Service - Terry`s Jaguar Parts
Contents
1. tank Check resistance of tank body to good chassis earth should be less than 2 Ohm Visual check clean re place as required Poor connection body to earth Poor connection on Lucar connector Red White wire Lucar rivet loose on low coolant probe Low coolant probe plat ing contaminated Remove probe from tank clean with wrewdbTes 7 probe Lucar is damaged or loosened durina re if all of the ve check Less likely causes but may In certain conditions with an out of specification unit cause a fault re satisfa Short to earth in W L wire or W L bulb holder pack Short to earth on probe wire White Red W R Intermittent open circuit on White Red W R low coolant probe wire Bad connection tank body to earth Poor connection on Lucar connector Red White R W wire Lucar rivet loose on low coolant probe Low coolant probe pilat ing contaminated replace fault WIL flashes on then goes Low coolant level off EE JD 16 92 JAGUAR Unplug low coolant unit lf the W L goes off circuit OK If W L remains itumi nated locate short circuit With unit and probe dis connected check the White Red wire resis tance to good chassis earth should be above 20 000 Ohm low coolant unit Check top up as re quired Ground probe wire at tank test drive vehicle If fault recurs check harness conn2. Ser SES ervice Bulletin AGUAR MODEL SUBJECT CUSTOMER CONCERN ADVICE TO CUSTOMER DEALER ACTION REPAIR METHOD SERVICE TOOLS PARTS INFORMATION ISSUE NO JD 04 92 APRIL 1992 SHEET 1 OF 1 S R 0 82 25 13 32 25 14 XJG XJS SAID V12 AIR CONDITIONED MODELS BLOWER MOTOR ASSEMBLIES Brush gear noisy operation ie low speed ticking squeak Installation of revised blower motor assemblies incorpo rating anew P35 motor will overcome the noise concerns New blower motors have been introduced from the follow ing VINs XJ6 Air Con 657163 XJS 183290 S I 486002 Yes Blower Assemblies incorporating the new motor are inter changeabie on vehicles prior to the above VINs see Parts Information below for model year variations Replacement of blower motor assemblies should be car ned out in accordance with the following Service Manual instructions XJ6 Volume 4 Section 82 Page 82 38 82 39 XJS Volume 4 Section 82 Page 82 62 82 63 S H Section 80 82 Page 82 39 82 40 N A Owing to the introduction of PMS harness connectors on biower motor assemblies fitted to XJ6 and XJS models from VINs AJ6 629286 XJS 179737 Part Numbers for replacement units on vehicles PRIOR to the above ViNs are as follows RH LH XJ6 CBC 8966 CBC 8967 XJS CCC 5546 CCC 5547 Jaguar Cars Limited Jaguar Cars Limited 2005 ERNS JD 04 92 JAGUAR Part Number
3. Jaguar Cars Limited 2005 ona JD 08 91 JAGUAR Ensure that the compressor is filled to the correct level with oil A MAXIMUM of 4 ozs 114 cc of refrigerant oil can be added to the compressor without discharg ing the refrigerant Using an oil injector tool such as Snap on oil injector tool ACT 111 add oil in 2 oz 57 cc increments Refer to the procedure detailed below NOTE LOW OR EXCESSIVE CHARGE WEIGHT OR A LOW OIL LEVEL WILL CAUSE COMPRESSOR NOISE Clutch drag or bearing noise refer to the clutch replacement procedure Section 82 of the Service Manual Compressors which leak oil or Freon must have the seals replaced in accordance with the procedure detailed in Section 82 of the Service Manual Replace the compressor only after checking all of the above mentioned items NOTE All returned compressors must be complete and sealed using the blanking plate provided on the replacement unit Procedure for compressor oil injector tool usage Operate the A C system Make sure that the system is full of Freon Refer to Sec tion 82 of the Service Manual for the test procedure Remove the sealing gaps from the high and low pressure A C charging points Check that the valve on the oil injector tool is closed Remove the threaded end cap from the oil injector tool and add 2 ozs 57 cc of compressor oil Replace the end cap Attach the short flexible hose on the oil injector to the low pressure fitting of the
4. is added to the 1894 MY specification The rack body consists of two aluminium pressure diecastings the rack mounting is un changed The pinion height 1 Fig 1 is increased by 7mm the steering column is altered to accommodate this change The fluid pipe union positions in the valve block are also altered with the fluid pipes being modified accordingly The steering rack assembly is a non serviceable item INTRODUCTION OF REAR WHEEL ALIGNMENT ADJUSTMENT A system of rear wheel alignment adjustment is now incorporated in the rear suspen sion assembly The iower suspension arm has a plate with a rectangular recess machined in the centre added to the rear pivot eye 1 Fig 2 The suspension arm pivot bolt hole 2 Fig 2 is elongated horizontaiy at this point The pivot bolt has an integral eccentric 3 Fig 2 below the bolt head which when IN position in the plate has a slight clearance at the sides but full clearance at the top and bottom Rotation of the bolt head with the eccentric constrained between the vertical faces causes the bolt shank to be moved in the horizontal plane thus displac ing the hub carrier and effecting wheel alignment adjustment XJS FROM VIN 187900 ITEM 27 EXHAUST SYSTEM DETAIL CHANGES From the above VIN a number of changes mainly to dimensions have been intro duced to exhaust systems The object of the changes is to improve clearance be tween exhaust system components the seat pan heat
5. the Receiver Drier Assembly must still be replaced if it is suspected that there is swarf or some other contaminant in the Drier as a result of a component failure in the Refriger ant Circuit the Drier is blocked damaged or leaking there is corrosion in the Drier or in the Refrigerant lines indicating the presence of moisture in the system Jaguar Cars Limited 2005 82 Service Bulletin DATE MARCH 1994 PAGE 1 of 2 REF JD 26 94 ALL JAGUAR AND DATMLER VARIANTS WITH AIR CONDITIONING ITEM 22 4J6 amp MJ12 VIN RANGE 507471 TO 667578 XJS VIN RANGE 100001 TO 190527 SERIES ITI 1985 MY TO VIN 487641 CONVERSION TO HFC 134A REFRIGERANT FROM CFC R12 As refrigerant R12 becomes increasingly less available world wide in favour of refrigerant HFC 134A which is more environmentally friendly it will become necessary to convert the refrigeration systems of certain vehicles which were originally manufactured with a refrig ation system filled with R12 refrigerant to accept HFC 134A refrigerant While the above situation may arise following component damage due to collision or from component failure Dealers may also be requested by customers to change their vehicle to the later refrigerant Apart from these situations vehicles equipped with CFC R12 systems should continue to be serviced using R12 refrigerant and only retro fitted to HFC 134A standards when R12 is no longer available or cost effective The princi
