Service - Terry`s Jaguar Parts
Contents
1. 34 76 aimler DATE MARCH 1994 PAGE 1 OF 2 REF JD 20 94 XJS ALL 4 0 amp 6 0 LITRE ITEM 20 AUTOMATIC TRANSMISSION GEAR SELECTOR CABLE ADJUSTMENT From VIN 192487 the setting procedure in manufacture has been revised The Service Manual setting procedure will remain unchanged XJ6 amp XT12 1994 MY FROM VIN 703024 ITEM 21 SLIDING ROOF DELETION OF MANUAL OPERATION HANDLE From the above VIN a manual operation Key is no longer supplied with each vehicle clipped to the rear of the roof console panel It is therefore recommended that all Dealers should keep handy a spare handle for emergency use in their workshop together with a small stock in their Parts Department for those customers who may wish to purchase a handle as an accessory In the event of a malfunction of the powered operation where no key is carried on the vehicle with a sunroof sliding panel partly or fully open the sliding panel may be closed as follows using a wide blade screwdriver and a pair of long nose pliers Release the turn screw of the roof console panel through a quarter turn slide the console panel rearwards to disengage the clips from the location tags Insert the blade of the screwdriver into the slot of the drive mechanism rotate the slot in the desired direction of travel as indicated by arrows on the surround plate through approximately 1 4 revolution until resistance is felt With long nose pliers on the rim of the cam2. a SS JAGUA DATE MARCH 1993 PAGE 1 of 9 REF JD 05 93 ERRATA WITH REFERENCE TO SERVICE BULLETIN JD 17 92 PLEASE NOTE THAT THE WAR RANTY COMPLAINT CODE SHOWN ON PAGE 2 AS 1LBK IS INCORRECT THIS CODE SHOULD READ iLKB V12 AND AJ6 ENGINES ITEM 01 12 INTRODUCTION OF GRADED CRANKSHAFT BEARINGS As part of Jaguar s on going commitment to improving quality three grades sizes of crank pin and journal bearings have been introduced on ail production V12 and AJ6 engines This will improve engine and vehicle refinement by reducing the maximum crank running clearances by approximately 20 Graded bearings were introduced on production from the following engine numbers V12 XJS 85 86817 V12 Series Ill 7P 76912 6 0 JaguarSport TBA 3 2 9B 111574 4 0 9E 9W 164637 6 0 litre JaguarSport engines will use the grading system when a common crank shaft is used for both JaguarSport and Jaguar 6 0 litre engines The three different grade diameters of the journals and pins are represented by a letter which corresponds to a colour i e P equals Pink R equals Red etc The grade of each individual journal and pin on each crankshaft is identified by having the grading diameter colour stamped on the No 1 balance weight indicating the grade of shell to be fitted as follows Jaguar Ca rs Limited Jaguar Cars Limited 2005 JD 05 93 JAGUAR V12 AJ6 A F indicates front A F Indicates front B Journals 1 to 7 B Journal
3. Process improvements and improved component quality now render the continued use of Barrs Leak unnecessary Mote On vehicles prior to the following VIN s Barrs Leak radiator leak sealer should stil be used XJ6 Models VIN 670522 XJS Models VIN 186210 XJ6 92 MY ITEM 05 FINAL DRIVE UNIT VIN range 665838 to 667716 A number of vehicles within the above VIN range have been fitted with an alternative final drive unit The current and alternative units can be distinguished by the number of boits in the output shaft seal housing five in the current final drive unit and three in the alternative The alternative final drive will not be supported with spare parts until mid 1993 therefore should there be any service concerns Jaguar Parts Oper ations will only supply the current final drive units To complete the repair it wiil be necessary to fit the appropriate speed sensor bracket For final drive unit part numbers EBC 10910 1 2 3 and EBC 10911 1 2 3 fit speed sen sor bracket EBC 9820 identified by a blue paint spot For all other final drive unit part numbers fit speed sensor bracket CAC 9884 FUN EDEM NGN Pitlo CUPS EN LION fLi0 XJ6 1991 MY 1993 MY ITEM 06 BATTERY QUIESCENT DRAIN INFORMATION To enable Jaguar Dealers and their technicians to keep abreast of both past and pres ent quiescent drain specifications the following information covers the vehicle range over the last three years METHOD OF MEASUREME
