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Service Bulletin - Terry`s Jaguar Parts

1. In addition to this amendment would Dealers please add 86 55 35 01 as 86 55 35 less JDS allowance 0 10 hours No other Repair Times are affected ALL MODELS ITEM 17 57 STEERING GEOMETRY DATA This Bulletin item has been compiled to assist workshop personnel by providing a complete steering suspension geometry data sheet for current models STEERING amp SUSPENSION GEOMETRY DATA FRONT ALL XJ6 153mm TOE IN DRIVE SHAFTS TOE IN SALOONS Sees BEAM PARALLEL HORIZONTAL 6 3 PARALLEL 160mm UNDER TO Yis REAR EDGE OF A 1 6mm ALL XJS 6 153mm TOE IN o gt DRIVE SHAFTS PARALLEL o VARIANTS UNDER SEAM PARALLEL 3 25 TO 025 TO HORIZONTAL 6 4 TO a 0 5 TO TO 4 375 075 162mm UNDER 0 8mm 1 9 3 2mm CRADLE SN V12 6 153mm TOE IN DRIVE SHAFTS PARALLEL o UNDER BEAM PARALLEL 325 TO 025 TO HORIZONTAL 64 TOs ar ee To 335 0 75 162mm UNDER 0 8mm ME At CRADLE LIMOUSINE SPECIAL TOOLS TOE IN fy SPECIAL TOOLS PARALLEL USED TO SET 3 2mm 0 5 TO 0 p USED TO SET TO 4 05 TO FRONT RIDE 05 10 REAR RIDE 0 8mm agg HEIGHT HEIGHT Note Please ensure the relevant service tools are used whenever the steering ge ometry is checked Jaguar Cars Limited Jaguar Cars Limited 2005 64 64 70 n JD 03 91 JAGUAR XJ6 ITEM 18 60 FRONT SUSPENSION LOWER WISHBONE BUSHES To extend the servic
2. JAGUAR aimler Service Bulletin Date JANUARY 1985 Sheet 1 of 3 Bulletin JD 01 85 ITEM 01 12 OIL PRESSURE SWITCH ALL MODELS During investigations into oil leakage from the oil pressure switch it has been noted that non approved pressure switches are being used Please note that Unipart switch GPS 117 IS NOT APPROVED for fitment on Jaguar vehicles and must not be used as the hexagon size prevents secure fitment in Jaguar applications The only oil pressure switch specified and approved for use on current Jaguar vehicies is C 42200 ITEM 02 26 COOLANT HEADER TANK XJS 3 6 XJ SC 3 6 Following reports of coolant loss from the header tank filler neck joint all header tanks are now pressure tested after stove enamelling The solder specification has also been improved to prevent any possibility of the solder melting during the stove enamelling process Header tanks are quality assured from VIN 119730 and Parts stocks are all to the latest condition Jaguar Cars Limited Jaguar Cars Limited 2008 26 57 ITEM 03 THERMOSTAT HOUSING GASKETS S HI XJS HE To overcome isolated instances of coolant loss from the thermostat housing new gaskets have been introduced on 6 cyl XK and V12 engines The new part numbers are detailed below Model Description Part No XJ6 3 4 Limo Thermostat Housing Gasket EAC 7044 XJ6 4 2 Thermostat Housing Gasket EAC 7046 XJ6 3 4 4 2 Limo Water Outlet Pipe Gasket EAC 7045 XJ12 XJS HE Thermostat
3. Remove the drain tube assembly 1 Fig 2 from the air con drain stub pipe 2 Fig 2 Fully seat the cutting tool guide to the air con stub pipe 3 Fig 2 Using the 6mm cutting tool carefully cut a hole in the air con baffle plate Remove the tool guide and clean the stub pipe Fit and fully seat the drain tube to the air con stub pipe Reposition the tube through the transmission tunnel grommet Fit and align the outlet duct to the air con unit Fit and tighten the securing screws Reposition the harness and the transmission tunnel carpet Repeat the above procedure for the remaining side Refit the dash liners Fit and align the console side casings Fit and align the outlet vents Fit and tighten the securing screws WARRANTY CLAIMS Warranty claims should be submitted quoting the foliowing Complaint Code 7STQ S R O time 1 00 hr XJS 0 45 hr XJ6 S R O number 82 91 10 Jaguar Cars Limited 2005 jin JD 03 91 JAGUAR XJ6 S NI V12 ITEM 25 86 COMPACT DISC CD PLAYER FAULT CODES In the event of customers complaining of compact disc player malfunction the rel evant CD error message will be displayed on the radio digital display The following table gives a fault diagnosis for each error message that may be displayed INDICATION CAUSE SOLUTION Disc change malfunc Replace the CD player Refer to Warranty Policy tion procedure if the unit is covered by manufac ES turer s warranty
4. perature Switch NOTE IF MICROPROCESSOR JLM 2211 IS FITTED TO VEHICLES BETWEEN VIN RANGE 565650 TO 594576 THE 560 OHM RESISTOR FITTED TO THE WATER TEM PERATURE SWITCH SHOULD BE REMOVED VIN RANGE PART NO DESCRIPTION PART NO DESCRIPTION 1990 MY Up toi JLM 2212 Microprocessor JLM 2121 Black Water Tem Sensor Enhance Compatible with perature Switch ment 594577 to 605856 A C 607111 Heater 1990 MY Sensor DBC 5722 Microprocessor JLM 2121 Black Water Tem Enhancement Compatible with perature Switch 605857 A C 607111 Heater Onwards ALL MODELS FITTED WITH SANDEN COMPRESSOR ITEM 35 82 NEW OIL SEAL PROTECTOR TOOL 99 A new oil seal protector tool JD 164 should now be used when changing the oil seal on ali models fitted with the Sanden compressor J13 101 FIG 1 The new tooi JD 164 see Fig 1 replaces the originai tool JD 148 and is used in pre cisely the same manner Full instructions for renewing a compressor seal are given in the respective Service Manuals under the following Operation No 82 10 11 Jaguar Cars Limited 2005 ervice Bulletin Servi i JAGUAR aimler DATE APRIL 1991 PAGE 1 of 10 REF JD 03 91 XJ6 ITEM 16 03 REPAIR OPERATION TIMES A printing error has been highlighted in the XJ6 Repair Time Schedule 86 55 35 Door Lock Infra Red Receiver Module Repair Time should read 0 35 hours and not 0 10 hours
5. 0 to 22 5 to 21 0mm 0 10mm 0 01mm XJ6 294 5 mm 22 0 mm Pre 90 MY Rear Disc 278 1 to 10 0 to 8 8mm 0 10mm 0 01mm 277 9 mm 09 5 mm Note Maximum rear handbrake drum diameter 181mm XJ6 90 MY ON Would Dealers please note that Jaguar Cars does not recommend the re grinding of discs and once the minimum disc thickness is reached the disc should be changed Please also note that grooved discs are NOT detrimental to the operation of the brakes ALL MODELS ITEM 22 PD l LABEL REMOVER Since December 1990 all cars despatched have a new system of windscreen label fix ing A strip of clear film with special adhesive is now placed at the top portion of the windscreen and all labels are affixed to the clear film Hence at PDI the clear film can be removed and all labels will be removed at the same time Occasionally residue windscreen adhesive or hardened bird lime may be difficult to remove Never use a metal scraper to remove these substances ALWAYS USE A PLASTIC SCRAPER XJ6 ITEM 23 CLOTH COVERED SEATS WOOL FIBRE MIGRATION Some incidence of cloth wool tweed covered seats showing wool fibres balling pilling has been recognised on XJ6 saloons This effect which is usually experienced between approximately 1 to 3 months in ser vice is NOT premature wear of the seat cloth it is actually caused by surplus wool fibres which migrate out of the cloth when occupants clothing comes into abrasive c
6. Cover Gasket LH EAC 7047 XJ12 XJS HE Thermostat Cover Gasket RH EAC 7048 The bolt tightening torques are atso revised to 6 cyl XK 23 28 5 Nm 12 21 btt V12 10 8 12 2 Nm 8 9 lb ft The improved gasket and revised tightening torques were introduced at the following engine numbers XJ6 3 4 8A 15616 Limo 7M 4974 XJ6 4 2 8L 173271 XJ12 7P 51620 XJS HE 8S 32778 ITEM 04 POWER ASSISTED STEERING RACK S I11 XJS Continual monitoring and examination of returned Power Assisted Steering racks has resulted in the following improvements L To prevent rack bar contamination due to the use of spurious lubricants during Service extensive testing by Jaguar and Adwest has resulted in the deletion of the rack damper grease nipple Greasing of the rack damper during Service is NOT necessary as initial greasing by the manufacturer is considered sufficient 2 To alleviate the possibility of scoring the rack bar with the steering alignment tool when checking the steering geometry a deeper and chamfered centralising pin hole has been introduced 3 A new tangential valve and torsion bar has been introduced These improvements have been implemented on steering racks built after date code 4L 0001 and were introduced progressively on to Jaguar production from VINS 413000 S I 120500 XJS Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 85 Sheet 2 of 3 RES SS O SS SS SS TY 70 74 76 82 ITEM 05 BRAKE BEDDING IN PR
7. Disc is in player mech anism Press the magazine eject button and insert an empty magazine E 02 Disc change malfunc tion Ifthe code disappears within a few seconds the unit is functioning correctly Ifthe code remains illuminated reptace the CD Player Refer to Warranty Policy procedure if the unit is covered by manufacturer s warranty Disc change majlfunc tion Press the magazine eject button and pull out the magazine Check that the error indication is ex tinguished then operate the function again If the magazine cannot be pulled out replace the CD Player Refer to Warranty Policy procedure if the unit is covered by manufacturer s war ranty E b Magazine ejection im Press the magazine eject button If the maga possible zine does not eject replace the CD Player Refer to Warranty Policy procedure if the unit is cov ered by manufacturer s warranty High temperature The error message will extinguish when the temperature returns to the operation range Misconnection or dis Check connection between CD changer and connection of the CD control unit changer EEEE No CD magazine in the insert the CD magazine CD changer No CD at No 2 pocket of Insert a CD into the No 2 pocket of CD maga CD magazine zine JUR z Us Q Q J Jaguar Cars Limited 2005 awe JD 03 91 JAGUAR ALL MODELS UK MARKET ONLY ITEM 26 86 ALPINE R
8. SPACER CIRCLIP BARREL RETENTION SHUTTER ASSEMBLY 1 2 3 10 11 LEVER ASSEMBLY CIRCLIP 12 13 14 APPENDIX B Tibbe Boot Lock Repair Kits Part Number JLM 2042 Boot lock repair kit Kit Contents ITEM DESCRIPTION QUANTITY SPRING SPACER BARREL 1 CTT a JA ge ee Ctt pa E a E DOE Bs E E 8 PrASTCSEA 1 ae HOUSING o O oen o tf DETENTPLUNCER SPAIN oT SHUTTERHOUSING o o o mt Jaguar Cars Limited 2005 17 80 JD 06 90 ISSUE 2 JAGUAR APPENDIX C Part No s for ignition and glove box replacement locks are Part No ignition lock JLM 1983 Part No fascia glove box lock BEC 1395 The ordering procedure will be advised separately by Jaguar Parts Division XJ6 2 9 amp 4 0 XJS SIII V12 ITEM 28 HEATER MATRIX ASSEMBLY Recent investigations into heater matrix leakage problems have identified a common fatigue pattern resulting in the development of fractures around the side and tube coilector plates Design modifications to address this problem have been introduced and assured from VINs 595079 XJ6 2 9 4 0 164472 XJS 482183 Series Ill V12 XJ6 2 9 4 0 amp XJS ITEM 29 Alm CONT INTE Ga F MIGrRA ON GAS L HAR Numerous reports have recently been received concerning vehicles arriving at Dealer Pre Delivery Inspection PDI with a low state of gas charge or the system to tally evacuated Jaguar Cars Limited 2005 18 Kone JAGU