6. vehicle A C system Attach one end of an A C system extension hose to the fitting on the side of the valve of the oil injector tool Attach the other end of the extension hose to the high pressure fitting of the vehicle A C system Run the engine at idie with the A C system operating Slowly open the oil injector tool valve until it is fully open Allow the oil to flow into the compressor for 2 minutes Close the oil injector tool valve Let the engine run an additional minute then switch off the ignition Carefully remove the charging hoses from the high and low pressure fittings and install the sealing caps Check the A C system for compressor noise If noise still exists repeat the pro cedure once more adding an additional 2 ozs 57 cc of compressor oil NOTE NEVER ADD MORE THAN 4 OZS 114 cc OF OIL TO THE A C SYSTEM Attach a self adhesive label to the A C hose adjacent to the low pressure hose fitting stating how much oil was added and the date Jaguar Cars Limited 2005 SS SES Service Bulletin JAGUAR L ee es Ch _ te ee b aimler DATE NOVEMBER 1991 PAGE 1 of 5 REF JD 09 91 ERRATA Would Dealers please note that in Service Bulletin JD 05 91 Item 31 Forged Alloy Wheels the Part No for the XJS road wheels should be CBC 6175 not CBC 9175 XJ6 MODELS ITEM 58 44 TRANSMISSION FRONT PUMP ASSEMBLY A new front pump assembly has been introduced which cannot be retro
7. discharge ignition systems are particularly prone to this effect during wet weather when the air space surrounding the spark plugs becomes charged with a gas composed of elec trons ions and air particles forming a state of general tonization Too much ioniz ation counteracts the spark plug tnsulation and causes a partial discharge which in turn gives out a blue light Under normal circumstances this will in no way affect the running of the car provid ing the spark plug insulators are kept clean Running problems would normally only occur if the spark plug insulators were coated in a film of dirt which would aliow high voltage tracking known as flashover be tween the spark plug terminal stud and earth thus causing a misfire However protection is provided against this eventuality by the inclusion of ribs along the insulator body To identify whether or not the spark plugs have been sub jected to Corona discharge plugs should be examined in daylight for the presence of a yellow brown stain at the base of the insulator next to the metal housing The actual stain is caused by oii contaminated particles in suspension around the spark plug insulator receiving the electrostatic charge of ionization and fusing them selves to the plug The stain is quite harmless and can usually be wiped off easily Corona discharge will cause no deterioration in service or malfunction of the spark plug Moisture or dirt may cause
8. flashover but Corona discharge does not Cleanliness is vital therefore spark plug Insulators should be kept clean and dry at all times Note Spark plugs returned under warranty may be rejected as no fauit found for the reasons given above AJ6 ALL MODELS ITEM 49 REAR SHOCK ABSORBERS Jaguar Cars Limited 2005 From VIN 667829 a new rear shock absorber is fitted to all non ride levelling ve hicles This new part is fully interchangeable with all previous components when JD 16 92 82 86 JAGUAR This new part number CCC 6923 should be used in all cases where rear shock ab sorbers are replaced with immediate effect Under no circumstances should this new part be mixed with old condition parts on a vehicle axle When faitures are identified in service single shock absorbers only need to be changed if the parts have less than 25 000 miles 40 000km service use The new units which have a black finish can be easily distinguished from the previ ous parts by a new sealed gaiter which will reduce dirt ingress XJS 6CYL V12 AND SERIES Ill V12 ITEM 50 RECEIVER DRIER BOTTLE When replacing the receiver drier battle Part Number CAC 1887 it is essential that the receiver drier bottle is mounted with the sight glass vertical This is to ensure that the pick up tube inside the drier bottle is always immersed in liquid refrigerant ifthe receiver drier bottle is mounted at angles in excess of 20 degrees from
9. from its pivot ball Importantt Ensure that the assistant holding the bonnet appreciates that as each strut is released and allowed to extend there will be a change from holding the bonnet down to the need to support the bonnet 6 Have the assistant raise the front end of the bonnet a short distance further until access is available to the catches Care is required that the rear corners of the bonnet do not contact the plenum panel below Jaguar Cars Limited 2005 10 11 12 13 l4 Release the RHS catch by operating the latch amm directly by hand Using the locally made release tool illustrated in Fig 1 below the IHS catch may ke released after passing the release tool across the top of the engine The notch on the end face of the tool prevents slippage from the catch Remove the bonnet by lifting it up and away from the engine compartnent aperture Trace and rectify the release problem Refit and adjust the bonnet to the aperture Refit the front grille Reconnect the battery and refit the battery cover Re code the radic re set the clock aT 13 80 C 190 1000 J11 295 Fige le The tool illustrated above should be locally manufactured from a length of steel rod 6 00mm diameter approximately 1000mm long The overall length however is not critical provided that the tool is sufficiently long to provide access across the engine compartment t Jaguar Cars Limited 2005