4. edge Ensure that on a vehicle being prepared for the customer that the carpet has remained correctly fitted during the delivery cycle Items 3 5 above should also be observed when refitting a carpet or when fitting a replacement carpet Figs 1 Jaguar Cars Limited 2005 JD 07 94 JAGUAR FURTHER IMPROVEMENT TO 1994 MY VEHICLES FROM VIN 698000 From the above VIN the rear edges of both Driver s and Passenger s side carpets are similarly retained by flat plastic strips Item A Fig 2 engaging in brackets on the front of the seat ECU covers Item C Fig 2 In addition a strip of VELCRO fastening Item D Fig 2 is fitted to the outer ends of both carpets with a corres ponding strip fitted to both ECU covers Item E Fig 2 thus providing additional security to the footwell carpet location CARPET FITTING PROCEDURE During final preparation of a new vehicle or when refitting a carpet or fitting a replacement carpet the procedure outlined previously should be observed In addition however ensure that the VELCRO strips Item E Fig 2 at the outer edges of both front carpets are fully engaged to the corresponding strips on the ECU covers after having correctly located the plastic retaining strips to the brackets and aligned each carpet within its footwell Fig 2 Jaguar Cars Limited 2005 MODEL CUSTOMER CONCERN ADVICE TO CUSTOMER DEALER ACTION REPAIR METHOD CS JAGUAR
5. piate surrounding the motor drive pull down on the cam plate until it is released and springs downwards through a short distance while slightly oscillating the screwdriver to assist release This action disengages the cam ring and mechanism from the motor drive Jaguar Cars Limited Jaguar Cars Limited 2005 RT JAGUAR T JD 20 94 JACXIAR Continue to hold the cam plate down against light spring pressure with the pliers while simultaneously rotating the drive mechan ism by means of the screwdriver As the drive and surrounding cam plate are engaged to each other by detents but tending to separate under spring action it is necessary to maintain the downward force on the cam plate by the pliers which must there fore be rotated as the screwdriver is rotated With the sliding panel fully closed remove the pliers Rotate the drive mechanism by means of the screwdriver in the opposite direction to that used above after approximately 1 4 turn with the slot aligned to the two detents in the cam plate the cam ring will return to its original location This action re engages the mechanism to the motor drive It may be found impracticable in the method described above to exert the force necessary to complete the normal actions of the sliding roof mechanism which after closure of the sliding panel raise and lock the panel against the surrounding fixed roof The above method should however enable
6. the cylinder head of an AJ6 engine has been removed in the course of a Service Repair Operation it may be noticed that a certain amount of erosion to the cylinder head face has occurred around the coolant passages of the cylinder head forming irregular cavities Provided that the eroded area condition C Fig 1 does NOT extend into the area occupied by any firing ring Item A Fig 1 of the head gasket using a head gasket as a template a repair can be effected and there is no need to replace the cylirder head Where erosion has resulted in the formation of cavities in less critical areas around the coolant passages condition D Fig 1 repair of the cylinder head should be undertaken Careful filling of the cavities to restore the cylirder head face to its original surface profile may be undertaken by means of a proprietary Plastic Metal eg BELZONA A suitable product will be available shortly from Jaguar Parts Operations under Part No JIM 11719 IMPORTANT CYLINDER HEADS SHOULD NOT BE REMOVED TO LOOK FOR THIS CONDITICN THE ABOVE ACTION SHOULD ONLY BE NECESSARY WHEN THE CONDITION IS NOTICED ON REMOVAL OF A CYLINDER HEAD FOR OTHER REPATR WORK 2 Jaguar Cars Limited 2005 JD 07 94 JACAR TECHNICAL BACKGROUND On engines prior to VIN 677386 XJ6 and VIN 187554 XIS the foundry practices involved in the manufacture of the cylinder head and the cylinder block resulted in elongated cored coolant passages at the up