9. as the system charges up This is due to hysteresis within the switch lf any of the measured warning pressures are incorrect to the figures given in the charts or if the warning switch sequence is incorrect i e W S 1 operates before W S 2 on charge up and after W S 2 as the pressure reduces post 90MY only change the pressure switch assembly and return the suspect assembly through normal war ranty returns procedure A new accumulator has a gas charge of 84 bar and in service must not fall below 30 bar This can be checked by fully depleting the boost pressure switching on the igni tion and recording the pressure immediately indicated by the gauge f this is below 30 bar the accumulator should be renewed 3 Jaguar Cars Limited 2005 es a JD 06 90 ISSUE 2 JAGUAR Maximum charge up time of the system from a fully depleted condition is 60 sec onds Ifthis time is exceeded even with the pressures complying to the figures previ ously given the pump should be regarded as suspect Battery voltage should be between 10 0 and 14 5 V measured with the pump run ning AJ6 ENGINES ITEM 24 57 POWER STEERING PUMP DRIVE DOG REMOVAL AND REPLACEMENT Instances have been reported of damage being caused to power steering pump drive dog removal tools JD 119 and 18G 1445 by incorrect usage This Bulletin describes the correct procedure to be adopted whilst removing and replacing drive dogs En sure the procedure is followed and no
10. be ALL DIMENSIONS IN MILLIMETRES 31426 Jaguar Cars Limited 2005 ITEM 84 76 MATCHED VENEER KITS S III XJS The introduction on 1986 MY vehicles of a A centre console veneered panel S III saloons and b A rationalisation of door cappings ALL model variants has brought about the need to restructure the veneer panel kits To keep the number of kits to a minimum the console panels will be supplied separately When ordering 2 replacement veneer kit Dealers should identify the relevant console panel and include it with their order Where possible kit numbers released previously in Parts Technical Information Bulletins Volume J5 Numbers J22 amp 23 will remain unchanged The following list which includes all the new kit numbers can also be found in Parts Technical Information Bulletin Volume J6 Number J5 Please note NEW kit numbers marked thus only affect vehicles manufactured AFTER 1986 M Y introduction VINs 431602 SIII 125020 XJS The other kit numbers affect all model variants from 1983 M Y unless otherwise indicated Part Number Model Clock Trip Computer Jaguar RHD except Japan JLM 198 JLM 196 j Japan JLM 199 JLM 197 Up to Jaguar LHD except Canada Japan USA JLM 201 JLM 200 Vin 431601 a ai Canada Japan USA JLM 203 JLM 202 Jaguar RHD except Japan JLM 540 JLM 541 431602 a ii Japan JLM 542 JLM 543 431602 Jaguar LHD except Canada Japan USA JLM 544 JLM 545 431602 ii Canada Japan USA J
11. damage will result REMOVAL PROCEDURE Secure the plate part of JD 119 in a bench vice as shown in Fig 1 rl J57 214 FIG 1 Hold by its wire one of the two nuts under a cut out of the pump s drive dog flange see Fig 2 J 215 Jaguar Cars Limited 2005 JAGUAR ISSUE 2 JD 06 90 Screw one ofthe two bolts into the nut and lightly tighten it see Fig 3 JAS 216 FIG 3 Repeat for the other nut and bolt but only enter the bolt by ap proximately two threads and position the pump under the plate see Fig 4 357 217 C FIG 4 oO Kf A ag z E in nc A Locate the boit heads in the slots and tighten the second bolt 457 218 Jaguar Cars Limited 2005 JD 06 90 ISSUE 2 J i A pa J57 219 FIG 6 157 240 KNN JAGUAR Assemble tool 18G 1445 as shown in Fig 6 ensure that the hexagon 1 is below the plate and the two flats 2 above Screw the centre bolt of the tool into the pump shaft so that it is fully engaged and finger tight and screw the centre section s hexagon up so that it contacts the underside of the plate Refer to Fig 7 Using a 22mm spanner hold the centre bolt 1 so that it cannot turn Using a 19mm open ended spanner turn the centre section of the tool 2 anti clockwise to with draw the pump s drive dog Support the pump in the hand and slacken the centre bolt to release the pump see Fig 8 Lift out
12. etc A labour allowance of 0 45 hrs may be claimed quoting Complaint Code 7QAT Repair Operation No 86 91 13 Modification Procedure Parts Required Eyelet Connector Internal diameter 4mm 0 15 in Self Tapping Screw No 8 x 13mm 0 50 in Suitable Star Washer dd 1 Disconnect the battery negative cable 2 Remove the jack assembly spare wheel and rear trim panel 3 Remove the RH side trim panel 4 Locate and remove the aerial earth lead from the relay mounting plate fixing Fig 1 A Relocate the side harness earth cable to relay mounting plate refit and secure the fixing screw 5 Mark out the new position for the aerial earth lead as shown in Fig 1 inset B 10mm 0 40 in C 7mm 0 28 in drill 2 5 mm 3 32 in hole Clean the paint from the surrounding surface to ensure a good earth connection 6 Position the aerial mast earth lead to the new fixing point ensuring that the shortest length possible can be fitted without putting any strain on the lead Fig 1 D Mark the earth braid ensuring the new length will be approximately 76mm 3 0 in when measured from the centre of the eyelets a 7 Cut the earth braid secure and solder the new eyelet 8 Locate and secure the eyelet to the new earth point using the recommended self tapping screw and washer 10 Apply a light smear of grease to the new earth fixing to prevent the possibility of corrosion 11 Refit the trim panels spare wheel jack assembly and reconnect
13. issued to all Econocruise agents When carrying out the fuel rail modification on a vehicle fitted with an AFTER MARKET ECONOCRUISE SYSTEM then the following test MUST be followed 1 Remove the throttle lever A by unscrewing the two M5 hex head screws from the throttle turntable Using a junior hack saw cut off the material B from one side of the throttle lever as shown Remove all sharp edges and burrs with a hand file Check to ensure the throttle goes to the fully closed position with the modified Jaguar throttle lever and ball joints fitted If necessary increase the clearance on the two fixing holes C Refit the throttle lever to the throttle turntable using the two hex head screws Again checking that there is adequate clearance Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 7 of 8 Slacken the nut and bolt holding the cable abutment bracket D and with the cruise control cable in position E rotate the abutment F to obtain clearance under the ball joint with the inner cable and clearance over the fuel rail with the outer cable Re tighten the nut and bolt holding the abutment bracket Check the operation of the cruise control cable and throttle by squeezing the bellows unit to pull the throttle on and then releasing CHECK THAT THE THROTTLE LINKAGE OPERATES CORRECTLY FROM FULLY OPEN TO FULLY CLOSED N B Should any problems be encountered contact your local Econocruise 99 Agent
14. note is made of the position of individual injector harness connectors and clamps prior to removal of the injector as their positions vary Fit Service Tools JD 116 1 Fig 2 to the replacement injector and hose assembly 2 Fig 2 Ensure that the face of the tool is located against the injector collar and that an injector clamping plate is correctly located prior to fitment Push the assembly onto the rail stub ensuring that the hose is fully seated in the hose to rail collar 4 Fig 2 N B 3 Fig 2 denotes fuel rail and that the harness connectors and clamping plates are in the correct positions Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 3 of 8 39164 NOTE The tool is not required on the longer hoses 1A and 1B injectors as they can be fitted by hand 9 Refit the rail and injector assembly 10 Reconnect the battery l1 Run the engine and check the hose integrity IMPORTANT The torque figure for all screw type connections on the engine fuel injection system is 9 11 1bf ft 12 5 15 Nm The torque figure for clip type connections on the engine fuel injection system is 17 21 ibf ft 1 92 2 37 Nm LABOUR ALLOWANCE gt When changing injectors the following repair operation times must be used 19 60 12 Complete injector set renewal 2 50 hrs 19 60 15 One injector renewal 1 55 hrs 19 60 16 Each subsequent injector renewal 0 10 hrs 19 60 14 Complete fuel rail and injector renewal 1 50 h
15. the battery Jaguar Cars Limited 2005 Jaguar Cars Limited 2005 GUAR Service Bulletin JAG aimler J DATE MAY 1990 PAGE 1 of 19 REF JD 06 90 Sill 5 3 ITEM 21 Sill 1990 MODEL YEAR RUNNING CHANGES Jaguar have introduced the following specification alterations since the production a of the first 1990 model year range Volume introduction for the following alterations is from January 1990 from VIN 483096 STEERING WHEEL The XJS sports pack steer ing wheel which was re placed on the XJS at 1990 model year is now fitted to the SIII V12 saloon includ ing the Canadian VDP see Fig 1 The Daimler Double Sixhowever retains its stan dard steering wheel FIG 1 SEAT BELTS All seat belts are now colour keyed except in territories where the colour is stipulated by legislation Six colours of webbing are utilised as shown in the following table WEBBING COLOUR DOESKIN BARLEY PARCHMENT MAGNOLIA WARM CHARCOAL WARM CHARCOAL WARM CHARCOAL 1 Jaguar Cars Limited Jaguar Cars Limited 2005 03 aw JD 06 90 JAGUAR Front Seat Belts The inner buckle is unchanged The retractor and B post running loops are as used on the XJ6 2 9 4 0 but with unique belt lengths Rear Seat Belts For the outboard seats the retractor assemblies are as used onthe XJS but with unique belt lengths Arecess is providedinthe rear quarter trim panel to give clearance with the re
16. the drive dog Jaguar Cars Limited 2005 JD 06 90 JAGUAR REPLACEMENT PROCEDURE a A Secure the plate part of JD 119 in a bench vice as shown in Fig 9 Note that this procedure utilizes the opposite end of the plate to that used in the removal pro cedure J 7 222 FIG 9 Place the drive dog on the pump s shaft dogs uppermost Assemble tool 18G 1445 as shown in Fig 10 note orienta centre section and screw the bolt into the pump s shaft until fully engaged and finger tight J57 223 FIG 10 Support the tool pump assem bly in the fork of JD 119 see Fig 11 J87224 Jaguar Cars Limited 2005 Kae JD 06 90 JAGUAR Refer to Fig 12 Use a 22mm spanner to prevent the bolt turning and use a 28mm spanner to turn the centre section of 18G 1445 in a clockwise direction to press the drive dog on to the shaft J57 225 FIG 12 ontinue pressing the drive dog 1 Fig 13 on to the shaft until the shaft 2 Fig 13 is ap proximately 1 8in 3 175mm proud of it Use a depth gauge or vernier caliper to check the dimension and ad just as necessary Vain 3 17Smm EV eee P Ua lt Yl 157 226 FIG 13 Jaguar Cars Limited 2005 i 70 76 JAGUAR JD 06 90 XJS 90 MY ITEM 25 POWER HYDRAULIC DIAGNOSTIC KIT ADAPTOR The test point adaptor JDS 9010 which is used on pre 1990 cars cannot be used on 19
