicle, vehicle, ex-factory, ex-factory, the Driver's Driver's side side carpet carpet is is fitted f i t t e d in in the the front front footwell, footwell, and and is is enclosed within w i t h i n aa plastic p l a s t i c covering covering which provides protection during vehicle vehicle delivery and and PDI. During' Durirq final final preparation p r e p r a t i o n of of aa new vehicle vehicle for for the the customer, custmer, the follCMl..n3 follming action action should be taken taken to to ensure ensure correct c o m e fitting: fitting: - 5 - Jaguar Cars Limited 2005 JD 07/94 - 1. 1. Re:roove carpet from the Remve the Driver's side side t the footwell. fmtwell. 22.. Remove the plastic p protective r o t s t i v e covering. mering. 3, 3. carpst in in half, half, an::i ard centralise centralise it in in the the footwell. fwtwell. Fold the carpet 4. 4. Lift the the rear edge of of the the carpet; carpet; align am and fully fully engage w a g e the bracket plastic 'J' 'Jr section strip on the the carpet carpet to to the Iretal metal b m h t on the front f r o n t of the the seat ECU BZU cover. m.(See (See Fig. Fig. 1.) 1.) the 5. 5. Align the carpet carp=t to to the the footwell; footwell; smooth smmth the carpet flat flat into into the footwell, fatwell, particularly at the the rear rear and. and sides of the the carpet. 6. 6. Fit pe::lals, F i t the forward forward edge edge of the the carpet carpt un:ier under the control pedals, ensuring" aligned over ensuring that that the cut-out cut-wt in in the the carpet is is correctly CO-ly the kick.-down clearance. k i c k d m switch to to provide the the required r-ed c l a m . is b e* to aa vehicle vehicle in in service, service, or should Where the carpet is being refitted to it it be necessary to to fit f i t aa replacement r e p l a m t : carpet, car@, items ibms 3-6 3-6 al::ove a b v e should be oJ:served observed to to ensure correct correct fitment. fitrent, - CARPECl? FITI'llIG FITTING PROCEDURE PASSENGER'S SIDE CARPET P~ - PASSENGER'S 'The The carpet on the Passenger's Passeyer's side of the vehicle is is similarly similarly retained at the the rear edge. edge. Ensure k s w e that on aa vehicle being prepared for for retained the the the customer customer that the carpet has remained r a i n 4 correctly c o r r e l y fitted. fitted during" dur* delivery cycle. Items Iterns 3-5 above above should also also l:e be ol:served observed when when refitting refitting a carpet, or 'When fitting a replacement carpet. a when fitting a repla-t carpst. Fig. 1. - 6 - Jaguar Cars Limited 2005 JD 07/94 Fl1RIHER IMPIVIlEMENl' 'IO 'ID 1994 1994 MY VEHI<:::rm VEHICLES :FK:M VIN 698000 From Fram the the above above VIN, W, the the rear edges edges of of 00t:h b t h Driver's Driver8s arrl and Passenger's 'Ag, side side carpets carpets are are similarly retaine:i retained by flat flat plastic strips strips (Item ( I t e r n 'A', Fig.2) in brackets on the front of the seat ECU covers, (Item Fig.2 ) engaging engag* in brackets on the front of the ElCU cavess, (Item ,'C', C', Fig. 2.) . In D' , Fig.2.). In addition, addition, aa strip strip of of 'VEl.CRO' 'VELCRO' fastening fastening (Item (Item I'Dl, Fig.2. ) is is fittecl fitted to to the the outer mter ems erds of of both both carpets, cmpzts, with w i t h aa corres:p:>nding fE' ,Fig.2.), thus ponding strip strip fitted fitted to to roth both ECU DXl covers covers (Item (1'E9,Fig.2.), thus providing p r o v i d i q additional additional security security to to the the footwell foatwell carpet location. lacation, CARPET' CARPET FI'ITING F ' I r n G ~URE pFn2EDURE During During final final preparation preparation of of aa new vehicle, vehicle, or or when when refitting refitting aa carpet or or fitting fitting aa replacement r e p l a m t carpet, carpet, the the procedure prcxedxe outline:i outlined previously previously should should be be o:tserved. obervd. Ln addition, addition, hCMever, hmever, ensure ensure that that the the 'VELCRO' 'ITlURl' strips strips (Item (I* 'El, In 'E', Fig.2.) at the the outer o u k r Erlges edges of of both front Fig. 2 .) at front carpets carpets are are fully fully engaged engaged to to the the corresporrling correspording strips strips on on the the ECU ECU covers, covers, after after having correctly comect:ly L m t d the the plastic retaining retaining strips strips to to the the brackets brackets and and aligned aligned eadl each located carpet carpet within w i t h i n its its footwell. fmtwell. Fig. Fig. 2. 