7. the sliding roof to be closed to a position wnich will provide a weatherproof and secure condition for the vehicle until the malfunction can be traced and rectified For the same reasons it may be found impossible to open a sliding roof panel from the fully closed position by the method outlined above Spare handles for manual operation of the sliding roof panel are available via Jaguar Parts Operations under Part No BBC 8355 Jaguar Cars Limited 2005 03 12 ANS JAGUAR Taimler DATE PAGE 1 OF 4 REF JD 27 94 XJG amp AJI2 1993 MY VIN 667579 CONWARDS ITEM 23 LEFT HAND DRIVE MODELS ONLY REPAIR OPERATION TIMES AMENDMENTS Ihe following Repair Operation Times are amended They are applicable to Left Hand Drive models only on which it is necessary to lower the steering column from its mountings to permit removal of the heater matrix Please amend your Repair Operation Time Schedule accordingly 80 20 29 Heater matrix renew Euro LHD 1 90 hours USA IHD 1 95 hours 82 25 10 Heater matrix renew Euro IHD 1 90 hours USA IHD 1 95 hours ALL JAGUAR AND DAEMLER MODELS WITH V12 ENGINES TTFM 25 SEALING OF BOLT THREADS OIL SUMP SANDWICH PLATE In the event of oil leakage around the base of the crankcase and the oil sump the following action should be taken before consideration of any gasket replacement 1 Check the torque of the securing bolts oil sump to sandwich plate and the exposed bolts
8. to a storage device located at the front left hand side of the vehicle in front of the road wheel The storage device is a plastic canister filled with charcoal 6 Fig 1 The charcoal ab sorbs the vapour enhancing the storage capacity of the canister When a vehicle is at rest with the engine turned off the flow of vapour is controlled by a pressure vacuum relief valve 3 Fig 1 so that a low positive pressure is main tained in the fuel tank If this pressure exceeds approximately 1 5 psi the pressure va cuum relief valve opens to allow the excess pressure and fuel vapour to bleed into the charcoal canister thus maintaining the low positive pressure Should there be any blockage of the line between the fuel tank and the charcoal can ister there are further pressure relief valves in both the evaporative loss flange and the fuel filler cap to prevent any excess tank pressure Whenthe engine is running the pressure vacuum relief valve is held open by engine vacuum allowing an unchecked flow of vapour from the fuel tankto the canister and zero pressure in the fuel tank i e atmospheric pressure The charcoal canister is connected to the vehicle s induction manifold via a purge con trol valve Fig 1 item 4 the operation of which is controlled by an electrical signal from the engine management ECU according to a pre determined map The canister is purged by drawing the vapour into the induction manifold the volume of vapo
9. vehicles within the above VIN range may have been fitted with a dipstick of incorrect specification The total number of vehicles affected is 7 continued Jaguar Cars Limited 2005 JD 27 94 JAGUAR In the course of PDI checks of automatic gearbox fluid level Dealers are requested to inspect and check the dipstick Ihe dipstick may be identified by measurement between the the tip and the Min Hot marking as illustrated below CORRECT DIPSTICK Measurement 32 nm INOORRECT DIPSTICK Measurement 56 mm v oe FC DSI Lo 1 OC Damm GS Where an incorrect dipstick is identified it should be replaced by one of the correct specification Part No EBC 8409 the incorrect item being returned through normal Warranty channels JST REESE Where vehicles within the affected VIN range have already been sold Dealers should take the first opportunity to inspect the automatic gearbox dipstick as above Warranty Fault Code 4 BH Z Jaguar Cars Limited 2005
10. 39 03 GREEN MAIN BEARING CENTRE SIZE 1 JLM 11140 01 PINK SIZE 2 JLM 11140 02 1 WHITE C 29314 1 SIZE 3 JLM 11140 03 GREEN MAIN BEARING REAR SIZE 1 JLM 11141 01 PINK SIZE 2 JLM 11141 02 1 WHITE EAC 3973 SIZE 3 JLM 11141 03 GREEN sco CRANKSHAFT 6 0 eee tose 4 Jaguar Cars Limited 2005 17 JD 05 93 JAGUAR AJ6 GRADED BEARING SHELLS 3 2 amp 4 0 LITRE PART NUMBERS PART NO COLOUR REPLACES CODE CONN ROD BEARING SIZE 1 JLM 11135 01 RED SIZE2 SIZE 3 JLM 11135 02 YELLOW EAC 2502 MAIN BEARING SIZE 1 FRONT INTERMEDIATE REAR SIZE2 SIZE3 JLM 11135 03 BLUE MAIN BEARING CENTRE SIZE 1 SIZE 2 SIZE3 JLM 11136 01 PINK JLM 11136 02 WHITE EAC 7957 red JLM 11136 03 GREEN EAC 7958 blue CRANKSHAFT 3 2L eBc10916 JLM 11137 01 PINK JLM 11137 02 WHITE EAC 7961 red JLM 11137 03 GREEN EAC7982 blue CRANKSHAFT 4 0L j amp BCw905 0 If a crankshaft or bearing problem is encountered on engines built prior to the intro duction of graded bearings the following applies If the bearing shells oniy have to be reptaced sets of the old condition shells will still be available and should be ordered as before If the crankshaft needs to be changed a graded bearing crankshaft will be supplied from Parts Operations and the relevant graded bearings will need to be fitted If a crankshaft or bearing problem