17. to Jaguar Service Bulletin JD 09 85 Item 66 This Bulletin Item dealing with the introduction of Kiekert Locking on 1986 M Y S III vehicles contained certain components which were listed with the incorrect part numbers The correct numbers are listed below BAC 8554 should read BBC 8554 BAC 6728 should read BBC 6728 BAC 6729 should read BBC 6729 BAC 6727 should read BBC 6727 ITEM 83 76 BOOT BADGES STEL From the commencement of 1986 MY vehicles all S III Saloons are being fitted with self adhesive boot lid badges These obviate the requirement for badge pin fixing holes in the rear boot lid vertical panel This bulletin identifies by illustration the correct locations for fitting these new types of badges Jaguar Cars Limited 2005 Fitment of Badge te 2 3 Thoroughly clean and dry the panel using a degreasing agent such as SBP3 or similar Mark the badge location Peel off the badge backing strip and carefully position the badge to the marks on the panel Secure by applying firm pressure BBC 2547 BBC 2601 ALL VDP BBC 2547 BBC 2603 BBC 6572 BBC 5100 DAIMLER 4 2 ALL DIMENSIONS IN MILLIMETRES IS1427 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 5 of 8 BBC 2547 BBC 2603 SOVEREIGN 4 2 BBC 2547 BBC 2670 JAGUAR 4 2 EXCEPT USA amp CANADA BAC 6324 BBC 2857 JAGUAR 3 4 amp JAGUAR 4 2 USA amp CANADA BBC 5100 BBC 6570 DAIMLER 5 3 of 10
18. 1S 7 230 On standard mounting bushes fit the new rubber faced thrust washers to the outer faces of the lower bushes Raise the rack assembly and align the crossbeam mountings Fit suitable pegs to the mounting positions to hold the rack in place Remove the peg from the passenger s side fit the shims as necessary between the rack lower mounting bush and the crossbeam Fit but do not tighten the rack mount ing bolt and nut Remove the peg from the pinion side fit but do not tighten the rack mounting bolt and nut Jaguar Cars Limited 2005 ja JD 07 90 JAGUAR 57 Fit and align the rack heatshields as necessary Fit but do not tighten the upper rack mounting bolt and nut Align the rack assembly with crossbeam base and finally tighten the securing bolts Reposition the steering column and steering rack centrally using the centralising pin as detailed and engage and fully seat the lower universal joint to the rack spline Fit and tighten pinch bolt and nut Lower the vehicle XJS amp SI ITEM 33 POWER STEERING RACK MOUNTING BUSHES A new Service Tool JD 165 has been developed to enable the steering rack mounting bushes to be replaced without disconnecting the hydraulic pipes and track rod ends The following service Repair Operations are now available CEE E ps E C w o w 57 10 30 Power Steering Rack Mounting 1 15 1 30 1 35 1 75 Bushes Renew 57 10 31 Sports Pack Power Steering Rack 1 20 1 35 1 40 1
19. 3784 XJS It is important that when investigating power steering fluid leakage this lubricating oil is not confused with the hydraulic fluid as under normal operating conditions a small amount of the oil will be present in the steering rack gaiters If any oil is lost from the gaiters then an equal amount to that lost should be added to the gaiter prior to the refitment of the gaiter clips It is not necessary under normal circumstances to add oil to the rack during Service unless a complete overhaul of the rack is undertaken The total oil capacity of the steering rack is 0 19 litres ITEM 43 82 AIR CONDITIONING IN CAR SENSOR XJS HE XJ S 3 6 XJ SC 3 6 Reference Service Bulletin JD 09 84 Item 77 XJS HE XJ 3 6 Models incorporating blown aspiration systems were introduced at VIN 123935 ITEM 44 84 WINDSCREEN WIPER MOTOR S ill During the pre delivery inspection PDI of S II Models incidences have been reported of the wiper motor failing to operate when initially switched on However if the control switch is left in the on position the wipers eventually commence operating Investigations have traced the fault to an intermittent poor connection between the wiper motor harness multiplug and the bulkhead sandwich block connector Should Dealers encounter this problem the connectors in question should be checked for continuity and tightened accordingly if found loose Production fitment has been confirmed satisfactory and assured
20. 80 Mounting Bushes Renew S HI 57 10 30 Power Steering Rack Mounting 1 30 Leo 1 75 Bushes Renew NOTE No other Repair Times are affected 82 AIR CONDITIONING HEATER MICROPROCESSOR To cater for changes to the air conditioning heater water temperature switch oper ation ref Service Bulletin JD 19 89 item 93 and the introduction of a revised tn car sensor aspiration system ref Service Bulletin JD 03 90 Item 12 circuitry changes within the air conditioning heater microprocessor have been necessary resulting in specific microprocessors being required to cover the vehicle ranges affected IN THE EVENT THAT REPLACEMENT OF A MICROPROCESSOR OR WATER TEM PERATURE SWITCH IS REQUIRED PLEASE REFER TO THE FOLLOWING LIST TO EN SURE THAT THE CORRECT PART NUMBER IS ORDERED AND FITTED Dealers who have recently received owner complaints with respect to the following symptoms and have been unsuccessful in rectifying the situation should ensure the appropriate microprocessor is fitted Jaguar Cars Limited 2005 i JD 07 90 JAGUAR 1 No fan speed response when either Low Normal or High is selected although the defrost mode operates normally 2 High speed fan in low mode slows down when Normal is selected 3 Control panel illumination out of sequence or flashing VIN RANGE PART NO DESCRIPTION PART NO DESCRIPTION Pre 1990 MY JLM 2211 Microprocessor JLM 763 Red Water Tem 500001 to 594576 Compatible with
21. 90 models due to a change in the brake system pipework from the motor pump unit The Bundy pipe now utilized must be replaced by a flexible hose and an adaptor before testing can proceed The parts required are Flexible hose Order No JDS 2024 Adaptor Order No JDS 2022 Sealing washer Order No JDS 2025 two off Service Bulletin JD 04 88 Note that the above parts are as used for 90 MY XJ6 2 9 4 0 The adaptor is stamped OE Procedure Ensure that the ignition is switched off Depressurise the system by depressing the brake pedal approximately twenty times Note that the pedal feel goes hard when the system is fully depressurised Disconnect and remove the short length of Bundy pipe that connects the accumulator as sembly 1 Fig 1 to the in line connector 2 Fig 1 on the bulk head Cap the ends of the pipe to prevent ingress of foreign matter Connect the flexible HOUSE a 4 gt fe aie washer to the in line con nector Assemble the adaptor 4 Fig 1 to the flexible hose and the accumulator assembly using the two sealing washers 5 Fig 1 JSi 1265 FIG 1 The procedure for pressure testing and bleeding the hydraulic system is given in Ser vice Bulletin JD 04 88 Item 25 XJ6 ITEM 26 VEHICLE WATER INGRESS VIA BOOT LOCK It has been established that water may enter the boot interior via the lock barrel on XJ6 vehicles Jaguar Cars Limited 2005 EN JD 06 90 JAGUAR To correct th
22. ADIO RDS SYSTEM This Bulletin Item is an explanation of the capabilities and operational instructions for the Radio Data System RDS This system is primarily intended for use within the United Kingdom but as there are some aspects of the broadcast information system transmitted in most European countries these explanatory notes will also be relevant to such territories RADIO DATA SYSTEM RDS The Jaguar radio is equipped with an advanced Radio Data System decoder to assist the driver in finding and staying tuned to a chosen radio station This system enables the radio to pick up inaudible signals transmitted on the FM wave band which permit automatic programme tuning display of the stations identity name and up to the minute traffic information RDS Programme Service Name The RDS system displays the station name rather than the frequency This informa tion is sent with all the other RDS data and is known as the Programme Service Name It is shown on the radio display in eight characters The Programme Service Name feature also identifies network splits when different programmes are being broad cast on FM and Medium Wave or Long Wave For example The normal display for Radio 4 is BBC R4 but when there are educa tional programmes on Long Wave the display will show BBC R4ED RDS Auto Tuning RDS is radio s first fully automatic tuning system Its benefit is that it tunes to a signal not a frequency RDS radi
23. AR 86 JD 06 90 It has been necessary due to the number of vehicles highlighted to introduce addi tional inspection and leak check stages during the production build sequence Integrity of the air conditioning system has now been assured from VINs 616106 XJ6 2 9 4 0 171329 XJS 3 6 V12 XJ6 REAR FOG LAMP LENS ITEM 30 As a running change on 1990 Model Year saloons a new camouflaged dot matrix fog reflex lamp lens has been introduced to replace the clear lens previously fitted This new lens has been introduced on all model variants from VIN 614671 Under no circumstances should lamp lenses assemblies be inter mixed on the same car unless as a market requirement where a replacement is required since continuity of style must be maintained Units can be identified visually as follows 19 Fig 1 A New dot matrix camouflage style Lens Part No JLM 2146 Fog Reflex JLM 2147 Non Fog Assy Part No DBC 5991 Non Fog Fig 1 B Clear Style Lens Part No JLM 1059 Fog Reflex JLM 1060 Non Fog Assy Part No DBC 2594 Fog Reflex DBC 2595 Non Fog Jaguar Cars Limited 2005 Service Bulletin JAGUAR DATE JUNE 1990 PAGE 1 of 6 REF JD 07 90 As a result of additional information received following the issue of Service Bulletin JD 06 90 it has been decided to re issue pages 3 4 5 6 15 16 and 17 18 These amended pages are included at t