2. - 7 - Jaguar Cars Limited 2005 . r--- - I -. ...--. --. - ..- . - . . . - .- -- -. Service Bulletin Bulletin Service . .. . ISSUE NO: NO: JD JD 08/94 08/94 ISSUE FEBRUARY 1994 1994 FEBRUARY PAGE 11 OF OF 33 PAGE SRO: 44-91-10 ALL JAGUAR JAfXW XJ6 X76 4. 4 .00 ALL A L L JAGUARWS 4.0 ALL JAGUAR XJS 4.0 MJDEL ENGINE srALLlNG ST-G A m T I C TRANSMISSION TRANSMISSION ENGINE -- AUICMATIC suBJKT CU- LJTW7 LITRE LLTRE LITRE CONCERN : mine stalls stallswhen when selectin;J seledirq Reverse Reverse or or Drive Drive from from Engine Park; most noticeable i&im the engine is coldPark; most noticeable when the engine is cold. The concern concernmay m y l::e be overcome overccrrne by by aa simple simple rectification reztification '£he w i t h i n the automatic transmission. within the automatic transmission. ADVICE 'IO CUS'IQ.1ER BACKGROUND The concern conarises from frcnn partial partial engagement e n g a g m t of of the the '!he arises torque convertor lock-up clutch, ming to the sticking torque convertor lock-up clutch, owing to the sticking of aa valve valve or or to toaa restricted restricted oilseal oilseal wi w thin i t h i n the t h e autoautoof matic transmission; t h i s may be easily be rectified. matic transmission; this may be easily be rectified. DEALER ACI'ION ACTION DEALER REPAIR MEI'HOO : Y e sI , where where necessary. necessary. Yes Tfie following follming initial initial diagnosis diagnosismust n u s t be. be urrlertaken d e r t a k e n to to The check that t h a t the the concern c o r n arises arises from from the the control control valves valves check forthe the lock-up lock-up clutch: clutch: for 1.Clleck Check engine engine set-up set-up condition, condition, using usingJDS. JDS. 1. 2 . Check Checktransmission trammissionfluid f l u i d level. level. 2. Interrogatethe theTransmission T r d s s i o n Control ControlUnit Unit for for Fault Fault 3.3 . Interrogate Wes, using usingJDS. JDS. Cc:xies, Where the the above above checks checks prove prove satisfactory satisfactory, proceed as as Where I proceEd follows: follows: Referring to to the the appropriate appropriate Service Sewice Manual, Mual, Section =ion Referring 44.2, remove removethe theValve ValveBlock BlockAssembly ASsmbly as asdescribed describedfor for 44.2, SFXI 44-40-01. 44-40-01. SRO JaguarCars CarsLimited Limited Jaguar Jaguar Cars Limited 2005 .JD08/94 1, Where the the vehicle vehicle has has covered covered less less than 1000 1000 miles miles 1. (1600 (1600 Km), Xml, approximately a m r o x h t e l y ,( from frm new: Fig. 1. 1. Fig. Remove Remove the oil o i l seal (Part ( P a r t NoNo. JLM 863), 8631, Item A, 1. Fig. 1. Should this this seal he be incorrectly fitted or restricted, restricted, it It'ay m y interfere interfere with the tJ:&ssion transmission fluid pressure so as as to cause cause a a partial engagement ~gement of the torque cornconvertor lock-up lock-up clutch; in in turn, turn, tthis h i s may cause cause the the engine to s ~ l at l lm/idlhq stall low/idling RIM. RPM. F it a Fit a new seal. 2. Where the vehicle has cavered ~. covere:l mre more than 1000 miles (1600 K Km) (1600 in) from new: Remove the the smews screws and retain* retaining plate, plate, allming allowing torque convertor convertor control valve, valve, Itern Item A, A, rremoval -1 of the torque F i g . 