11. ANT BOTH THE THREADS OF THE BOLTS AND THE THREADS INTO WHICH THE BOLTS ARE FITTED MUST BE THOROUGHLY DEGREASED OTHERWISE THE LOCTITE 542 WILL NOT CURE TO CREATE AN EFFECTIVE SEAL Using a clean cloth and or a bottle type brush apply Ioctite Primer to the threads in the crankcase Allow to dry When refitting the sandwich plate retaining bolts concerned apply Loctite 542 to the bolt threads Torque setting 21 27 Nm Note Both illustrations show part of the sandwich plate as viewed from below with the oil sump having been removed Fig l XJ12 MODELS 431 2196 2 Jaguar Cars Limited 2005 44 JD 27 94 JAGUAR Fig 2 XJS VI2 MODELS 151 2195 If undertaking repairs on engines earlier than those listed below refer to Service Bulletin JD 08 92 Item 29 for details of gasket and fastener changes introduced at those engine numbers which should be retrofitted to earlier engines TP 67281 GLL 8S 86317 XJS V12 8W 10641 AJR S 6 0L ALL XJ12 6 0 Litre engines from 1993 25 MY and XJS 6 0 Litre engines from 1993 5 MY are to the latest condition and do not require any changes of fasteners PARTS INFORMATION Loctite 542 sealer should be ordered via Jaguar Parts Operations under Part Number JIM 1746 Gasket s should be identified from the current Parts microfiche for tne vehicle concerned XJS 4 0 LITRE VIN RANGE 193616 TO 193853 ITEM 26 DIPSTICK AUTOMATIC GEARBOX A small number of
12. CERNED IS ONLY REQUIRED AS A PRECAUTION IN THE EVENT OF MAJOR SERVICE REPATRS Vehicles affected may only be recognised by Engine Number within the ranges XJ6 amp XJS 4 0 Litre Engine No 9E 185496 to 9E 186799 X36 3 2 Litre Engine No 9B 116832 to 9B 117005 Replacement bolts should be ordered via Jaguar Parts Operations Washer faced bolt Part No FB 110125 J Oty Vehicle 4 ANY DISPLACED PARTS SHOULD BE RETURNED TO JAGUAR WARRANTY RETURNS AT BAGINTON THROUGH THE NORMAL CHANNELS FAILURE TO DO SO MAY RESULT IN THE CLAIM FOR THE ABOVE PARTS BEING DEBITED Torque Setting Bolt Convertor Housing to Intermediate Plate 49 54 Nm JAGUAR amp DAIMLER XJ6 AND XJ12 1994 MY ALL VARIANTS ITEM 09 FROM VIN 687219 FRONT FOOIWELL CARPETS FITTING PROCEDURE Additional to the information in Service Bulletin JD 38 93 Item 40 a further improvement to the method of retention of front footwell carpets on 1994 MY Saloon models has been introduced Both versions are described and illustrated in this Service Bulletin Note In both cases correct fitment of the carpet within the footwell is essential to eliminate the possibility of subsequent displacement of the carpet FROM VIN 687219 TO VIN 697999 Introduced as a first improvement for 1994 Model Year vehicles the rear edge of both the Driver s and Passenger s footwell carpet Item B Fig 1 has a J section plastic strip Item A Fig 1 which engages with a correspo
13. Cars Limited 2005 TEE JD 05 93 JAGUAR Note These figures were calculated for a new battery discharging from 80 charged to 20 charged The base quiescent drain figures will vary between markets Accessory parts will reduce the vehicle stand time Non approved accessories are likely to reduce considerably the vehicle stand time IMPORTANT Vehicle drain figures should be calculated according to their indi vidual specifications This information must be passed on to the appropriate workshop technicians STAGES OF QUIESCENT DRAIN IMPORTANT Thecurrent figures used here are only examples The time scales shown are however accurata VEHICLE QUIESCENT DRAIN FIGURES 0 5 minutes 500 milliamps example 6 21 minutes 75 milliamps example 22 minutes onward 25 milliamps example The above example highlights the significant drop in current demand which can be measured after the vehicle has been left for a few minutes Note The current drain will not drop to this final value if the keys are left in the ignition even if the ignition is not switched on ALARM QUIESCENT DRAIN FIGURES RF Alarm with ultra sonic intrusion sensors 1 3 days 16 milliamps 4 28 days 10 milliamps 29 days onward 6 milliamps Note Thecurrent drain will only drop to this final value if the alarm is armed if the alarm is left disarmed then there will be a constant drain of 10 milliamps for as long as the vehicle is left Fo