24. D 06 90 JAGUAR This Bulletin has therefore been compiled to meet the above requirement and also o provide a method for determining the ke odes for individua Ope K The content of this Bulletin is divided into the following two sections Section A Identification of the key code cut sequence Section B The repair procedure for the door and boot locks SECTION A Prior to the introduction of the Tibbe system key cut codes were determined by cross referencing a unique code to a list of cut codes This procedure is no longer applicable because the Tibbe number and cut code are the same Determining this code is achieved by simple visual examination of the operational portion of a Tibbe key To define the key code for all Tibbe keys refer to Fig 1 The illustration shows that the Tibbe key has eight cuts on the operational portion of the key Reading the key code requires that the observer recognises the three types levels of the cut which are used to form the cut portion These three cut types can be de fined as follows Type Numeric value s s Ta mr a v A Position B No cut B Position Full cut C Therefore when each cut type has been determined write down Its nu meric value starting from position A reading the sequence of cuts in the direction of the arrow 2 ss NOTE The key Number Cut code for the key shown in Fig 1 is 21322312 SECTION B LOCK REPAIR PROC
25. EDURE Three repair kits are now available from Jaguar Parts Division which can be used to effect repairs to the right and left hand front door and boot lock The construction of the remaining two vehicle locks is such that it prevents a repair being undertaken The method of replacing these locks is explained in Appendix C Lock Repair Kits Part No Description a JLM 2040 L H door lock repair kit JLM 2039 R H door lock repair kit JLM 2042 Boot Lock lock repair kit Jaguar Cars Limited 2005 11 JD 06 90 JAGUAR NOTE For kit contents see appendix A and B ithin the clean room area ofthe service workshop prior to undertaking a repair an area of the work bench should be prepared by covering it with a clean lint free cloth or paper towel A clean working area for the following procedure is essential NOTE At every stage of the following repair procedure absolute cleanliness must be observed because any dirt or contamination of the inner lock will prevent the lock functioning correctly Relationship Between the Lock o AR Disc and Key Cuts e A All lock repair kits will contain y a total of 12 discs which are di VA vided into three formats of which there are four discs for each format Identification of each disc format is achieved by reading the notch sequence found on the edge of each disc o See Fig 2 for the discto key cut O G S relationship C JSI 1249 AN NY AN
26. JS1I 44G6 ITEM 88 JAGUAR SPECIAL TOOLS S ILI XJS Due to improvements to the current range of vehicles the following new special tools or modifications have been introduced POWER ASSISTED STEERING RACK A modified steering rack with a deeper and chamfered centralising pin hole introduced from VIN s 413000 S III 120500 XJS This requires the use of a new steering rack centralising pin This tool supercedes the existing tool No 18G 1466 and the Jaguar spares supply tool No 12297 The new tool has a longer locating shank and a rounded end and is numbered JD 117 It is also suitable for use on steering racks prior to this modification This tool is mandatory and is available from V L Churchill Ltd or its dealers Jaguar Cars Limited 2005 18G 1468 AUXILIARY DRIVES OIL SEAL REMOVER AJ6 With the introduction of a modified auxiliary drives dog to the AJ6 engine it is necessary to modify the existing 18G 1468 auxiliary drives oil seal remover This modification requires the inside bore of the tool to be enlarged as shown in Fig 1 DIMENSION A 37 5 mm DIMENSION B 22 15 mm JST432 FIG 1 This modification will not affect its application on earlier engines and should be completed as soon as possible as later engines have the modified auxiliary drive dogs fitted Future supplies from V L Churchill will already be modified and numbered JD 118 18G 1445 POWER STEERING PUMP DRIVE DOG REMOVE REPLACER AJ6 A
27. LAN o Au FE TFR In ia Gee VA En This relationship is the same for all Tibbe lock assemblies Therefore using the key cut number shown in Fig 1 the disc relationship and the lock disc order would be as shown below for key number 21322312 KEY CUT NO TYPE DISC TYPE FORMAT NOTCH SEQUENCE DS To ATOS E DR RR Disassemble Door Lock 1 Remove faulty door handle assembly from the vehicle door Jaguar Cars Limited 2005 12 JAGUAR JD 06 90 A Remove C clip A Fig 3 B Remove plastic actuation arm return spring and spacer washer B C amp D Fig 3 C Remove circlip which retains the lock barrel into its hous ing E Fig 3 ystazso SS ee ae FIG 3 D Hold handle in the atti tude shown in Fig 4 and gently extract the lock barrel assembly and steel roller A Fig 4 from its housing Remove the shutter as f Ea JSi 1251 FIG 4 E The lock barrel assembly should be kept in its assembled condition so that itcan be used as a checking reference when assembling the replacement kit The kit contents will allow the replacement of all parts as outlined in Appen dix A Assemble Door Lock 1 Select new discs and spacers from the kit and arrange them in assembly order appertaining to the key cut sequence 2 Proceed to assemble discs and spacers into new lock barrel supplied with the kit As each disc spacer is installed a smear of lubricating grease sup
28. LM 546 JLM 547 431602 Sovereign RHD JLM 189 JLM 133 E LHD except Canada JLM 190 JLM 134 Canada JLM 195 JLM 143 Daimler RHD JLM 191 JLM 139 LHD JLM 548 JLM 549 431602 Jaguar LHD VDP Canada Japan USA JLM 194 JLM 142 XJS 3 6 RD JLM 144 ji XJS 3 6 LHD JLM 145 o XJS V12 RHD JLM 474 125020 XJS V12 LHD JLM 475 125020 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 6 of 8 76 86 CENTRE CONSOLE VENEERED PANELS Manual Auto with Auto without Model Transmission Speed Control Speed Control Jaguar S III not VDP BBC 6604 BBC 6598 BBC 6601 Jaguar Sovereign S III Jaguar VDP Daimler 4 2 BBC 7551 BBC 7552 BBC 7553 Daimler Double Six Jaguar XJS N A N A N A These veneer kits are primarily for vehicles in warranty and are to be ordered as required ITEM 85 REAR SCREENS S iII On S III vehicles manufactured during 1983 84 Service have established that certain conditions can cause a fault to develop which results in the failure of the rear screen demister circuit The introduction of new screens BBC 6550 Clear BBC 6551 Tinted has eliminated any potential failures on vehicles manufactured after VIN 426000 4 2 5 3 VIN 429462 3 4 To prevent any possibility of repeat failures on vehicles in Service all stocks of rear screen BAC 3182 and BAC 3183 have been withdrawn When carrying out service replacements of ANY S III rear screen ONLY part No BBC 6550 or BBC 6551 may be used O
29. N CANADA AUSTRALIA V12 vehicles supplied to the above markets are now fitted with auxiliary air valve EAC 2273 in place of EAC 4438 This is to prevent the possibilty of engine stall during the warm up period and was introduced at Engine Numbers 7P 54121 S TII 8S 37841 XJS ITEM 77 19 FUEL PRESSURE TEST S III V12 XJS V12 Due to the redesign of the V12 fuel injection rail and the introduction of union connections on the fuel hose assemblies it is necessary to modify the Epitest fuel pressure gauge before it can be used on the latest fuel rail The modification to the gauge should be carried out as follows 1 Remove the two short hoses 1 Fig 1 from the existing gauge JS a5 FIG 1 2 Obtain fuel hose assembly Part No EAC 8088 from parts stock and cut the hose into two equal lengths of 60 mm 2 36 in Fig 2 Blow through the hose assembly to ensure all cutting debris is clear X 60 mm 2 36 in X Je JSI 136 FIG 2 3 Insert the tee piece 1 Fig 3 in the open ends of the hose 2 Fig 3 and secure with hose clips Part No EAC 3215 2 Tighten the clips to a torque of 17 21 1lbf ins 1 92 2 37 Nm Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 2 of 8 IS IT FIG 3 This modified pressure gauge must now be used to check fuel pressure when required using the following procedure l Depressurise the fuel system 2 Disconnect the battery 3 Disconnect the fuel r
30. OCEDURE ALL MODELS With the recent introduction of semi metallic brake linings it is important that all Service Personnel are aware of the optimum procedure for the bedding in of these linings Details are as follows In order to ensure optimum brake performance and refinement throughout the life of the brake friction linings and brake discs it is essential that a controlled brake bedding procedure is undertaken during the early life of the friction linings The procedure used should ensure that the friction linings quickly achieve normal operating conditions as a result of low energy applications without being subjected to high energy input levels The procedure recommended for the first 320 km 200 miles is of deliberate frequent light application wherever possible similar to that used during normal town driving On open road driving the above conditions have to be simulated Try NOT to brake from speeds in excess of 96 km h 60 mph reduce speed by short brake applications i e 80 65 km h 50 40 mph at intervals of approximately 1 5 km 1 mile This procedure will ensure satisfactory brake lining disc conditioning and lead to optimum brake life and performance ITEM 06 ALLOY WHEELS S IHN XJS Reports of difficulty in removing alloy wheels due to corrosion between the mating faces of the wheel and the hub spigot has resulted in a greasing operation being introduced on production The hub spigot bore of the wheel is no
31. ail to the outlet pressure regulator hose assembly EAC 8088 at the rail and regulator and remove the hose assembly 1 Fig 4 Ensure that any fuel spillage is absorbed using suitable cloths FIG 4 4 Replace the hose assembly with the modified pressure gauge Tighten the connections to a torque of 9 11 1bf ft 12 5 15 Nm 5 Reconnect the battery 6 Carry out the pressure test REFIT l Depressurise the fuel system 2 Disconnect the battery 3 Remove the modified pressure gauge and replace with the original hose assembly tighten the union connections to a torque of 9 11 1b tt 12 8 15 Neds 4 Reconnect the battery Jaguar Cars Limited 2005 ITEM 78 19 ELECTRONIC FUEL INJECTOR RENEWAL SLIL FIZFAIS VIZ Due the 1 to the introduction of the square section fuel rail on V12 engines following procedure must now be used when replacing fuel injectors Depressurise the fuel system Disconnect the battery Remove the fuel rail and injector assembly NOTE Remove the rail and injector assembly to a suitable workbench to carryout the injector replacement Using a hot soldering iron 1 Fig 1 at the top of the hose 2 Fig 1 burn through the hose until it is possible to remove the hose and injector assembly H9 185 Remove the fuel rail collar IMPORTANT Under no circumstances should the hose be cut as damage to the fuel rail stub may arise leading to subsequent fuel leakage NOTE Ensure that a