2. Fig. 2. bore; check that the valve Clean the valve and its bore; bore. moves freely and smoothly in the bore. Should there he tick, be any tendency of the valve ta to sstick, gently lap the valve until a smooth-running ffit i t is achieved. achieve::l. controls the flaw flCM of fluid to the torque This valve controls lock-Up clutch. Should t the stick, the convertor lock-up h~ valve stick, resultant inmrrect y lead to the w ine incorrect fluid flaw flow m may engine stalling at low IaN RPM. Rm. - 2 - Jaguar Cars Limited 2005 ** JD 08/94 ISSUE 2 ** Fig. 2. Thoroughly clean clean all a l l partsj parts; re-asseroble re-assemble us~ using aa new new 'Ihoroughly spring and oil o i l filter. filter. spr i.ng and lbb: When When refitting refitting the the valve valve body, body, the the 13 13 secur~ securing Note: s a e w s should should be b tightened tiqhtmed to to aa torque torque sett~ setting screws of 8 Mn. of 8 NIn. SERVICE 'TOOlS W L S SERVICE : JD 126 126 Control CorrtJol Unit U n i t oil oil seal seal remover/replacer. remver/replacer. JD PmS PARI'S m m O N INFORMATION : Oil Filter Filter (XIS) (WS) Oil oil Filter Filter (XI6) (XJ6) Oil Oil Seal Seal oil Spring, torque torque convertor convertor Spring, a T l t l ? ~ lValve control valve AI:MINISI'RATION INFDRMATION 3LM 664 664 JIM JLM 2128 2128 JIM JLM 863 863 JIM JLM 11273 11573 JIM Ij WARRANTY CDDE _Y 44 CC GG X Aukomtic TransInission, Wanmission, lock-up lock-up -- Automatic clutch, stalling. stalling, clutch, II REPAIR OPERATION OPERATION CODE CODE AND AND I.AOOUR TIME TIME AIl..C*lANCE m C E REPAIR SRO: 44-91-10 1. 75 hours. - 3 - Jaguar Cars Limited 2005 Service Service Bulletin Bulletin Pl\GE 1 OF 2 REF: JD 20/94 XJS AIL AIL 4.0 4.0 «h 6.0 6.0 :r..r:mE LLTiE XJS 44 44 I'I'FH: 20 - AUIU1ATIC TRANSMISSION A-TIC TRANSMISSION - GEAR GEAR SELEcroR SELECIUR CABLE CABLE AIDUS'IMENI' A A J U m morn VIN VIN 192487 192487 the the setting setting procedure praxdure in in manufacture manufacture has has been been revised. revised. From '!he The service Service Manual Manual setting setting procedure procedure will will remain remain unchangoo.. unchanged. XJ6 76 76 « XJl2 1994 MY' JiK:M VIN 703024 ITEM: 21 SLIDING SLIDING RCXJF W30F -- DELErION D E U T I O N OF OF MANUAL MANUAL OPERATION OPERIlTIUN HANDLE HANDLE From the the above above VIN, W, aa manual manual operation operation key key is is no no longer lower supplied supplied with with From each vehicle, vehicle, clipped clipped to to the the rear rear of of the the roof rmf console console panel. panel. each It is is therefore therefore reoommended recmmaded that that all a l l Dealers Dealers should should keep keep handy handy aa spare spare It handle, for for emergency mergericy use use in in their their workshop, workshop, together tqether with w i t h aa snall smll handle, stock in in the their P a r t s Department D e m t for for those those cust c u omers s t ~ who who s nay m y wish w i s h to to stock ir Parts purchase aa handle handle as as an an accessory. accessory. purchase In the the event event of of aa malfunction malfunction of of the the powered powered operation operation where where no no key key is is In carried on on the the vehicle, vehicle, with with aa sunroof sunroof sliding sliding panel panel partly partly or or fully fully carried open, panel using aa wide-blade wide-blade open, the the sliding slidp n e l may may be be closed closed as as follows, follcws, using scretdriver and and aa pair pair of of long-nose long-nose pliers: pliers: screwdriver &lease the the turn t u m screw screw of of the the roof roof console console panel p n e l through through aa Release quarter turn, tum, sl slide the console console panel panel rearwards rearwards to to disengage diseslgage the the quarter ide the clips clips from fram the the location location tags. taqs. Insert the the blade blade of of the the screwdriver screwdriver into into the the slot slot of of the the drive drive Insert mechanism; rotate rotate the the slot slot in in the t h e desired desired direction direction of of travel t r a v e l (as (as mechanism; indicated irdicated by by arrows ~ G W on on S the t h e surround surround plate) plate) through through approximately approximately 114 revolution, revolution, until until resistance resistance is is felt. felt. 1/4 With long long nose nose pliers, pliers, on on the the rim rim of of the the cam cam plate p l a t e surrounding surrourding With the motor rotor drive, drive, pull the pull down d m on on the the cam cam plate plate until until it it is is released released and springs springs