14. Cpaimlen aimler ISSUE NO JD 08 94 FEBRUARY 1994 PAGE 1 OF 3 SRO 44 91 10 ALL JAGUAR XJ6 4 0 LITRE ALL JAGUAR XJS 4 0 LITRE ENGINE STALLING AUTOMATIC TRANSMISSION Engine stalls when selecting Reverse or Drive from Park most noticeable when the engine is cold The concern may be overcome by a simple rectification within the automatic transmission BACKGROUND The concern arises from partial engagement of the torque convertor lock up clutch owing to the sticking Of a valve or to a restricted oilseal within the auto matic transmission this may be easily be rectified Yes where necessary The following initial diagnosis must be undertaken to check that the concern arises from the control valves for the lock up clutch i Check engine set up condition using JDS 2 Check transmission fluid level 3 Interrogate the Transmission Control Unit for Fault Codes using JDS Where the above checks prove satisfactory proceed as follows Referring to the appropriate Service Manual Section 44 2 remove the Valve Block Assembly as described for SRO 44 40 01 Jaguar Cars Limited Jaguar Cars Limited 2005 JD 08 94 l Where the vehicle has covered less than 1000 miles 1600 Km approximately from new Y i A KG S d INN Remove the oil seal Part No JIM 863 Item A Fig 1 Should this seal be incorrectly fitted or restricted it may interfere with the transmissi
15. NT In order to correctly measure quiescent current technicians MUST adhere to the fol lowing procedure Disconnect the battery negative lead Connect ammeter between the battery negative post and negative iead Select high meter range ie equal to or more than 10 amps Switch the ignition on then off then remove the key Do notcrankthe engine Observe and record the measurements obtained over the time scales identified in this Bulletin 7 Jaguar Cars Limited 2005 JD 05 93 E JAGUAR Note Whilst testing is being carried out no vehicle systems must be activated For this reason on 1993 Model Year vehicles the boot light should be dis abied and its lock latched shut QUIESCENT DRAIN FIGURES Approximate values in milliamps COMPONENT VEHICLE MODEL YEARS a X5 3 con heater E 1 3 13 20 20 Transmission control e aae LU D E EE ee head unit Air bag module u Engine ECU ssa Seat memory modules 05 Ne Gearshift interlock contro module E 1 0 Eh S 2s PeswEU SSCS 1 39 Door lock ECU L3 up CS 5 w w B WP WR WR Wmemge SSCP 39 FRMBwb ux f o 98 98 F L H Bulb fail unit FIRTH Buib fail unit TUK LOS 8 39 a FAL H Bulb fail unit UK R R H Bulb fail il unit SPECIFICATION TOTAL NOMINAL VALUE BASE RF ALARM DISARMED VEHICLE STANDING TIME IN DAYS INC ALARM Jaguar
16. XCESSIVE REMOVAL OF MATERIAL FROM THE CYLINDER HEAD FACE MAY LEAD TO PINKING DETONATION PROBLEMS Note On rebuilding the engine ensure that the cooling system contains the correct mixture of Jaguar Anti Freeze Coolant Corrosion Inhibitor See relevant Service Manual Section 26 Description and Anti Freeze XI6 amp XIS 4 0 LITRE 1994 MODEL YEAR ITEM 08 XJ6 3 2 LITRE 1994 MODEL YEAR 44 TRANSMISSION FIXING BOLTS On a number of the above models manufactured during November and December 1993 four of the ten bolts which fix the automatic trans mission convertor housing to the intermediate plate have been found to be of incorrect material specification The bolts concerned are indicated by arrows in the illustration below 351 2139 The suspect bolts are black in colour if refitted in the course of a service repair operation involving the separation of the transmission from the engine they would be likely to suffer thread stripping when tightened to the upper limit of recommended torque Should the occasion arise to separate the transmission from the engine in the course of a service repair operation the affected bolts should be replaced by bolts of correct specification Tests have indicated that there is little likelihood of the affected bolts failing in service Jaguar Cars Limited 2005 76 JD 07 94 JAGUAR IMPORTANT TRANSMISSION UNITS SHOULD NOT BE REMOVED TO LOOK FOR ANY CONCERN REPLACEMENT OF THE BOLTS CON