32. air time schedules Where numbers are duplicated i e 19 60 12 Injector Engine Set Renew REPLACE the existing repair time with the new repair time Jaguar Cars Limited Operation Time Hrs Number Description S III XJ S 19 20 15 Auxiliary Air Valve Feed Hose Renew 0 25 0 25 19 22 01 Hot Start Switch Renew 0 25 0 25 19 40 56 Hose Fuel Cooler to Fuel Return Pipe Renew 0 55 0 55 19 40 62 Hose Fuel Feed Pipe to Pressure Regulator Valve Renew Dedo 0 60 19 40 63 Hose RHD Pressure Regulator Valve to Fuel Rail Renew 0 30 0 30 19 40 64 Hose LDH Pressure Regulator Valve to Fuel Rail Renew 0 35 0 35 19 40 78 Hose Pressure Regulator Valve to Fuel Cooler Renew 0 60 0 60 19 45 09 Pressure Regulator Valve LHD Renew 0 45 0 45 19 45 10 Pressure Regulator Valve RHD Renew 0 35 0 35 19 45 13 Pressure Regulator Valve Engine Set Renew 0 55 0 55 19 45 18 Pressure Regulator Valve Vacuum Elbow Renew 0 25 0 25 19 45 19 Pressure Regulator Valve Vacuum Hose Renew 0 25 0 25 19 60 12 Injector Engine Set Renew 2 50 2 50 19 60 14 Fuel Rail and Injector Assembly Renew 1 50 1 50 19 60 15 Injector Renew 1 53 Leo 19 60 16 Injector Extra Each Renew 0 10 0 10 86 35 10 Distributor Cap Renew 0 80 0 80 86 35 23 Distributor Breather Filter Renew 0 25 0 25 86 35 32 Ignition Coil Renew 0 40 0 40 No other repair times are affected Jaguar Cars Limited 2005 ITEM 76 S LII V12 XJS V12 12 AUXILIARY AIR VALVE JAPA
33. and close the bonnet Jaguar Cars Limited 2005 JSI 864 Fig 1 ITEM 31 79 PAINT COLOUR CODE ALL MODELS Please note the change of Jaguar Sales Code and BLVC on clear over base colour Glacier White This follows reformulation to improve opacity JBC 742 BLVC NDP Glacier White replaces JBC 721 BLVC NDK Glacier White o This reformulation was progressively introduced from VINs 149361 XJS ITEM 32 86 ELECTRIC AERIAL XJ6 2 9 3 6 During investigations into signal reception quality improvements in the aerial signal to noise ratio i e weak transmission signal high background noise strong signal low background noise have been gained by shortening and repositioning the electric aerial earth braid Where instances of weak signal strength are suspected the following detailed modifica tion should be carried out amp Jaguar Cars Limited 2005 SERVICE BULLETIN JD 05 88 SHEET 3 of 3 Please Note This modification will offer some improvement in signal strength but will not overcome the more prevalent reception interference encountered in certain areas of the British Isles resulting from low level transmissions utilized by the BBC and some local radio stations The interference referred to is caused by signal break up which affects Radio 3 VHF transmissions and is commonly interpreted as a chuffing sound which coincides with the vehicle passing land based obstructions i e trees high buildings
34. ange discs and spacers in key code order refer to Fig 5 Jaguar Cars Limited 2005 14 Kaw JAGUAR A 10 Th tz ISSUE 2 Fit plastic seal onto lock barrel at position A Fig 7 Assemble disc and spacer washers into lock barrel in key cut order Using smear of lubricating grease supplied in kit apply it to each face of disc spacers Align steel roller with slots Fig 7 It is important that only the lubricat ing grease supplied in the kit is to be used Fit shutter housing into lock barrel and insert retaining key A Fig 8 Fit pivot spring and pin into shutter housing whilst tensioning the spring as shown at C Fig 8 JSi 1256 FIG 8 Align disc and spacer washers using key Apply lubricating grease to the steel roller and fit into the lock barrel at positions shown in Fig 7 Apply lubricating grease to detent plunger and spring A Fig 10 fit into lock barrel Lubricate and fit steel spring clip into lock barrel housing B Fig 10 15 JD 06 90 ht 28s FIG 7 Locate the shutter flap D Fig 8 into the shutter housing fit the closing plate E Fig 8 Insert plastic tension ring F Fig 8 into the lock barrel retain ing cover fit cover G Fig 8 over the lock barrel With the aid of another workshop operative hold the lock barrel as sembly on a block of hardwood using a flat end punch and hammer peen the edge of the cover into the thr
35. assis hinge bolts has been introduced to prevent the possibility of engine related ignition noise being radiated from this source which could interfere with radio signal transmissions Should Dealers receive reports of radio interference suspected as ignition based prior to VIN 523964 then the earth braid strap Part No DBC 4727 should be fitted as shown in Fig 1 before undertaking further investigations Parts Required Part No Description Oty DBC 4727 Earth Braid 1 SH 108201J Bolt 1 FN 108041J Nut 1 FW 105E Washer 1 D A labour allowance of 0 30 hours may be claimed quoting Fault Code 7QAT Repair Operation No 86 91 14 Procedure 1 Open the bonnet 2 Release and remove the LH bonnet hinge lower bolt and discard Fig 1 A 3 Clean the paint from around the surrounding surface of the hole to ensure a good earth connection 4 Position the earth lead and secure using a new bolt Part No SH 108201J and washer Part No FW 105E Fig A amp Bl 5 Remove the LH side radiator grille assembly 6 Release and remove the fixing nut from the lower hinge bracket Fig 1 C 7 Clean the paint from the surrounding surface of the studs to ensure a good earth connection 8 Route the earth lead to the lower stud as shown Fig 1 and secure using a new fixing nut Part No FN 108041J Fig 1 C 9 Apply a light smear of grease to the fixing points to prevent the possibility of corrosion 10 Replace the radiator grille pane
36. ation This means at the present time that most of the presets will display No FM NOTE When used correctly RDS and TP are very effective additional features to the car radio capability However if these facilities are used without full understanding they may cause a situation confusing to the operator This is less likely to occur as more RDS radio stations become available lf drivers are not fully familiar with the RDS and TP systems they should be advised to switch them off until they can be satisfactorily instructed in the proper use When the RDS and TP are switched off the red light on the RDS button will go out and the TP indicator will disappear from the display Jaguar Cars Limited 2005 in JD 03 91 JAGUAR RDS TROUBLE SHOOTING GUIDE INCORRECT RESPONSE FROM REASON AND RECTIFICATION RDS Radio does not display pro Press RDS button for 2 seconds the red light on gramme service name the button will come on If programme service still does not appear the radio station selected is not an RDS station The radio will then retune to the strongest station it can find Note This may not be the desired station if not de select RDS RDS button is pressed but no RDS station found due to non availability of or insufficient signal strength to receive RDS data Radio will continue search every minute until RDS station found To stop this de select RDS by holding button for 2 seconds Radio has lost rec
37. e life of lower wishbone bushes a revised bush has been intro duced Part numbers are unchanged Parts stock is to the latest condition Introduc tion VIN 637400 XJ6 ITEM 19 REAR SHOCK ABSORBERS To overcome reports of rear shock absorber failure a revised unit has been intro duced Introduction VIN 631228 Revised Part No CCC 3538 Replacement Policy Front and rear shock absorbers may be changed individually provided that the follow ing criteria are satisfied 1 The remaining shock absorber has covered less than 25 000 miles 40 000 kms 2 The replacement shock absorber has the same part number as that of the shock absorber fitted to the vehicle XJ6 ITEM 20 REAR SUSPENSION A FRAME MOUNTING BUSHES To extend the service life of rear suspension A frame mounting bushes a revised bush as been introduced Part numbers remain unchanged All parts in stock are to the latest condition Introduction VIN 636200 XJ6 ITEM 21 BRAKE DISC With the introduction of the 1990 MY XJ6 models changes were made to the brake disc dimensions Disc dimensions are as specified in the following table Jaguar Cars Limited 2005 oS JD 03 91 JAGUAR 76 76 MODEL DiAMETER NEW MINIMUM MAXIMUM MAXIMUM THICKNESS THICKNESS DISC THICK THIN oo NOUT VARIATION Front Disc 291 0 to sem Oto 27 Oimm 290 8 mm sem 5mm Bw all Rear Disc 295 0 to 10 0 to kul a 10mm 0 01mm 294 8 mm 09 5 mm Front Disc 295
38. eable with Part No DAC 6103 However will Dealers please note that the connections for the WARNING LIGHT and the EARTH have been reversed The warning light terminal is now at the bottom and the earth terminal is now in the middle Harness Identification and Colour Code DAC 6103 DAC 10183 V Supply 670 Green Orange Emn 8 bex Boom Mie Warning Light Brown Pink Midde Bottom Note Parts Operations now only stock the latest condition element Part No DAC 10183 10 Jaguar Cars Limited 2005
39. ee slots in the lock barrel rim Fig 9 JS 1258 FIG 9 Jaguar Cars Limited 2005 tone JD 06 90 ISSUE 2 JAGUAR 13 Finally align and fit lock barrel into the lock barrel housing This is achieved by aligning the detent plunger with the slot and pushing fully home until the plunger engages into the rear of the housing C Fig 10 14 Check for correct operation of the lock using the boot key Finally refit the lock into the boot and test for correct operation JS 1257 FIG 10 WARRANTY CLAIMS PROCEDURE Claims should be submitted quoting the following applicable codes Front Doors for Jaguar Sovereign models Complaint code R H door 8BGN L H door 8EGN S R O 76 92 01 Labour time allowance is 0 95 hours Front Doors for Daimler VDP models E Complaint code R H door 8BGN L H door 8EGN S R O 76 92 01 50 Labour time allowance is 1 00 hours Boot Lock barrel repair All models Complaint code 9DKN S R O 76 92 02 Labour time allowance is 0 55 hours APPENDIX A Tibbe Front Door Lock Repair Kits Part Numbers JLM 2039 Right hand door lock repair kit JLM 2040 Left hand door lock repair kit Jaguar Cars Limited 2005 16 JAGUAR ISSUE 2 JD 06 90 Kit Contents DOT o ARELARO o DT SERPRO O DOS o SAR DO a QUANTITY i DOE Ds DT O SERRO ET BUSHCINKAGE ROD RETAINER RR RS O RETURN SANS a DE DRT TOA PLASTIC
40. eption of the RDS data due to ve hicle moving out of transmitter range or loss of signal owing to being in a tunnel under a garage forecourt canopy or similar shielding If the latter is the case wait until the vehicle is clear of the shielding then retune to the original station There is a 45 second delay before retuning occurs The radio cannot find six FM stations or if RDS is selected the radio cannot find six RDS FM sta tions Similarly if TP has been selected then the radio is unable to find RDS stations providing traffic information If this occurs switch off the TP function The station selected does not have traffic informa tion facility and will retune to one that does If it cannot find one it will automatically switch off TP mode and retune to the original station This means until many more stations have RDS TP ser vices it may not be possible to listen to a chosen Station and receive traffic news when in radio mode The signal of the station selected has become too weak to receive the TP identification data The radio will retune to another TP station If none available the radio will turn off TP function Radio cannot find any stations Allow the radio to make two full sweeps of the wave band If it con tinues to search check that the aerial cable is plugged in at radio and aerial connections Check that the RDS button has not been acciden tally pressed during the last 45 second TP indica tor will show