10. introduced see Fig 1 J5I 1773 FIG 1 The procedure for the removal of this new relay is as follows WITH THE IGNITION OFF 1 Open the boot and remove the battery cover see Fig 2 2 Remove the negative lead from the battery 3 Disconnect the transit relay from the battery a 4 Remove the white yellow W Y ignition wire from the transit relay pS JD 16 92 JAGUAR d31 778 5 Remove the positive lead from the transit relay terminal post A Fig 3 6 Reverse the positive lead clamp and refit the clamp to the positive lead B Fig 3 FIG 3 7 Displace the battery 8 Tie back and secure the white yellow W Y ignition wire see Fig 4 Jaguar Cars Limited 2005 CRIS IDE TUHAT THICK I CAT DODCRAAIRIC CL WY IRI ATER WLECECRI C criipenrn JD 16 92 03 9 Refit the battery Fe JAGUAR 10 Refit and secure the positive and then negative lead of the battery 11 Replace the battery cover NOTE ALLUKDEALERS MUST CONTINUE TO RETURN THE DISPLACED TRANSIT RELAYS REMOVAL OF THE TRANSIT RELAY SHOULD BE CARRIED OUT NO LONGER THAN 24 HOURS BEFORE THE VEHICLE IS HANDED OVER TO THE CUSTOMER THE RADIO AND TIME CLOCK MUST BE RESET AFTER THE RELAY IS RE MOVED IMPORTANT UNDER NO CIRCUMSTANCES SHOULD THE RELAY BE USED OR RE TAINED AS AN ISOLATION DEVICE FOR ROAD USE XJS REPAIR OPERATION TIMES Air Conditioning Blower Motor Assembly ITEM 45 The repair op
11. on XJ6 models To avoid any confusion they are identified as follows Bracket Description Of Use Part No CAC 9884 For all Drive Units prior to the introduction of EBC 9750 and EBC 9751 ino colour identification EBC 9820 For all Drive Units from the introduction of EBC 9750 and EBC 9751 identified by a spot of blue paint 4 Jaguar Cars Limited 2005 ESS JAGUAR DATE SEPTEMBER 1993 PAGE 1 of 5 REF JD 26 93 00 ERRATA 00 PLEASE NOTE THE FOLLOWING ERRATA IN RECENT SERVICE BULLETINS 1 JD 17 93 dated August 1993 Page 6 FOURTH DIGITS The Fourth Digit codes J and V have been duplicated Please delete code J so that in future only code V will be used for Thread Dam age JD 17 93 dated August 1993 Page 7 Lines 21 amp 22 The entry 9YV is duplicated on these lines The first entry should read 9YU Engine Compartment JD 24 93 dated Septernber 1993 Page 2 Line 12 This line should read 44 15 39 09 As 44 15 39 Less JDS etc XJ6 AND XJ12 1994 MY ALL VARIANTS ITEM 26 INFORMATION ADDITIONAL TO THE 94 MY TECHNICAL GUIDE The 1994 Model Year specification is enhanced by the inclusion of two new features designed to refine both the handling and cosmetic qualities of Jaguar saloons INTRODUCTION OF THE ZF PHASE 2 STEERING RACK 51259 FIG 1 Jaguar Cars Limited Jaguar Cars Limited 2005 er JD 26 93 JAGUAR 30 The ZF Phase 2 Steering Rack Fig 1
12. shield and the rear axle thus giving less possibility of fouling The items affected are 1 es Intermediate pipe shortened by 10mm New Torca clamp tack welded in production for ease of assembly to the rear catalytic convertor to clamp to the intermediate pipe Note that in service the tack welds may be cut away with a chisel enabling the clamp to be discarded New clamps should always be used when the exhaust sys tem is being re assembled The rear catalytic convertors with attached clamps as above have a longer outlet pipe The canvertors fit lower in the vehicle than previously improving clearance between convertors and the seat pan heat shield Jaguar Cars Limited 2005 51 57 JD 26 93 JAGUAR NMB 6740AA EBC 9257 7 EBC 11122 EEC inc GB Middle East EB 11128 EBC 11129 New Part Nos Market Application XJ6 AND XJ12 ITEM 28 IDENTIFICATION OF FINAL DRIVE UNITS LIMITED SLIP DIFFERENTIALS Dealers may find that certain owners particularly those who may also drive high per formance vehicles under sporting or competition conditions express concern that their saloon vehicle appears to have a defective or inoperative limited slip differential unit or that the final drive appears to be of a plain or conventional type Some clarification is therefore necessary concerning the performance characteristics and identification of limited slip differential units A Powr Lok d
13. the ratchet straps securing the brake switch harness Disconnect the vacuum hose from the blower motor assembly servo unit Disconnect the blower motor multi way connectors Undo and remove the steering column lower mounting securing nuts Linde and remove the steering column upper mounting securing nuts Lower the steering column assembly Retrieve the column upper packing shims Remove the washer bracket from the column Manoeuvre the steering column towards the centre of the vehicie for access Undo and remove the steering column outer stabilizer bar s upper and lower securing nuts Displace and remove the steering column stabilizer bar Fig 1 Reposition the vehicle harness connectors to gain access to the blower motor assem bly securing bolts Undo and remove the blower motor assembly securing bolts Displace and remove the blower motor assembly Remove and discard the unit tntake gasket Remove the pliable trunking to assembly securing tape Remove the trunking from the unit REFIT Fit and align trunking to the new blower motor assembly secure the trunking to the assembly with tape Smear the new intake gasket with a suitable adhesive Fit the gasket to the blower motor assembly intake Fit and align the blower motor assembly into its mounting position Connect the pliable trunking to the air conditioning unit Refit and tighten the blower motor assembly securing bolts Fit and align the trunking retaining clip Co
14. 76 ALL MODELS ITEM 48 USE OF LISTED PLASTIC PADDING BODY REPAIR PRODUCTS Being widely available through Body Refinishing trade suppliers Jaguar make the following recommendations as a result of laboratory tests carried out on the two products concerned Plastic Padding WB2000 Stonechip Plastic Padding ULTIMA Universal Body Filler WB_STONECHTP This is a sill coat repair product spray applied as a water based emulsion Though primarily an air dried product it may be force dried lf necessary It is confirmed that this material MAY be employed as a repair product on Jaguar and Daimler vehicles where the repair will be the subject Of Warranty Tests indicate however that the product will give a coarser finish than that given by the original factory finish sill coating Two coats of the product are recommended to give a minimum dry fiim thickness of 400 microns Colour finishing by the conventional 2K process should be force dried at 60 C maximm Low bake at 90 C may produce fine boil effects It should be noted that repairs adjacent to clear coat must be preceded by thorough flatting of the clear coat 360 grit paper to achieve satisfactory adhesion and anti chip performance ULTIMA UNIVERSAL BODY FILLER This is a filler product to be knife applied over etch primed metal surfaces After appropriate sanding a conventional 2K colour process may be applied This product is NOT APPROVED for body repai