17. amp Rebuild 4 85 Hours Please amend your Repair Time Schedule accordingly No other Repair Times are affected ALL JAGUAR AND DAIMLER MODELS WITH V12 ENGINE TTEM 05 TIMING CHAIN TENSIONER ACCESS GROMMET Whenever the access grommet to the timing chain tensioner of a V12 engine is refitted both the grommet and its location in the timing cover should be cleaned to remove all traces of oil A bead of RIV sealant should be applied between the ridges of the gromet which will prevent any possibility of an oil weep from the grommet area Jaguar Cars Limited Jaguar Cars Limited 2005 w JAGUAR JD 07 94 JAGUAR ALI WITH AJ6 ENGINE ITEM 06 i2 AJG ENGINE SUMP DRAIN PIUG REVISED TORQUE SETTING The torque setting for the sump drain plug on ALL AJ6 engines has been reduced from 65 79 Nm to Revised torque setting 48 63 Nm This revised setting should be used whenever a sump drain plug is refitted Fnsure that the latest pattern of washer incorporating a rubber sealing ring is used when refitting a drain plug Part No EBC 9044 available via Jaguar Parts Operations In production engines assembled with the revised torque setting are fitted from approximately VIN 684700 XJ6 and VIN 189150 XJS ALL WITH AJG ENGINES TTEM 07 PRIOR TO VIN 677386 XJ6 PRIOR TO VIN 187754 XJS 12 CYLINDER HEAD EROSION THIS SERVICE BULLETIN SUPERSEDES THE ENTIRE CONTENTS OF SERVICE BULLETIN JD 08 92 ITEM 31 Where
18. is encountered on engines with the graded bear ings the following applies If the bearing shells only have to be replaced the relevant shells as noted on the No 1 balance weight see above should be ordered If the crankshaft needs to be replaced a graded bearing crankshaft will be supplied by Parts Operations and the relevant graded bearings should be ordered separately ALL MODELS ITEM 02 EVAPORATIVE EMISSION CONTROL SYSTEM in order to meet stricter world wide emission regulations an Evaporative Emission Control System is now fitted to al Jaguar vehicles Introduction VIN s are XJS 184907 SERIES IH 486831 XJ6 664941 Evaporative Emission Control Systems are designed to prevent fuel vapour which consists mainly of hydro carbons escaping into the atmosphere The following is a resum of major components of the system and the way in which the system functions 4 Jaguar Cars Limited 2005 JD 05 93 JAGUAR MAJOR COMPONENTS Ea PM qu IS ED ee ei px oS 181 186 Fuel Tank Evaporative loss flange Pressure Vacuum relief valve with vacuum operated by pass valve Purge control valve Purge air port on charcoal canister Charcoal canister Purge port on induction manifold Electrical connection to ECU Induction manifold Jaguar Cars Limited 2005 JD 05 93 JAGUAR 18 THE SYSTEM FUNCTIONS IN THE FOLLOWING WAY Fuel vapour generated in the fuel tank is passed in a controlled manner
19. it Control will be exercised concerning the return cf TCUs Ali displaced units must be accompanied by an ECU Information Label JJM 10 59 99 as detailed in UK Policy Letter JHSC 239 or Export Policy Letter JOSC 137 Both Policy Letters were dated March 1993 It is essential that Dealers replacing TCUs supply the following additional information on the above label attached to the displaced TCU VIN and gearbox serial number instead of JDS identified codes Reference to Bulletin JD 42 93 For UK market the Warranty Return Ref No For Export markets the Claim Number and Dealer Codes FAILURE TO SUPPLY ALL OF THE ABOVE INFORMATION CLEARLY amp LEGIBLY WILL RESULT IN CLAIMS BEING REJECTED WARRANTY CODES XJ6 and XIS 4CGE REPAIR OPERATION CODES SRO 44 15 32 Transmission Control Unit renew 0 75 hours Jaguar Cars Limited 2005 00 03 12 DATE FEBRUARY 1994 PAGE 1 OF 7 REF JD 07 94 ERRATUM PLEASE NOTE THE FOLLOWING ERRATUM IN SERVICE BULLETIN JD 43 93 JD 43 93 dated December 1993 Page 2 line 16 This line SHOULD read Part Nos C 2243A to C 2243X Please amend the original Service Bulletin accordingly XJo amp XJ12 FROM VIN 593884 ITEM 04 REPAIR OPERATION TIMES ADDITIONAL The following Service Repair Operation is now available for replacing the vehicle set of wishbone bushes and is applicable to vehicles from VIN 593884 60 35 29 Upper amp Lower Wishbones Vehicle Set Strip