41. ervice Manual Part Number JJM 10 0406 Vol ume 3 Section 70 and in XJ6 Service Manual Part Numbers JJM 10 04 05 90 Eng lish JJM 11 04 05 40 French JJM 12 04 05 40 Dutch JJM 13 04 05 40 German JJM 14 04 05 40 Italian JJM 15 04 05 40 Spanish JJM 17 04 05 40 Japanese Volume 3 Section 70 NOTE All pressures are quoted in bar Pressure Switch Upper Switching Point Lower Switching Point Pump Stops Running Pump Starts Running as Pressure Drops Warning Switches NOTE The following pressures are measured by reducing pressure from a fully charged system This can be achieved by operating the brake pedal several times with the pump motor power supply disconnected Post 90 MY Low Post 90 MY ABS Pressure Warning Warning Switch Switch W 5 1 W S 2 Maximum Nominal s 0 o 8 Minimum 98 0 88 0 8 NOTE Only one set of pressures exist for the pre 90 MY switch assembly the low pressure warning LPW and ABS warning acting simultaneously The slight delay of the ABS warning behind the LPW is caused by the ABS electronic control unit ECU Pre 90 MY Pressures not identified on the charts are those for the warning lights to extinguish during charge up of the system These pressures should be no greater than their warning illumination pressure shown in the chart plus 30 bar e g if W S 1 operates at 105 bar as pressure is reduced the same switch may not operate until 135 bar is reached
42. es ITEM 27 57 PAS STEERING RACK MOUNTING BUSHES XJS 3 6 SPORTS PACK The steering rack and pinion mounting bushes fitted to XJS 3 6 vehicles with sports pack suspension are secured in position with Loctite 601 Service Tool 18G 1324 should still be used to remove and refit them When fitting new bushes use Loctite 601 refer to the manufacturer s guide lines for application instructions ITEM 28 66 RIDE HEIGHT SENSOR XJ6 2 9 3 6 To improve reliability and reduce quiescent current drain levels a new ride height sensor Part No DBC 3439 incorporating CMOS technology has been introduced from VIN 523301 The new sensor is fully interchangeable with the previous PMOS type sensor Part No ITEM 29 74 TYRE REPAIR ALL MODELS Due to differing legislative requirements concerning the repair of tyres in all markets and the various make type of tyres being fitted to Jaguar vehicles the following statement will be incorporated in all handbooks and service literature lt is recommended that damaged tyres are replaced and not repaired in view of the high performance capability of the vehicle ITEM 30 76 BONNET CHASSIS EARTH XJ6 2 9 3 6 To ensure a good earth exists between the bonnet and the vehicle chassis an earth braid strap has been introduced from VIN 523964 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 05 88 SHEET 2 of 3 The earth strap which is fitted between the LH bonnet hinge and the vehicle ch
43. ff Diode AAU 5034 D Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 85 Sheet 3 of 3 MODIFICATION PROCEDURE e Disconnect the battery Remove the passenger side A post lower trim panel to expose the lower bulkhead 2 door harness See Fig 1 Passenger side RHD is shown LHD is symmetrically opposite FIG 1 JS1 281 CA Locate the interior door switch purple white PW cable and cut 4 Fit insulations sleeves C Fig 2 and crimp solder Lucar connector A and B Fig 2 to the purple white PW cable Connect diode unit D Fig 2 in circuit and strap or tape to the harness FIG 2 5 Refit the A post lower trim panel and reconnect the battery Jaguar Cars Limited 2005 ITEM 11 IGNITION COIL S 111 4 2 To improve the ignition performance on S Ill 4 2 Models a new Ducellier coil with ballast resistor together with a modified amplifier and engine harness have been introduced from Engine No 8L 173271 Interchangeability with the previous ignition system is affected Jaguar Cars Limited 2005 aa JAGUAR aimler Service Bulletin Date JUNE 1985 Sheet 1 of 1 Bulletin JD 06 85 ITEM 42 57 OIL FILLED P A S RACKS S I XJS Power assisted steering racks are now oil filled by the supplier with Shell Spirax EP 80 oii This has replaced the Shell Retinax A grease fill Racks to this condition were introduced on Jaguar production at the following VIN s 426768 S lll 12
44. from VIN 425848 Jaguar Cars Limited Jaguar Cars Limited 2005 ITEM 45 ELECTRIC DOOR MIRRORS S 11 XJS HE XJ 3 6 MODELS A number of electric door mirrors returned under warranty as being inoperative have been found to have only the mirror glass section detached from one or more of the motor drive levers By simply relocating and securing the detached levers the mirror operation has been returned to normal This candition is most evident on export models where the fuse controlling the mirror circuit has been removed for transit purposes and manual adjustment of the mirror glass has caused the detachment If when investigating inoperative electric door mirrors it is found that the mirror glass has become detached it can easily be replaced using the following procedure Align the three ball end operating arms A Fig 1 with the three sockets on the mirror glass B Fig 1 and push each one fully home in the numbered sequence 1 2 3 Fig 1 JSI 376 FIG 1 Jaguar Cars Limited 2005 E Service Bulletin JAGUAR a imies Date November 1985 Sheet l of 8 Bulletin JD 11 85 ITEM 75 03 FUEL AND IGNITION SYSTEM REPAIR TIMES S III V12 XJS V12 The following repair times have been published for 12 cyl engined vehicles following the production fitment and retrospective fitment of the restyled fuel system Where new numbers have been issued insert the relevant descriptions and repair times into the rep
45. g tool bearing an 18G number then the new part will be JD e g JD 119 ITEM 89 BODY SEALING AND PRESERVATION MANUAL AKM 9137 ALL MODELS In the recently published English language copy of the above manual the trading title of a company supplying wax injection equipment was quoted incorrectly Please note and amend your copy as follows Page 23 2 SATA HKD 1 Supplier Minden Industrial Newmarket Road Bury St Edmunds Suffolk IP33 3TS Telephone No 0284 3418 Jaguar Cars Limited 2005 E JAGUAR DATE MARCH 1988 SHEET tof3 BULLETIN JD 05 88 Service Bulletin ITEM 26 09 USED ENGINE OILS ALL MODELS The Society of Motor Manufacturers and Traders having set up a working group reporting to the Car and General Technical Board have advised motor vehicle manufacturers to disseminate the following information on used engine oils Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitis In addition used engine oil contains potentially harmful contaminants which may cause skin cancer Adequate means of skin protection and washing facilities should be provided Health Protection Precautions 1 Avoid prolonged and repeated contact with oils particularly used engine oils Wear protective clothing including impervious gloves where practicable 2 3 Do not put oily rags in pockets 4 Avoid contaminating clot
46. he end of this Bulletin and are clearly identi fied as issue 2 Oo Would Service Personnel concerned please remove and destroy the original copies and replace them with the amended pages XJ6 2 9 3 6 amp 4 0 ITEM 31 00 POLICY ITEMS COMPLAINT CODES GEARBOX LINEAR ROTARY SWITCHES Investigation into recent warranty claims for gear selector linear switch XJ6 2 9 and rotary switch XJ6 4 0 problems have been confused as a result of dealers using the incorrect warranty codes Note for XJ6 2 9 and 3 6 litre gear selector linear switch problems use 7HX for XJ6 4 0 litre rotary switch problems use 4GH XJS SIII ITEM 32 57 PAS STEERING RACK MOUNTING BUSHES Service tooling JD 165 has been introduced to aid replacement of the steering rack assembly mounting bushes fitted to XJS and SIII models The tooling eliminates the need for rack removal in performing this task The tooling is shown in Fig 1 Standard mounting bushes can be removed and re placed using tooling items 1 2 and 3 Sport mounting bushes fitted to some XJS mo dels are removed using tooling item 4 in conjunction with items 1 and 2 amp Sport type mounting bushes can be identified by their steel faced thrust washers Standard mounting bushes are fitted in conjunction with rubber faced thrust washers Jaguar Cars Limited Jaguar Cars Limited 2005 joss JD 07 90 JAGUAR 2 357 227 FIG 1 PROCEDURE Raise and support the front of
47. hes particularly underpants with oil Overalis must be cleaned regularly Discard unwashable clothing and oil E First Aid treatment should be obtained immediately for open cuts or wounds O 7 Use barrier creams applying before each work period to help the removal of oil from the skin 8 Wash with soap and water to ensure all oil is removed skin cleaners and nail brushes will help Preparations containing lanolin replace the natural skin oils which have been removed 9 Do not use petrol kerosine diesel fuel gas oil thinners or solvents for washing skin obtat scticatadyvi 4 mich a ab so a ea plo un f E A UC GSYO pA 11 Where practicable degrease components prior to handling 12 Where there is risk of eye contact eye protection shouid be worn for example chemical goggles or face shields In addition an eye wash facility should be provided Jaguar Cars Limited Jaguar Cars Limited 2005 Environmental Protection Precautions It is illegal to pour used oil on to the ground down sewers or drains or into water courses The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is fitted in cases of doubt check with the Local Authority Dispose of used oil through authorised waste disposal contractors licensed waste disposal sites or to the waste oil reclamation trade If in doubt contact the Local Authority for advice on disposal faciliti
48. hten the bolt to draw the mounting bush into the tool body Fig 3 Repeat the procedure for the remaining bushes y N a oe A A Er aS G E Q REMOVAL OF SPORT MOUNTING BUSHES FIG 3 Assemble tool items 1 and 2 to either end of the sport bush removal tool item 4 Position the tooling between the lower sport mounting bushes locate the tool diam eters to the mounting bush and mounting bush housing Supporting the tool turn the nut clockwise to jack the bush outward Fig 4 Care and discretion should be exercised regarding the stresses exerted during bush removal Remove the bush rotate the tooling and repeat the procedure for the remaining sport bush Note sport bushes are only fitted at the lower mounting positions Jaguar Cars Limited 2005 JD 07 90 JAGUAR 157 229 FIG 4 REFITTING MOUNTING BUSHES ean mounting dus ousings ana crossbeam MOUNTING iocans Note sport mounting bushes are to be secured in position with Loctite 601 Clean the outside diameter of these bushes prior to application Position tool item 2 to the inside face of the bush housing Position and align mounting bush to the outside face of the bush housing Fit tool item 1 pass the draw boit through the assembly and fit the pillar nut Tighten the draw boit to fully seat the bush into housing Fig 5 Repeat the procedure for the remaining bushes TO A E J AS ae FIG