downwards damwards through throuqh aa short short distance, distance, while while slightly slightly and oscillating the t h e screwdriver screwsdriver to to assist assist release. release. This Tl-&saction action oscillating disengages the the cam cam ring rirq and and mechanism mechanism from from the the motor motor drive. drive. disengages jaguar Cars Cars Limited Limited Jaguar Jaguar Cars Limited 2005 JD 20/94 continue Continue to to hold hold the the cam cam plate plate down dawn against against light light spring spring pressure pressure while simultaneously simultaneously rotat:i.n:j rotatitq the the drive drive mechanmxha.nwith w i t h the the pliers, pliers, while ism ism by by means means of of the the screw::iriver. screwdriva. (As (As the the drive drive and and surrourrling ~ o ~ i earn cam plate p l a t e are are ergaged engaged to to each each other ather by & detents, detents, (rut ( k t terxiing tending to to separate separate urrler urder spring spring action) action) it it is is necessary necessary to to maintain maintain the the mich must must therethazdownward dDwnward force force on on the the cam cam plate plate by by the the pliers, pliers, VJhich fore fore be k rotated rotated as as the the screwdriver screwdriver is is rotated} rotated).. With the W i t h the the sliding s l i d i n g panel panel fully fully closed, closed, remove r-ve the pliers. pliers. Rotate Rotate the drive drive mechanism m d m i s m 'rYj by means means of of the the scremriver, scra&river, in in the the opposite opposite the direction to to that that used u s d above; above; after af& approxhtely 1/4 1/4 turn, turn, with with direction approximately the the slot slot alignerl aligned to to the the two .twa detents detents in in the the cam cam plate, plate, the the cam cam rirq will will return return to to its its original original lcx::ation. location. nus This action action rererirv;J engages engages the the mechanism mechanism to to the the motor mtor drive. drive. It It may may be be found found impracticable, impracticable, in in the the method method described described alxNe, W e , to to exert exert the force force necessary necessary to to complete complete the the normal normal actions actions of of the the sliding s l i d i n g roof roof the mechanism, mechanism, which, which, after after closure closure of of the t h e sliding sliding panel, panel, raise raise and ard lock lock the panel panel against against the the surrounding surrounding fixed fixed roof. roof. The The above above method rcethcd the should, should, however, however, enable enable the t h e sliding sliding roof roof to to be k e closed closed to t o aa position position which which will w i l l provide provide aa weatherproof weatherproof and and secure secure condition cordition for for the the vehicle, until u n t i l the the nalfunction mlfunction can can be be traced traced and & rectified. rectified. Vehicle, For the the same same reasons, reasons, it it may m y be be found found llnpossible impossible to to open open aa sliding sliding For roof roof panel, p e l , from from the the fully fully closed closed position, position, by by the the method rwthod outlined. outlined above. above. Spare Spare handles, handles, for f o r It'anual manual operation opesation of of the the sliding sliding roof roof panel, panel, are are available available via via Jaguar Jaguar Parts P a r t s Operations, Operations, under under Part P a r t No. No. SEC BBC 8355. 8355. - 2 Jaguar Cars Limited 2005 n g - I . -. . . -- ~~2 JA~ . . . Service Service Bulletin Bulletin II 1---- PlIGE 1 OF 4. REF: JD JD 27/94 REF: XJ6 & XJ12 03 03 1993 MY ITl'M: 23 VIN 667rs79 CHtiARCS REPAIR OPERATION OPERATION TIMES TIMfZS -- AMENCMENI'S -S '!he The following following Repair Operation Opzration Times Times are are amen:.:led.. armded. They They are are applicable applicable to to Left Left Hand Hand Drive Drive mcdels d e l s only, only, on on which which it it is is necessary to to lower lover the the steering steering column calm from from its its mountings muntings to to penn.it permit removal removal of of the the heater