20. nding section Item C Fig 1 fixed to a bracket on the front of the Seat ECU cover CARPET FITMENT PROCEDURE DRIVER S SIDE In a new vehicle ex factory the Driver s side carpet is fitted in the front footwell and is enclosed within a plastic covering which provides protection during vehicle delivery and PDI During final preparation of a new vehicle for the customer the following action should be taken to ensure correct fitting 5 Jaguar Cars Limited 2005 JD 07 94 JAGUAR l Remove the Driver s side carpet from the footwell 2 Remove the plastic protective covering 3 Fold the carpet in half and centralise it in the footwell 4 Lift the rear edge of the carpet align and fully engage the plastic J section strip on the carpet to tne metal bracket on the front of the seat ECU cover See Fig 1 5 Align the carpet to the footwell smooth the carpet flat into the footwell particularly at the rear and sides of the carpet 6 Fit the forward edge of the carpet under the control pedals ensuring that the cut out in the carpet is correctly aligned over the kick down switch to provide the required clearance Where the carpet is being refitted to a vehicle in service or should it be necessary to fit a replacement carpet items 3 6 above should be observed to ensure correct fitment CARPET FITTING PROCEDURE PASSENGER S SIDE The carpet on the Passenger s side of the vehicle is similarly retained at the rear
21. on fluid pressure so as to cause a partial engagement of the torque convertor lock up clutch in turn this may cause the engine to stall at low idling RPM Fit a new seal 2 Where the vehicle has covered more than 1000 miles 1600 Rm from new Remove the screws and retaining plate allowing removal of the torque convertor control valve Item A Fig 2 Clean the valve and its bore check that the valve moves freely and smoothly in the bore Should there be any tendency of the valve to stick gently lap the valve untii a smooth running fit is achieved This valve controls the flow of fluid to the torque convertor lock up clutch Should the valve stick the resultant incorrect fluid flow may lead to the engine stalling at low RPM 2 Jaguar Cars Limited 2005 JD 08 94 SERVICE TOOLS PARTS INFORMATION ADMINISTRATION INFORMATION TISSUE 2 JAGUAR 334 2101 Figa 2 Thoroughiy clean all parts re assemble using a new spring and oil filter Note When refitting the valve body the 13 securing screws should be tightened to a torque setting of 8 Nm JD 126 Control Unit oil seal remover replacer Oil Filter XIS JIM 664 Oil Filter XJ6 JIM 2128 Oil Seal JIM 863 Spring torque convertor JIM 11573 control vaive WARRANTY CODE 4CGY Automatic Transmission lock up clutch stalling REPAIR OPERATION CODE AND LABOUR TIME ALLOWANCE SRO 44 91 10 1 75 nours Jaguar Cars Limited 2005
22. per face of the cylinder block facing small diameter drilled passages in the cylinder head separated by the gasket Coolant flow between cylinder block and cylinder head is controlled by the diameter of the holes in the cylinder head gasket Item B Fig 1 J5 2137 Figagi In service the material of the head gasket collapses into the larger cored passage of the cylinder block leaving a gap between the cylinder head and the gasket surrounding one or more coolant passages Coolant in this gap may in certain circumstances boil locally and cause erosion of the cylinder head material From the above VINs the coolant apertures in the cylinder head have been enlarged to correspond with the apertures in the cylinder block hence coolant can no longer be trapped between the cylinder head gasket and cylirder head face REPAIR METHOD On a cylinder head on which erosion within the above permissible limits has occurred the cavities should be filled with a suitable Plastic Metal It is desirable that such infilling should restore the eroded area to be flush with the machined face such that any re machining of the face is unnecessary However should it become impossible to maintain the required surface finish and dimensions without machining reference should be made to Service Bulletin JD 02 93 Issued January 1993 for full details of sizes limits surface finish etc Jaguar Cars Limited 2005 JD 07 94 JAGUAR IMPORTANT E