49. is problem a modified boot lid lock finisher plinth has been introduced on all XJ6 models built from VIN 616664 The new plinth finisher incorporates water drainage cut outs on its lower edge as shown in Fig 1 a5 1266 FIG 1 To rectify cars built prior to the above VIN which exhibit this problem the following rectification procedure should be employed to allow excess water to drain from the boot plinth finisher Procedure for Providing Water Drainage from Boot Plinth Finisher 1 Open the boot lid and remove the chromed plinth finisher and its rubber mount ing gasket 2 Using a suitable block of e wood placed on a work LN bench place the rubber gasket on to the block see Fig 2 3 Measure from the gasket centre line a dimension of 50 mm in each direction along the bottom edge of the rubber gasket then using a 5mm hole punch and ball pien hammer cut Sao out holes at the 2 x 50 mm Es measured positions on the gasket see Fig 2 FIG 2 4 Refit the plinth and the gasket onto boot lid Warranty claims may be submitted where appropriate quoting S R O 76 91 47 Time allowance 0 20 hrs Fault Code 9FBJ XJ6 2 9 amp 4 0 ITEM 27 76 TIBBE KEY AND LOCK INTRODUCTION Monitoring during the period since the introduction of the Tibbe locking system has identified that the procedure for the repair replacement of the Tibbe locks should be clarified Jaguar Cars Limited 2005 10 Re J
50. modified power steering pump drive dog on the AJ6 engine necessitates a new steering pump dog remover The existing tool 18G 1445 is still required for replacing the drive dog The new remover tool is JD 119 and should be used in conjunction with 18G 1445 ELECTRICALLY OPERATED SUNROOF XJS With the introduction of the optional glass electric sunshine roof two pilot plate alignment keys will be required to align the pilot plates after repairs These keys are now available through V L Churchill or agents and are numbered JD 113 OERLIKON CUT GEARS S III XJS Jaguar Cars are progressively introducing Salisbury axles with Oerlikon cut gears for the XJS and S III range of vehicles The ratios affected are the 2 88 and the 3 06 Identification of axle units containing Oerlikon cut gears is by a white O painted on the axle cover When overhauling these axle units a new pinion height setting button will be required This new tool is now available from V L Churchill or agents and numbered SL3 2 All the above tools are mandatory minimum standard tools and wiil be added to the Service Minimum Standards List at the next issue Jag ar Gars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 8 of 8 99 It is Jaguar policy to issue all new tools with a Jaguar Part Number JD Where a tool is modified e g 18G 1468 it will be issued in modified form from V L Churchill bearing a new JD number Where a tool accessory is developed to a existin
51. n the latest condition screens the vertical hotline busbar has been repositioned to avoid possible contact with sealants or trim finishers To identify whether a replacement screen is to the latest condition measure the distance between the vertical busbar and the edge of the screen Early condition will be 16 mm later condition will be 28 mm Dealers who use subcontract screen repairers should inform them of these changes Failure to do so may result in the rejection of any subsequent warranty claims ITEM 86 IGNITION AMPLIFIER S IIl V12 XJS V12 Reports in Service of an intermittent misfire have been traced to a faulty connector in the ignition amplifier to fuel injection ECU harness The connector in question is a single bullet type Fig 1 located adjacent to the ignition amplifier connecting the white slate wire from the ignition amplifier to the white wire from the fuel jinjecddomitdaGdes To prevent any further incidences of this problem occurring a new type of posi lock connector has been introduced from VINs 438567 S III 127026 XJS JSI 441 FIG 1 KEY A Ignition amplifier B White slate wire C White wire D To ECU ITEM 87 86 CRUISE CONTROL S III V12 XJS V12 It has been brought to Jaguar Cars Ltd attention that the Econocruise after market Cruise Control System is affected by the current modification to the V12 engine fuel rail The following text is an extract from an Econcruise Service Bulletin
52. o will search out the strongest signal available and auto matically switch frequencies as necessary To broadcast FM radio services throughout the UK the BBC uses over 100 trans mitters and 22 different frequencies So as you travel you move out of range of one transmitter into the influence of another Without RDS the driver on a long journey has to retune manually several times with the Jaguar RDS radio system retuning is automatic RDS Travel Service Although there is a wide range of travel information available from National and Local Radio a driver only requires traffic information relevant to the locality RDS provides this precise information automatically As soon as the authorities learn of a traffic problem they inform the nearest local radio station who then signalthe BBC andIBA central computers The traffic news is then re broadcast by the BBC or IBA trans mitters inthe relevant area This broadcast will interrupt a radio programme cassette tape or CD play on all radios with the RDS feature provided Traffic Programme TP has been selected When the traffic news flash is over the system automatically switches back to the driver s original listening choice Jaguar Cars Limited 2005 JD 03 91 JAGUAR RDS Operation 1 Toactivate pressthe RDS button onthe radio and hold for at least 2 seconds when a beep will be heard and a red light will show on the button The radio then gathers RDS information and display
53. on display Radio keeps searching for another station but returns to original station selected Radio retunes to another station even though station was previ ously an RDS station Upon operating the A Mem most or all of the presets display No FM when pressed Upon pressing the TP button the radio retunesto another sta tion Whilst in TP mode the radio re tunes Radio is searching for a station continuously Radio starts retuning Jaguar Cars Limited 2005 88 88 JD 03 91 cua XJ6 2 9 3 6 ITEM 26 FUEL TANK ELEMENT Fuel tank element DBC 4735 has been superseded by DBC 10284 for all XJ6 models up to the introduction of 1991 MY The change has been required because of a ra tionalisation of terminal housing mouldings introduced by the supplier Interchangeability is unaffected DBC 10284 will become effective when stock of DBC 4735 held by Parts Operations is exhausted XJS CONVERTIBLE ITEM 27 FUEL TANK ELEMENT Owing to supplier tooling modifications minor changes have been required to the fuel tank sender unit resulting in Part No DAC 10183 superseding Part No DAC 6103 as arunning change during 1990 MY Fuel tank assemblies equipped with the latest element are identified by a red spot on the rear face of the sender unit Part No DAC 10183 is fully interchang
54. ontact with the seatcloth The effect is further enhanced by fibres from occupants clothing combining with these surplus seat cloth fibres To re address this issue Jaguar in conjunction with the supplier of the seat fabric is developing a shorter woven fibre which should not exhibit fibre migration The in troduction of this modified cloth will be indicated in a future Service Bulletin issue Jaguar Cars Limited 2005 gt JD 03 91 JAGUAR 82 During the intervening period up to the introduction of this modified cloth all seat covers identified as suffering from balling pilling should have these fibres re moved by carrying out the following rectification 1 Remove all visible loose fibres from the seat covers by hand 2 Clean Jaguar covers using Jaguar cloth upholstery cleaning agent available through Parts Operations Follow the directions for use as shown on the cleaning agent dispenser Part No JLM 9870 refers N B DO NOT REPLACE SEAT COVERS TO OVERCOME BALLING PILLING XJS XJ6 ITEM 24 AIR CONDITIONING CONDENSATE DRAIN TUBES Should water appear in the footwells of vehicles within the following Vin range XJ6 553357 to 611400 and XJS 145000 to 169700 then the following modification may be carried out NOTE The tool to carry out this modification is JD 178 Condensate Drain Hole Tool The tool consists of two parts an oilite bush which acts as a guide for the burr which is used as the cu
55. plied in the kit should be applied to each face of these parts Jaguar Cars Limited 2005 13 A JD 06 90 JAGUAR 3 The single spring spacer should be fitted between the last two discs in stalled into the lock barrel C Fig 5 4 Align discs and spacers so that the steel rolier locates into the lock barrel A and B Fig 5 5 Lubricate and fit new shutter assem bly from kit into door handle Lubri cate and fit steel roller into lock barrel A Fig 5 Fit the lock barrel assembly into the lock housing 6 Refit the lock barre retention circlip Reassemble lock using new parts as supplied in the parts kit FIG 5 p A Es NA k f 2 4 7 Finally check that the disc E AS assembly is correct by r VE viewing the disc assem C i E bly at the position shown 3 N p Fi E 1 NM E s A in Fig 6 2 Y E 351 1254 NOTE This check can also be employed to identify the key cut code on all XJ6 ve e hicles fitted with Tibbe locks 8 Test the lock for correct operation using the key Refit the door lock handle into the door and test the lock latching function Repairing Replacing Boot Lock Applying the procedure outlined in Service Repair Operation 76 19 19 remove boot lock barrel assembly from its housing Discard this lock barrel after checking thatthe es 114 Ill 8 DOCKING mn a ale da Method for Assembly of New Lock Barre 1 Using kit JLM 2042 arr