matrix. matrix. Please Please amend amend your your Repair Repair Operation Operation Time Time Schedule S c h d u l e accordingly. accordingly. Heater Heater I1E.trix matrix -- renew renew 80-20-29 80-20-29 m o lHD LED Euro USA USA - Heater Heater matrix matrix - renew renew 82-25-10 82-25-10 1HD LHD Euro lHD EuroLHD USA USA LHD lHD 1.90 hours hours 1.90 1.95 hours 1.95 ~ O W S 1.90 1.90 hours ~OWS 1.95 hours ham 1.95 ITEM: 25 12 - SEALING SEMJXG OF OF BOLT BOLT THREADS THRl%DS - OIL O I L SUMP SUMP SANIXtITCH SANDWICH PLATE PLPITE In the the event event of of oil oil leakage leakage around around the the base base of of the the crankcase crankcase and and the the In o i l sump, s q , the the following following action a d i o n should should be be taken taken before before consideration consideration of of oil any gasket gasket replacement: replacement: L meek the the torque torque of of the t h e securing securing tclts, bolts, oil oil sump sump to to sandwich h i & Oleck plate, and and the the exposed exposed bolts, blts , sandwich W i c h plate plate to to crankcase crankcase plate, Torque Torque Setting: Setting: 21 21 -- 27 27 NIn. m. 2. clean the the area area in in which h i c h oil oil leakage leakage has has ClC!curred. occurred. Clean 3. R c a d test test the the vehicle; vehicle; examine examine for for oil oil leaks. leaks. Road ONLY VJhere where aa fresh fresh oil o i l leak leak is is apparent apparent after after the the atove above action a d i o n should shad ONLY either the the sandwich sanctwich plate plate to to crankcase crankcase gasket gasket and/or and/or the the oil oil sump swrrp to to either W i c h plate p l a t e gasket(s) gasket(s) be be replaced. replaced. sandwich continued .. / Jaguar JaguarCars Cars Limited Limited Jaguar Cars Limited 2005 JD 27/94 In addition addition to to the the possibility possibility of of oil o i l leakage leakage at at either either of of the the above W e In gaskets, oil may also spread upwards along the threads of cestain gaskets, oil may also spread upwards along the threads of certain bolts which which retain retain the the sandwich sandwich plate plate and and reffle baffle tray. t r a y - The The heads heads of of bolts the bolts are i n contact with oil, while the tops of the threads in the bolts are in contact with oil, while the tops of the threads in the crankcase are exposed -1ly. event of the o i l smp In the the crankcase are expose:i externally. In the event of the oil SlIII'p being removed removed to to allow allow replacement replacement of of either either gasket, gasket, the the threads m e a d s of of being the blts concerned should be sealed by the application of ' m i t e the 001ts concerned should be sealed by the application of 'Loctite 5 4 2 ' sealer542' sealer. is Nal' NOT necessary nxessary IIt t is to remove remove the the sandwich sandwich plate p l a t e to to undertake undertake the the to followingrectification. rectification. following The bolts bolts concerned concerned are are identified identified by by shading shading in in Fig. Fig. 11 below helm and and in in 'llie Fiq. 22 opposite. opposite. Fig. Remove the the bolts bits identified identified by by shading; shading; thoroughly thoroughly clean clean ard and Remove degease t h e m , using a suitable solvent; w i p or blcw thm dry. degrease them, using a suitable solvent; wipe or blow them dry. m: (9(9 l::x:>lts bolts on on XJS XJS V12 V12 engines; wines; 77 bolts blts on on XJ12 XS12 engines). engines) Note: . using aa suitable suitable solvent solvent and and aa 'l:ottle'-type I bottle'-type brush, thomqhly using brush, thoroughly clean out any residual w i n e oil from the threads in the the clean out any residual engine oil from the threads in crankcase; blow out the threads ushq an airline. crankcase; blOlN out the threads using an airline. : ~: BOTHTHE THE'IHREADS TW!EXlS OF O F THE THEBOLTS BOLTS AND AND THE THE THREADS THREADS INIO Dim OOI'H WHICH THE: BOLTS ARE FITTED MUST BE THOROtXHLY WHIaI THE BOLTS ARE FITI'ID MUS!' BE 'IHOROOOHLY D-m, OTI-EWtSETHE THE 'lOCTITE' ' m I T E 1542 542 WILL WILL Nor NOTCURE CURE D.EX:;RFASED I OTHERWISE TO CREATE AN EFFECTIVE SEAL. 