15. It is recommended that Dealers should obtain sets of these or their equivalent from their local distributors In addition certain connections can be blanked off using a Bonnet Stop Part No BD 10224 available via Jaguar Parts Operations It is important to note that plugs and caps kept for repetitive use on Refrigeration Circuits should be kept segregated from those used for other purposes such as blanking off fuel or hydraulic components ALL MODELS FITTED WITH AIR CONDITIONING ITEM 50 RECEIVER DRIER ASSEMBLY Current instructions require that the Receiver Drier Assembly be replaced whenever the Refrigeration Circuit is opened even though there may be no reasons to suspect the serviceability of the Drier This Service Bulletin revises that requirement and permits the Drier to remain in service provided blanks are installed on component and refrigerant line connections inmediately after disconnection blanks are only removed from component and refrigerant line connections immediately prior to reconnection Note 1 Refer to Item 49 above of this Service Bulletin for details of the blanking plugs and caps required amp Jaguar Cars Limited 2005 2 Refer to Service Bulletin JD 45 93 for details of the latest standard O ring seals for R134A systems on XJ6 and XJ12 models 3 When reconnecting the refrigerant line new O ring seals lubricated with the recommended refrigerant oil must be used However
16. Lok differential is fitted to a particular vehicle by a BLACK CROSS on the identification label on the rear cover of the differential housing In addition from VIN 684618 ail Powr Lox differentials have a metal tag stamped P L attached to one of the bolts securing the rear cover XJS MODELS ITEM 29 STEERING RACK ASSEMBLY Commencing at VIN 188105 a revised pattern of steering rack assembly has been in troduced on all XJS models Jaguar Cars Limited 2005 JD 26 93 74 JAGUAR These units identified below are fully interchangeable with the steering rack assem blies on all earlier XJS derivatives In common with the XJ6 XJ12 steering racks supplied through Jaguar Parts Oper ations the racks will be supplied with a Centralising Pin installed Upon fitment of the rack assembly to the vehicle this pin must be removed and repiaced by a screw and special washer as listed below Whilst an Exchange Programme of rack assemblies will be introduced initial units will all be new The appropriate suffix N or E should be used NEW Part No REPLACES Part Nos Applications CCC 6012 CCC 5660 amp CCC 5666 Vi2 Sportspack RHD amp 3 6 4 0 Litre Coupe RHD CCC 6013 CCC 5661 amp CCC 5667 V12 Sportspack LHD amp 3 6 4 0 Litre Coupe LHD CCC 6014 CCC 5662 amp CCC 5668 V12 Standard Spec RHD amp 4 0 Litre Convertible RHD CCC 6015 CCC 5663 amp CCC 5669 V12 Standard Spec LHD amp 4 0 Litre Convertible LHD JZS 100046 Sc
17. XJS 1993 5 Model Year vehicles a revised pattern of bonnet release catch has been introduced as a ruming change In the course of development of the new type of catch a method of gaining access to the engine compartment has been established to overcome the problem which would arise in the rare event of release cable failure This method allows the bonnet to be released and opened without panel or paintwork damage to the bonnet itself or adjacent panels The bonnet release problem may then be traced and rectified Strict observance of the following method is essential to avoid cosmetic damage Lie Ensure that the radio code is known prior to disconnection of the battery Open the boot Remove the battery cover and disconnect the kattery 2 Apply masking tape to the outside edges of the bonnet and adjacent panels wrapping the tape as far as possible around the panel edges Fit wing covers 3 Remove the front grille 4 Remove the bolts retaining the bonnet hinges Important Have an assistant ready to prevent the front end of the bonnet being raised by the action of the gas struts as the bolts are removed 5 Allow the front end of the bonnet to be raised through a short distance by the gas struts the rear end meanwhile pivoting on the strikers still engaged to the catches Continue to raise the front end slowly and carefully until access is available to the bonnet ball joint of each gas strut Carefully release each ball joint
18. age concerned See 82 10 20 82 10 08 for removal etc Reassembly and fitting is the reversal of this procedure noting that special tool JD 164 must be placed over the compressor shaft for seal installation and that the replacement seal must be fitted with the aid of JD 197 Jaguar Cars Limited 2005 30 DATE DECEMBER 1993 PAGE 1 of 6 REF JD 44 93 XJS 4 0 LITRE 1994 MY FROM VIN 190528 ITEM 46 EXHAUST SYSTEM DETAIL CHANGES USA amp CANADA ONLY Prior to the above VIN for the USA and Canada markets ONLY the exhaust system basically consisted of downpipe plain intermediate pipe twin catalytic convertors over axle pipes rear silencer assemblies Commencing at the above VIN the exhaust system layout becomes downpipe intermediate Y pipe with integral single catalytic convertor twin plain silencers over axle pipes rear silencer assemblies The following part numbers are applicable to the later condition from VIN 190528 NEW PART NOs DESCRIPTION MARKET APPLICATION EBC 10144 Intermediate Y pipe with integral USA amp CANADA catalytic convertor EBC 9782 Intermediate silencer assembly RH USA amp CANADA EBC 9783 Intermediate silencer assembly LH USA amp CANADA Jaguar Ca rs Limited Jaguar Cars Limited 2005 4 76 4JS 1993 5 MODEL YEAR RUNNING CHANGE ITEM 47 BONNET RELEASE MECHANISM Coinciding approximately with the introduction of
19. at it operates correctly and does not stick ELECTRICAL CHECK PROCEDURE CIRCUIT SYSTEM DETAILS Jaguar Cars Limited 2005 The system operates by measuring the resistance of the coolant With resistance below 5 000 Ohm the warning light is off The light will iHuminate with the resistance To JD 16 92 JAGUAR W W R B W U ey O 0 4 COMPONENT CIRCUIT CODE WIRING CODE 1 Ignition IGN supply W White 2 Low coolant control unit W R White Red 3 Warning light W L W U White Blue 4 Header tank B Black 5 Low coolant probe 6 Header tank earth via fixing bolts FAULT CAUSE ACTION W L does not illuminate at Blown W L or open circuit Check by shorting white any time Bulb check on W L wire blue VWV U wire to earth does not occur i e 1sec W L should come on on following ign Earth wire at unit open cir cuit Check resistance to good chassis ground less than 2 Ohm ignsupplytounitopencir Check supply at unit cuit should be battery voltage if the above checks are satisfactory replace faulty low coolant unit W L on all the time with Low coolant Check and top up as re ign quired Ifthe coolant level is satisfactory the following check will determine which part of the circuit is at fault Disconnect the probe wire at the tank and short to ground if the W L goes out pro ceed to A if the W L stays on go to B