56. pproximately 15 degrees rearwards ITEM 10 DOOR POCKET WARNING LAMPS S HMI JAGUAR VDP amp SOVEREIGN ONLY During the winter period especially in markets where the ambient temperatures are particularly severe it is possible for the electric aerial mast to freeze temporarily Isolated incidences have been reported of the main circuit fuse blowing through the aerial operation being impaired Should this occur it is possible for the door casing puddle lamps to illuminate with the doors closed and in some cases due to the problem going unnoticed can result in the battery discharging when the vehicle is parked Through subsequent investigations the cause has been traced to a feed back circuit developing through the interior fight circuit which is also protected by the same fuse Jink Fuse No 3 Main Fuse Box LHD Fuse No 13 Auxiliary Fuse Box RHD To prevent this involuntary illumination and possible battery discharge modified bulkhead harnesses incorporating diode protection on the interior light circuit will shortly be introduced Introductory VINs will be issued in a further Service Bulletin However should this problem be encountered on vehicles already in Service the following modification may be implemented Labour allowance 0 45 hrs Complaint Code 7K7S PARTS REQUIRED Description Part No Code see Fig 2 1 off Lucar Connector GHF 2051 A 1 off Lucar Connector GHF 2060 B 2 off Lucar Insulation Sleeve GHF 2151 C 1 o
57. rs HOSE REPLACEMENT When engine bay hose connections which incorporate clip EAC 3215 2 are disconnected then the subject length of hose must be replaced with a new hose assembly and a new clip Under no circumstances should the original hose be refitted The hose assemblies affected are as follows CBC 2179 Underfloor pipe to valance EAC 7938 Pressure regulator to cooler CAC 5868 Cooler to return pipe INJECTOR PART NUMBERS The part numbers for the new injectors are EAC 7874 Injector hose assembly short EAC 7875 Injector hose assembly long EAC 7876 Collar Jaguar Cars Limited 2005 19 34 27 EMISSION CONTROL SYSTEM USA SIII As part of an exercise aimed at improving the consistancy of CO readings on vehicles supplied to the West Coast on the USA vehicles destined for Los Angeles have had the carbon cannister to the fuel tank venting system disconnected at the connection under the RH wheel arch The carbon cannisters have been disconnected at the RH wheel arch from the following VIN s Track 1 436732 Track 2 436841 Therefore between the above VIN s a mixed condition may exist however after VIN 436841 all vehicles arriving at Los Angeles will be disconnected During the vehicles PDI the flexible breather pipe situated to the rear of the front right hand wheel arch must be connected to the steel bundy pipe It is important that if a blanking cap is fitted to the vent pipe then this m
58. s the Programme Service name in place of the frequency provided the programme chosen is an RDS station If it is not an RDS station the radio will automatically retune to the strongest RDS station it can find 2 To select Traffic Programme press the RDS momentarily TP will appear on the display Ifthe radio is not tuned to an FM station with RDS traffic information it will search for one that is If no RDS TP station is within range the TP mode will cancel and the TP indicator will disappear from the display RDS Traffic Programme Stations At the present time only a few RDS stations carry the Traffic Information facility How ever an increasing number of RDS stations are being equipped to provide TP data The existing RDS TP stations are BBC Radio Stations IBA Radio Stations Radio West Midlands Power FM Southampton Greater London Radio Key 103 Manchester Radio Bedfordshire L B C London Radio Kent Radio Essex Auto Memory A Mem In normal operation the Auto Memory A Mem will programme the six strongest stations on the selected wave band into the presets 1 to 6 When RDS is selected and the A Mem function operated the radio will programme the six strongest RDS sta tions into the presets If there are less than six RDS stations in range the latter of the presets will display No FM Similarly if TP is used with A Mem activated the radio will only programme the six strongest RDS stations carrying traffic inform
59. the vehicle Turn the ignition key to prevent steering lock engagement Position adhesive tape along the top edge of the steering column upper cowl and along the steering wheel boss Apply and shape a smaH amount of plasticine to the shoulder of the steering rack cen tralising pin 18G1466 This will prevent oil loss when the pin is fitted Remove the centralising pin access plug from the steering rack and insert the pin With help from another person rotate the steering wheel until the pin is fully engaged Fig 2 Mark the position of the steering wheel on the adhesive tape Remove the pin and refit the access plug FIG 2 Remove the securing nut and bolt from the steering column lower universal joint On catalyst vehicles space is extremely confined Release the joint from the steering rack Jaguar Cars Limited 2005 i JD 07 90 JAGUAR Undo and remove the rack to crossbeam lower and upper securing nuts and bolts Displace and remove the rack heatshields as necessary Remove the non pinion side mounting bush to crossbeam shims and lower the rack assembly Remove and discard the rubber faced thrust washers of the standard lower mounting bushes REMOVAL OF STANDARD MOUNTING BUSHES Position tool body item 3 to the inside face of the mounting bush housing Insert the draw bolt through the too body and mounting bush Fit tool item 1 washer and pillar nut to the outer face of the mounting bush Tig
60. tractor assemblies The outboard buckle and strap assemblies are as used on the XJ6 2 9 4 0 but with unique belt lengths The N centre lap belt and buckle is now joined with the out board buckle and strap as FIG 2 semblies to form a single mounting plate see Fig 2 Note that the position of the mounting plate is inverted on the XJ6 to that shown on Fig 2 NOTE Torque tightening values are unchanged at Front seat belts 24 to 28 Ibf ft Rear outboard seat belts 18 to 20 Ibf ft Rear centre bulkhead belts 18 to 22 Ibf ft XJS COUPE amp CONVERTIBLE ITEM 22 REPAIR OPERATION TIMES The following repair time amendments and additions should be made to Repair Operation Times supplement Issue 2 76 81 11 Heated Backlight Renew 12 cylinder 6 cylinder coupe columns 165797 on should read 1 65 hrs not 1 40 hrs Both convertible columns for this S R O should read N A New repair operation 76 81 11 70 As 76 81 11 Convertible only A time of 1 05 hrs should be inserted in both convertible columns for this S R O No other repair times are affected Jaguar Cars Limited 2005 Kens 12 JAGUAR ISSUE 2 JD 06 90 CURRENT XJS amp XJ40 ITEM 23 TEVES BRAKE SYSTEMS TEST PRESSURES The following are the correct reference pressures to be used whilst checking the op erating pressures of the brake system with the Jaguar Power Hydraulic Test Kit They replace the pressures quoted in XJS S
61. tting tool XJ6 Remove the driver s side dash liner 2 Remove the passenger s side dash liner 3 Undo and remove the footwell vent securing screws and remove the foot well vents 4 Reposition the carpet from the trans mission tunnel for access to the drain tube 5 Remove the drain tube assembly 1 Fig 1 from the aircon drain stub pipe 2 Fig 1 6 Fully seat the cutting tool guide to the air con stub pipe 3 Fig 1 FIG 1 JS11447 7 Using the 6mm cutting tool carefully cut a hole in the air con baffle plate 8 Remove the tool guide 9 Clean the stub pipe 10 Fully seat the drain tube to the air con stub pipe 11 Reposition the transmission tunne carpet 12 Repeat the above procedure for the other side 13 Fit and align the footwell vents 14 Fit and tighten the securing screws 15 Refit the dash liners Jaguar Cars Limited 2005 JD 03 91 JAGUAR XJS p 10 Th TZ 1a 14 15 16 17 18 12 20 21 22 Remove the driver s side dash liner Remove the passenger s side dash liner Undo and remove the console side casing vent screws Remove the vents and side casings Remove the aircon unit outlet duct se curing screws and remove the duct Reposition the carpet from the trans mission tunnel for access to the drain tube Reposition the vehicle harness for ac cess FIG 2 Displace the drain tube from the trans mission tunnel grommet
62. ust be removed prior to connection mm JSI 241 ITEM 80 TRANSMISSION OIL COOLER PIPES S III V12 XJS V12 To improve the integrity of the transmission oil cooling circuit revised oil cooler pipes have been introduced on V12 Models from VIN s 435665 S III 126093 XJS The radiator cooler and the transmission unit have also been modified to accommodate the revised pipes which now incorporate screw connector fittings Further details and part numbers wiil be advised when parts are available ITEM 81 P A S PUMP DRIVE XJ S 3 6 XJ SC 3 6 To improve the power steering pump drive durability on 3 6 models a revised drive arrangement illustrated in Fig 1 has been introduced from engine number 9D 102539 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 11 85 SHEET 4 of 8 JST439 FIG 1 Part numbers are as follows A Pump Driving Dog EAC 7081 B Coupling EAC 7107 C Setscrew SX 108255 J D Washer FW LOSE E Auxiliary Shaft Driving Dog EAC 7080 F Pins 2 off EAC 7643 The engine auxiliary shaft has been modified to accommodate the new driving dog As a result these new components are not interchangeable with engines built prior to the above number When replacement engines are supplied with the later type auxiliary shaft Part No EAC 6747 and drive dog fitted the P A S pump should be modified by fitting the later type drive dog A Fig 1 using Service Tool 18G 1445 ITEM 82 76 KIEKERT LOCKING S III Amendment
63. w coated with Shell Retinax A grease This was introduced at VIN Nos 411159 SM 119708 XJS ITEM 07 AUTOMATIC REAR SEAT BELTS XJS AUSTRALIA All XJS vehicles landed in Australia after January 1st 1985 will incorporate 3 point inertia reel rear seat belts ITEM 08 AIR CONDITIONING SERVO UNIT S 111 XJS HE XJ S 3 6 XJ SC 3 6 Further to Service Bulletin JD 11 84 Item 85 Reference Step 3 To prevent excessively low pressure being generated in the air conditioning system under certain operating conditions the servo motor unit Ranco override function has now been deleted Units to the modified condition were introduced from VINs 411931 S HI 120267 XJS HE XJ S 3 6 XJ SC 3 6 Jaguar Cars Limited 2005 82 86 ITEM 09 RECEIVER DRIER S 111 4 2 AIR CON MODELS ONLY To improve the efficiency of the Receiver Drier the Drier has been repositioned to enable maximum refrigerant flow through the internal pick up pipe This repositioning has resulted in the sight glass now being on the left hand side and in the vertical position This change was introduced at VIN 412060 When fitting replacement Receiver Drier Bottles on Series III 4 2 Models prior to the above VIN the Receiver Drier should be fitted as described above The fitment of the Receiver Drier Bottle CAC 1881 on Series III 5 3 XJS HE and XJS 3 6 Models remains unchanged i e the Drier mounted with the sight glass on the right hand side and the sight glass angled a

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