'TO CREATE AN EFFECTIVE SEAL. U s i n g aa clean clean cloth cloth and/or M / o r aa 'bottle'-type 'bottle1-typebrush, brush, apply apply 'Lactite 'mite Using P r k P to the threads in the crankcase. Allm to dry. Primer' to the threads in the crankcase. AllOW" to dry. When refitting refitting the the sandwich sandwich plate plate retain:irq retaining bolts bolts concerned, concerned, When apply 'Lnctite 542' to the bolt threads. apply 'Loctite 542 t to the bolt threads. Torquesetting; setting: 21-27 21-27 NIn. Nm. Torque NAE: Note: Both illustrations illustrationsshow showlE!tl of of tl1e the sandwich d i c h plate, plate, as Both v i d bela+, w i t h the o i l s u p having h s n removed. removed. viewed fran belClW"I with tl1e oil sump having been Fig. 1. XJ12 MODELS - 2 Jaguar Cars Limited 2005 JD 27/94 l l Fiq. 2. 2. Fig. XTS V12 V12 IDDErB MODELS XJS If undertaking undertaking repairs repairs on on engines engines earlier earlier than than those those listed listed belo.v, helm, If refer to to service Sesvice Bulletin Bulletin JD JD 08/92, 08/92, Item Item 29 29,I for for details details of of gasket gasket and and refer fastener changes, changes, introduced introduced at at those those engine engine numbers, n m k e r s , which which should should 00 be fastener retrofitted to to earlier earlier engines. engines. retrofitted 7P 67281 8S 86317 8W 10641 S.III XJS V12 XJR-S 6.0L W12 6.0 6.0 Litre Litre engines engines (from (from 1993.25 1993.25 MY) M Y ) and and XJS XSS 6.0 6.0 Litre Litre engines eslgines AIL XJ12 (from 1993.5 MY) are to the l a t e s t condition, and do not rquire any (from 1993.5 MY) are to the latest cond. it ion , and do not require any -es of fasteners. fasteners, changes of PARTS INFORMATION INFDRPRTION PARI'S 'Lcctite 542' 5 4 2 ' sealer sealer should should be be ordered order& via via Jaguar Jaguar Parts Parts Operations, Operations, 'Loctite u n d Part ~ Part Number N u i n b s r Jlli JLM 1746. 1746. under Gasket(s) should should be be identified identified from from the the current current Parts P a r t s microfiche microfiche for for Gasket(s) the vehicle c o r n e d . the vehicle concerned. XTS 4.0 4.0 LI'lRE LITRE VIN VIN ~ RAW32 193616 193616 'ill !ID 193853 193853 XJS 44 44 I'I'EM: 26 DIPSTICK -- AuroMATIC AUPOMATIC GEARBOX GEARBOX DIPSI'ICK A small smll number n m b r of of vehicles vehicles within within the the above above VIN VIN range range may m y have have been been A f i t t e d w i t h a dipstick of incorrect specification. fitted. with a dipstick of incorrect specification. The total t o t a l number numkr of of vehicles vehicles affected affectad is is 7. 7. The continued. .. I - 3 Jaguar Cars Limited 2005 JD 27/94 I n the the course course of of POI PDI checks checks of of automatic automatic gearbox g e a r b x fluid fluid level, level, Dealers Dealers In are r q e s t e d to inspect and check the d i p s t i c k : are requested to inspect and check the dipstick: The dipstick dipstick may may be be identified identified by by measurement measurement between between the the the the & t The tip and t h e 'Min Hott marking, as i l l u s t r a t d below: ard the 'Min Hot' rroarking, as illustrated below: ~ DIPSTICK: ~ DIPSITCX: Measurement = 32 mm. Measurement = 56 mm. x MOT I J S I- -2207 2207 )51 Where an an incorrect incorrect dipstick d i p s t i c k is is identified, identified, it it should should be he replaced replaced by by Where one of the correct specification, Part No, E 8409, the hcorred one of the correct specification, Part No. EBC 8409, the incorrect item being being returned. returned through through nonnal normal warranty Warranty channels. channels. item Where vehicles vehicles within w i t h i n the t h e affected affected VIN VIN range range have have already already been been SOld, sold, Where Dealers should take the first opportunity to i n s @ the automtic Dealers should take the first opp:Jrtill1ity to inspect the automatic gearbox dipstick, d i p s t i c k , as as above. m e . gearbox Warranty Fault F a u l t Code: Code: 44 BB HH ZZ warranty - 4 - Jaguar Cars Limited 2005