20. ated to cover the fuel gauge anti slosh module introduced on XJS Facelift models 7JU Anti Slesh Module 88 25 25 Jaguar Cars Limited Jaguar Cars Limited 2005 ee JD 08 91 JAGUAR ALL MODELS ITEM 51 12 CYLINDER PRESSURE CHECK 19 WARNING Would all technicians please note that before performing acylinder pres sure check Repair Operation No 12 25 01 all fuel should be purged from the fue rail Purging of the fuel rail may be achieved by disconnecting the fuel pump relay and then cranking the engine for ten seconds XJ6 ALL MODELS amp XJS 3 6 4 0 ITEM 52 CRUISE CONTROL ACTUATOR LINKAGE ADJUSTMENT Should customer complaints be received of an increase inthe cruise control response time and a degree of hunting of the set speed the cruise control actuator linkage ad justment should be checked in accordance with the following procedure before tak ing any further action Dealers should ensure that the clearance between the end of the actuator to throttle link slot A Fig 1 and the shoulder bolt B Fig 1 is 0 5mm to 1mm C Fig 1 S R O 19 75 11 Allowance 0 10 hrs Complaint Code 7VCP FIG 1 Jaguar Cars Limited 2005 ane mos AAR XJS V12 ITEM 53 44 TRANSMISSION OIL COOLER CONNECTION 60 There have been a number of oil coolers returned with damaged coupling connector bosses the cause of which can be attributed to poor workshop practice where back ing spanners have not been used to suppor the i
21. ation quoted there is no need to carry out the adjust ment If not remove the hub nut split pin and cover 2 3 Fig 1 Jaguar Cars Limited 2005 ion JD 08 91 JAGUAR 77 82 Note For identification purposes only Fig 1 shows XJS S Ill amp Limo type hub Fig 2 shows XJ6 hub Adjust the nut as necessary to give a reading of 0 0508mm 90 0254mm 0 002in 0 001in Always try to achieve the mid point of the tolerance i e 0 0508mm 0 002in Align the hub nut cover and secure with a new split pin When the new split pin is fitted ensure the end float is re checked using the DTI gauge Fig 2 If necessary re adjust using the same method until the end float is correct Always finish the adjustment by checking with a DT gauge Always ensure the end float is within the limits quoted Refit the grease cap Refit the road wheel Carry out the adjustment procedure on the opposite front hub When finished lower the vehicle from the stands Ensure the wheel nuts are tightened to the specified torque Remove the absorbent cloth from around the brake fluid reservoir cap ensuring the area is clean and dry Before moving the vehicle pump the brake pedal to centralise the pads ALL MODELS ITEM 55 BODY REPAIR To avoid the risk of causing permanent damage to vehicie ECUs during body repairs the following precautions must be observed prior to using any electrical welding equipment 1 Disconnect the veh
22. ctory operation and condition at the regular service intervals Brake fluid to be renewed at 2 years or 30 000 miles 48 000 km intervals whichever is the sooner For North America only 18 months or 30 000 miles 48 000 km Note Service Manuals will be up dated at the next reprint Jaguar Cars Limited Jaguar Cars Limited 2005 EN JD 03 92 JAGUAR ALL AJ6 amp ENGINED VEHICLES ITEM 22 26 WATER PUMPS 80 82 84 A revised water pump assembly has been introduced on AJ6 engines The assembly now has a gasket between the two halves instead of RTV sealant as previously used The revised assembly is fitted from the following engine numbers 3 2 107696 4 0 157275 The part number of the new assembly ts EBC 8550 and replaces EBC 4437 The part number of the gasket is EBC 9220 Note THE GASKET CANNOT BE RETRO FITTED TO RTV SEALED WATER PUMPS IF A LEAK BETWEEN THE TWO HALVES IS APPARENT THE OLD STYLE PUMP ASSEMBLY MUST BE REPLACED BY EBC 8550 When EBC 8550 has been fitted to an engine the bolts securing the two halves to gether must be r e torqued to 21 5 Nm 28 5 Nm to overcome the possibility of gasket relaxation XJ6 XJ S S III ITEM 23 AIR CONDITIONING HEATER MICROPROCESSOR Refer to Service Bulletin JD 09 91 Item 62 To improve the retention of the air conditioning heater servo drive motor ICs inte grated circuits secured to the microprocessor unit heatsink the supplier has now changed the pr
23. ectors locate open circuit Check resistance of tank body to good chassis earth should be less than 2 Ohm Visual check clean re place as required Remove probe from tank clean with wire wool if probe Lucar is damaged or loosened during re moval replace probe Jaguar Cars Limited 2005 Service Bulletin JAGUAR ee em eee Cs DATE APRIL 1992 PAGE 1 of 4 REF JD 03 92 Owing to revised information received from Engineering pages 11 of Service Bulletin JD 01 92 3 4 and 9 10 of Service Bulletin JD 02 92 are being re issued and are pro vided at the end of this Bulletin marked Issue 2 Existing pages of the above should be removed and discarded to be replaced with the revised version XJ6 3 2 amp 4 0 ITEM 20 03 ADDITIONAL REPAIR OPERATION TIME The following Repair Operation Times are now available 12 29 16 Cylinder Head Gasket Rear Blanking Plate Renew 1 40 Hrs Gasket 12 29 17 Cylinder Head Rear Blanking Plate Renew 1 40 Hrs Please amend your Repair Operation Time Schedule accordingly No other Repair Times are affected XJ6 XJS ITEM 21 10 BRAKE SYSTEM SERVICE RECOMMENDATIONS With the introduction of new brake components on the above models the brake servicing recommendations have changed No routine replacement of system seals is necessary as the seals are designed to last for the life of the vehicle The braking system must still be inspected for satisfa
24. eration times for renewing the air conditioning blower motor assem blies have been re studied on 1992 MY vehicles The new operation times for vehicles from VIN 179737 are as follows Right hand drive vehicles 82 25 13 Blower Assembly Left Hand Renew 2 25 13 09 As 82 25 13 Less JDS Allowance 82 29 14 Blower Assembly Right Hand Renew 82 25 14 09 As 82 25 14 tLess JDS Allowance Left hand drive vehicles 82 25 13 Blower Assembly Left Hand Renew 82 25 13 09 As 82 25 13 Less JDS Allowance 82 25 14 Blower Assembly Right Hand Renew 82 25 14 09 As 82 25 14 Less JDS Allowance Please amend your repair times accordingly No other repair times are affected 0 95 Hrs 0 60 Hrs 1 60 Hrs 1 25 Hrs 1 60 Hrs 1 25 Hrs 0 95 Hrs 0 60 Hrs Jaguar Cars Limited 2005 Kaa JD 16 92 JAGUAR XJ6 XJS ITEM 46 10 BRAKE SYSTEM SERVICE RECOMMENDATIONS Note This bulletin supersedes Item 21 of Service Bulletin JD 03 92 With the introduction of the ABS brake system from the following VINs the brake servicing recommendations have changed 1 XJ6 from VIN 594576 2 XJS 5 3 convertible from VIN 147269 3 XJS 5 3 coupe from VIN 148782 4 XJS 3 6 coupe from VIN 148945 No routine replacement of system seals is necessary The system and components which are sealed for tife require no maintenance Repair is by replacement The braking system must still be inspected for satisfactory opera
25. fitted to earlier modeis as the intermediate plate is not compatible should this later type be fitted inadvertently to an earlier transmission unit the inter nal pressures created will blow out the pump seal this is because the ventilation channe is now in a different position Part No Qty Description 2 9 3 2 amp 3 6 Litre Models lip to Gearbox Serial No 1158414 JLM 1957 JLM 885 From Gearbox Serial No 1158415 JLM 2286 JLM 10715 1 Front Pump Assembly ntermediate Plate 1 7 Front Pump Assembly ntermediate Plate 4 0 Litre Models Up to Gearbox Serial No 35365 JLM 10441 JLM 10448 From Gearbox Serial No 35366 JLM 10716 JLM 10717 1 1 Front Pump Assembly ntermediate Plate ront Pump Assembly f aa ntermediate Plate Jaguar Cars Limited Jaguar Cars Limited 2005 eS Service Bulletin JAGUAR aimler DATE OCTOBER 1992 PAGE 1 of 8 REF JD 16 92 ERRATA Owing to revised information the torque figure for the coolant temperature trans mitter to engine XJS models is 14 5 to 19 5 Nm The torque figure given in Service Bulletin JD 10 92 and Section 88 of XJS Service Manual JJM 10 04 06 20 should be ignored and only the revised figure used Service Manuals will be amended at the next reprint XJ6 93 MY FROM VIN 667829 ITEM 44 BATTERY TRANSIT RELAY REMOVAL Owing to the relocation of the battery into the boot at 93 MY a revised battery transit relay has been
26. icle battery and alternator 2 Disconnect and remove all ECUsin the immediate area of any panels to be electri cally welded As a general rule all ECUs within 2 feet of the area to be welded should be removed for more detailed information refer to the relevant Service Manual 3 When using welding equipment the earth return clamp should be located as close as possibte to the area of repair XJ6 ALL MODELS ITEM 56 DRIVER S BLOWER MOTOR ASSEMBLY The repair operation time for renewing the driver s side blower motor assembly has changed on all XJ6 Vehicles from VIN 629286 The repair operation times are now as follows Jaguar Cars Limited 2005 EN JD 08 91 JAGUAR Left Hand Drive Vehicles 82 25 13 Blower assembly Left Hand Renew 01 25 Hours 82 25 13 09 As 82 25 13 Less J D S Allowance 00 90 Hours Right Hand Drive Vehicles 82 25 14 Blower Assembly Right Hand Renew 01 25 Hours 82 25 14 09 As 82 25 14 Less J D S Allowance 00 90 Hours Please amend your repair time schedules accordingly No other repair times are affected To achieve these times in service adhere to the following procedure REMOVE Open the bonnet and disconnect the battery earth lead Remove the driver s side dash liner Remove the retaining clip fram the air conditioning unit s pliable trunking Displace the pliable trunking from the air conditioning unit Displace the relay bases from their mounting brackets Cut and remove
27. ifferential essentially varies from a conventional bevel gear unit in hav ing the addition of friction plates between the output bevel gears and differential cas ing the friction plates are loaded by input torque to the differential unit in addition to a Static pre load The mode of operation of such a unit is that the speed of rotation of a slipping road wheel is limited by the braking action of the friction plates and greater torque is applied to the road wheel having the better grip on the road surface This principle is commen te all friction plate differential units The capacity to transfer torque is expressed as the Bias Ratio which can be modi fied to suit the vehicle application Theselection of Bias Ratio is acomplex process being a compromise between vehicle handling refinement and traction A HIGH Bias Ratio will tend towards a locked differential condition as may be suited to a high performance vehicle tuned for competition purposes a vehicle so fitted will benefit from greater traction capabilities than one fitted with a low Bias Ratio unit but at the expense of refinement and ease of handling It is basically tn the interests of refinement that the Powr Lok differential units fitted to current Jaguar Saloon models ts of the LOW Bias Ratio type whilst still confer ring the benefit of partial locking between the rear wheels under conditions of low tyre adhesion Dealers may confirm that a Powr
28. nnect the blower motor multi way connectors Connect the vacuum hose to the blower motor assembly servo unit Jaguar Cars Limited 2005 ae JD 08 91 JAGUAR SZ Fit and align the steering column stabilizer bar and tighten the securing bolts 10 14 Nm Fit and align the washer bracket to the column Loosely fit the steering column upper mounting securing nuts Fit the steering column packing shims as necessary Fit and tighten the steering column lower mounting securing nuts 20 22 Nm Fully tighten the steering column upper mounting securing nuts 20 22 Nm Reposition the brake switch harness to the blower motor assembly Secure the brake switch harness to the unit with ratchet straps Fully seat the relay bases to their mounting brackets Refit the driver s dash liner assembly Reconnect the battery earth lead and close the bonnet 151635 Fig 1 S NI XJS amp XJ6 UP TO VINs ITEM 57 506664 USA 506448 CANADA 507471 R O W AIR CONDITIONING COMPRESSOR GM A6 TYPE Investigations have confirmed the unnecessary replacement of compressors for noise and leaks If excessive compressor noise exists check the following items Compressor drive belt tension Compressor mountings A C refrigerant hose routing ensure that hoses are not in contact with other com ponents Ensure that the refrigerant charge weight is correct refer to Section 82 of the Ser vice Manual for additional information
29. ntegral hexagon connector of the oil cooler This results in a fracturing of the connecting tube when torque is applied upon tightening or loosening the connection Technicians should use a backing spanner to hold the integral boss whilst tightening the cooler pipe connection to a torque of 15 17 Nm XJ6 XJS SI LIMOUSINE ITEM 54 FRONT HUB END FLOAT ADJUSTMENT The following instructions supersede all previous instructions provided in service manuals Manuals will be updated at the next reprint Front hub end float on the above models should be set between 0 0254 to 0 0762mm 0 001 to 0 003In To achieve this in service use the following method Note Prior to adjusting the hub end float an absorbent cioth should be placed around the brake fluid reservoir cap Slacken the road wheel nuts 1 4 turn each Jack up the front of the vehicle and support with axle stands Remove one wheel nut mark the wheel relative to the stud and remove the remaining wheel nuts Remove the roadwheel and tyre assembly l Dependent upon model gently prise the brake pads free or manipulate the brake cali per to ensure the brake pads are free within their mountings i e the disc is free to rotate Prise off the hub grease cap 1 Fig 1 Fit a Dial Test Indicator DTI to the hub Fig 2 Grasp the hub unit Firmly pull and push the unit oscillating at the same time to de termine the DTI end float reading lf the reading is within the specific
30. ocess to Rivscrews This modification commenced during mid November 1991 and replaced the previ ous bolt type fixings Air conditioning heater units fitted with revised microprocessors were progressively introduced from VINs XJ6 659029 XJS 183501 S I 486299 XJ6 ITEM 24 WINDSCREEN WIPER ARM AND BLADE From VIN 657725 all XJ6 vehicles have been fitted with a revised wiper arm and blade assembly These new parts are interchangeable with cars built prior to this VIN when changed as an assembly only Dimensional changes prevent the fitment of a mixed condition of arm and blades Dealers are reminded that wiper blade replacement remains a part of the 7500 mile 12000 km service schedule for all vehicles Jaguar Cars Limited 2005 JD 03 92 JAGUAR XJS ITEM 25 86 STOP LIGHT FAILURE SENSOR MODULE LOCATION From VIN 179737 92MY Facelift XJS the stop light failure sensor module is located in the boot of the vehicle attached to the inside of the boot side reinforcement panel drainage channe L H Fig 1 Can J81 1687 FIG 1 Prior to VIN 179737 90MY XJS the module is located beneath the centre console veneer finisher attached to a bracket in front of the stowage compartment Ftg 2 386 1317 FIG 2 3 Jaguar Cars Limited 2005 F JD 03 92 JAGUAR XJ6 ITEM 26 88 EXTERNAL SPEED SENSOR BRACKETS IDENTIFICATION Two external speed sensor brackets are available for use
31. pal change involved is the replacement of the existing compressor lubricating oil compatible ONLY with R12 refrigerant by an oil compatible with both HFC 134A refrigerant and with residues of the earlier lubricating oil which it is not possible to eliminate completely from the refrigerant system In addition it is also necessary to replace the input shaft seal of the compressor by a seal compatible with the later refrigerant Full details are contained in a Technical Guide which is being issued at the same time as this bulletin The necessary Parts for the above conversions are available from Jaguar Parts Operations in kit form KiT PART NO MODEL APPLICATION JIM 11610 All XJ6 amp x12 up to VIN 667578 All XJS up to VIN 190527 JIM 11611 3 series ILL models Post 1984 MY Jaguar Cars Limited Jaguar Cars Limited 2005 JD 26 94 JAGUAR Service Operation and Labour Time Allowance The following Fitting Operation Times apply AJG XJ12 3 10 hours 593884 667578 SANDEN 709 112586 179739 3 00 hours 5 2 LITRE 100001 188104 HARRISON 3 10 hours XJS 6 AL ESLUS el SANDEN 709 3 45 hours SERIES IIL PRIOR TO 487641 HARRISON 3 10 hours Details of the retro fit procedure are contained in the Technical Guide Air Conditioning System HFC Refrigerant Retrofit Jaguar Cars Limited 2005
32. rew All above applications JZW 100019 Washer All above applications in common with XJ6 and XJ12 models the above assemblies can not be serviced To assist identification where warranty claims are submitted for the fitment of re placement units the following NEW warranty codes should be utilised 5PA Power Steering Rack amp Pinion 5PD Rubber Gaiter SPF Rack Pipes 5PG Rack Pipe Unions 5PH Track Rod LH BPJ Track Rod RH SPK Rack Mounting Bush LH SPL Rack Mounting Bush RH 5PM Rack Mounting Bracket LH 5PN Rack Mounting Bracket RH 5PO Front Wheel Tracking 5PR Outer Track Rod Ball Joint LH SPS Outer Track Rod Ball Joint RH 5PT Rack Mounting Bracket Fixings XJ6 1993 MY ITEM 30 HUB CAP DAMAGE To prevent distortion to the hub caps arising from over tightening of the securing screw a new plastic snap on pattern of hub cap has been introduced from VIN 684705 The road wheels affected are the Roullet alloy Part No CCC 2708 and the Radial alloy wheel Part No CCC 3524 The new pattern of hub cap is available as Part No CCC 5281 Jaguar Cars Limited 2005 kaa JD 26 93 JAGUAR 74 76 80 82 ALL XJ6 XJ12 XJS MODELS ITEM 31 FROM VIN 673299 XJ12 676725 XJ6 188105 XJS 16 INCH ALLOY WHEELS A new surface finish is now being applied to 16 inch Alloy wheels which will provide increased protection against corrosion and pitting arising from brake dust Dealers should b
33. ring to the attention of owners concerned that ONLY the Jaquar ap proved wheel cleaner should be used acid based cleaning products may lead to dis coloration of alloy wheels The revised condition wheels are available through Jaguar Parts Operations under Part Number MHB 6115AA XJS FROM VIN 187645 ITEM 32 DOOR ARM REST ESCUTCHEON A re designed chrome escutcheon securing screw concealer for the door arm rests has been introduced from VIN 187645 This revised item Part No BEC 23781 provides an increased clearance between the escutcheon and the trim cover of the arm rest compared to the previous condition XJ6 4 0 amp 3 2 XJ12 ITEM 33 HEATER MATRIX COOLANT LEAKS Investigations into heater matrix units returned with the complaint of coolant leakage have resulted in design changes Modifications to the top and bottom tanks and col lector plates have been introduced to correct this concern Heater units incorporating the modified matrix assemblies were introduced at VIN 680591 All current stock held by Jaguar Parts Operations is to the revised condition XJ6 XJ12 SERVICE MANUAL ITEM 34 ERRATUM SECTION 82 PAGE 82 23 Your attention is drawn to an error inthe text on the above page in Issue 2 dated Jan wary 1993 The correct version of the text is included below a revision bar is placed to the left of the changed text which is also underlined Until this section is re issued please amend the Service Manual p
34. rs which carry Warranty The product is assessed as equivalent to other similar materiais of the catalysed polyester type and shares with them the tendency to produce micro blistering around the interface between the repair and original materials particularly in high humidity conditions Hence on Jaguar and Daimler vehicles its use must be confined to repairs which do not carry Warranty Jaguar Cars Limited 2005 82 82 ALL MODELS FITTED WITH AIR CONDITIONING ITEM 49 BLANKING PLUGS FOR REFRIGERATION CIRCUITS Attention is drawn to the need for connections on Refrigeration Circuit components to kbe blanked off whenever the circuit is disturbed for servicing or component replacement in order to prevent contamination of the circuit by the ingress of moisture and foreign material As well as being necessary for on vehicle components this also applies to components being returned under Warranty since subsequent investigation of these components is often compromised by contamination of their interior before receipt at Jaquar Components being returned to Jaguar should be blanked off using the blanks installed on the replacement part Components on the vehicle should be blanked off using suitable internal line plugs and external line caps A set of plugs and caps found suitable for most of the components in the Refrigeration Circuit is the Vacuum and Fuel Line Plug Set available from Snap on Tools under their Part No THX 312
35. s for replacement units on vehicles FROM the above VINs are as follows RH LH XJ6 CCC 5400 CCC 5401 XJS CCC 5544 CCC 5545 S N V 12 The harness connector on Series Ill blower motors has not changed For replacement units incorporating the new motor the following Part Numbers apply RH LH 3 111 CCC 5546 CCC 5547 ADMINISTRATION WARRANTY CODES INFORMATION XJG FTACRH XJS 7TB LH 3 11 754 REPAIR OPERATION CODES XJ6 XJS MODELS SRO 82 25 14 RH SRO 82 25 13 LH SRO 82 25 14 09 SRO 82 25 13 09 LESS JDS ALLOWANCE LESS JDS ALLOWANCE SH SRO 82 25 14 RH SRO 82 25 13 LH Jaguar Cars Limited 2005 tr Service Bulletin JAG cunt DATE OCTOBER 1991 PAGE 1 of 7 REF JD 08 91 XJS ITEM 49 WARRANTY CODES in the latest edition of the XJS Warranty Code book codes for the battery and spare wheel covers have been duplicated To rectify this situation and prevent further confusion when submitting claims the following codes have been removed from the warranty system CODE DESCRIPTION 9DS Spare Wheel Cover 8PZ Battery Cover Boot Therefore with immediate effect Dealers should NOT submit further claims for these codes All future claims for the above parts should be submitted using the following codes only 9D0 Battery Cover SDR Battery Cover Support Panel 8NU Spare Wheel Cover XJS FACELIFT ITEM 50 WARRANTY CODES The following new warranty complaint code has been alloc
36. the vertical there is a risk under certain conditions that vapour rather than liquid may enter the pick up tube Should this occur erratic air conditioning performance may result XJS 4 0L V12 ITEM 51 LOW COOLANT WARNING LIGHT FAULT DIAGNOSIS Dealer investigations into low coolant warning light concerns have resulted in a high number of low coolant probes and control units being replaced unnecessarily as most probes and control units tested by the supplier reveal no faults In order to re duce this unnecessary replacement the following electrical checks should be carried out by Dealers before condemning or replacing components where the cause is found to be low coolant levet The checks should include inspection of the coolant sys tem for leaks which is best achieved by pressure testing the coolant system to locate the source of the leak Coolant leaks may be caused by loose hose clip connections worn or damaged pres sure cap seals or damaged hoses Lack of coolant recovery from the atmospheric recovery bottle may be a further reason for low coolant level in the header tank Transfer of coolant from the atmospheric recovery bottle relies on the presence of a vacuum as the coolant contracts when the engine is turned off Checks should be made to ensure that the recovery bottle and its connections through to the header tank are leak free and unrestricted In addition the vacuum valve in the header tank should be checked to ensure th
37. tion and condition at the regular service intervals Because of its hygroscopic nature brake fluid must be renewed at 2 year or 30 000 mile 48 000 km intervals whichever is sooner XJ6 ALL MODELS ITEM 47 18 LAMBDA SENSOR SPLASH SHIELD Following reports of the intermittent display of Fuel Failure 44 on the instrument pack it was found that this symptom could be caused by water penetrating the lamb da sensor A lambda sensor splash shield has been introduced from VIN 664941 which can be fitted retrospectively and should be installed whenever a lambda sensor is changed This will reduce the possibility of water ingress JD 16 92 CUAS 18 64 JAGUAR The six inch silver heat proof sleeve is fitted by sliding it over the sensor prior to its replacement After the sensor has been fitted Dealers should ensure that the sleeve is pushed fully back down to cover the whole sensor ALL MODELS ITEM 48 IGNITION SPARK PLUGS Spark plugs have been returned under warranty with a yellow brown stain visible on the insulator housing Dealers have incorrectly interpreted this as leakage of com bustion gases between the insulator and metai housing and the cause for spark plug misfire The following is an explanation for the staining and the more likely cause for spark plug misfire During most atmospheric conditions a form of static discharge common to high volt age conductors can occur which is commonly known as Corona
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