23. r general current measurement and battery charging procedures please refer to the Battery Care Manual 9 Jaguar Cars Limited 2005 SUBJECT CUSTOMER CONCERN ADVICE TO CUSTUMER DEALER ACTION REPAIR METHOD ISSUE NO JD 42 93 DECEMBER 1993 PAGE 1 OF2 SRO 44 15 32 AJ6 4 0 LITRE AND XJS 4 0 LITRE VIN RANGE AJE 629286 TO 667829 AJS 179737 TO 185820 AUTOMATIC GEARSHIFT QUALITY Harsh upshift under light throttle at 50 MEH B0 KPH A modified transmission control unit TCU is now available which gives a significant improvement in gearshift quality when the gearbox mode switch is in the NORMAL position In SPORT mode there is a marginai improvement in shift quality Yes l PRELIMINARY CHECKS Dealers should ensure that the customer complaint is not caused by any of the fol lowing a Engine tune b Gearbox oil level c Selector cable adjustment d Rotary switch setting Use JDS to interrogate the TCU for fault codes 2 VERIFICATION Dealers must verify that the correct parts are fitted Transmission Part No EBC 4409 Transmission Control Unit Part No DBC 10110 Jaguar Cars Limited Jaguar Cars Limited 2005 PARTS INFORMATION ADMINISTRATION INFORMATION 3 RESOLUTION Where the customer complaint persists after the above checks replace the existing TCU by the modified unit The modified TCU is available through Jaguar Parts Operations Part No LMA 2400AA Transmission Control Un
24. s 1 to 7 C Pins 1 to 6 C Pins 1 to 6 The bearing sheil is identified by having the colour on one of its edges The grade letter and colour for each diameter are as follows V12 JOURNALS GRADE LETTER GRADE COLOUR GRADE DIAMETER PINK 3 0005 INS 76 212MM 3 0008 INS 76 220MM WHITE 3 0009 INS 76 222MM 3 0012 INS 76 230MM GREEN 3 0013 INS 76 233MM 3 0016 INS 76 240MM GRADE LETTER GRADE COLOUR GRADE DIAMETER 2 2993 INS 58 402MM 2 2996 INS 58 409MM Y YELLOW 2 2997 INS 58 412MM 2 3000 INS 58 420MM BLUE 2 3001 INS 58 422MM 2 3004 INS 53 430MM 2 Jaguar Cars Limited 2005 JD 05 93 JAGUAR AJ6 JOURNALS GRADE LETTER GRADE COLOUR GRADE DIAMETER PINK 3 0002 INS 76 207 MM 3 0006 INS 76 216MM WHITE 3 0006 INS 76 217 MM 3 0010 INS 76 226MM PINS GRADE LETTER GRADE COLOUR GRADE DIAMETER 2 0852 INS 52 966MM 2 0856 INS 52 975MM YELLOW 2 0856 INS 52 976MM 2 0860 INS 52 985MM BLUE 2 0860 INS 52 986MM 2 0864 INS 52 995MM New Part Numbers for the graded bearing shells are as follows I V12 GRADED BEARING SHELLS 5 3 amp 6 0 LITRE PART NUMBERS PART NO NO PER COLOUR REPLACES ENGINE CODE CONN ROD BEARING SIZE 1 JLM 11138 01 RED SIZE 2 JLM 11138 02 12 YELLOW C 38933 SIZE 3 JLM 11138 03 BLUE MAIN BEARING SIZE 1 JLM 11139 01 PINK FRONT INTERMEDIATE SIZE 2 JLM 11139 02 WHITE G 293131 SIZE 3 JLM 111
25. sandwich plate to crankcase Torque Setting 21 27 Nm 2 Clean the area in which oil leakage has occurred 3 Road test the vehicle examine for oil leaks ONLY where a fresh oil leak is apparent after the above action should either the sandwich plate to crankcase gasket and or the oil sump to sandwich plate gasket s be replaced continued Jaguar Cars Limited Jaguar Cars Limited 2005 e vun JD 27 94 JAGUAR In addition to the possibility of oil leakage at either of the above gaskets oil may also spread upwards along the threads of certain bolts which retain the sandwich plate and baffle tray The heads of the bolts are in contact with oil while the tops of the threads in the crankcase are exposed externally In the event of the oil sump being removed to allow replacement of either gasket the threads of the bolts concerned should be sealed by the application of Loctite 542 sealer It is NOT necessary to remove the sandwich plate to undertake the following rectification The bolts concerned are identified by shading in Fig 1 below and in Fig 2 opposite Remove the bolts identified by shading thoroughly clean and degrease them using a suitable solvent wipe or blow them dry Note 9 bolts on XJS V12 engines 7 bolts on XJ12 engines Using a suitable solvent and a bottle type brush thoroughly clean out any residual engine oil from the threads in the crankcase blow out the threads using an airline IMPORT
26. ur being controlled by the purge valve via the ECU The vapour ts then dis posed of during the combustion process ALL 4 0L AUTO MODELS ITEM 03 TRANSMISSION CONTROL UNIT TCU Should an automatic transmission failure warning be accompanied by fault codes 17 and 08 torque control and select possible open circuit technicians may assume that the transmission control unit TCU is faulty and erroneously logging the fault codes particularly if no fault is immediately evident with the wiring However it is unlikely that the TCU is at fault as the most likely cause of the fault is in the wiring to the engine management ECU The puil up resistors for the torque control and select lines are located in the en gine management ECU Ifthe supply to this ECU is faulty there will be no pull up and the voltage on the select and controi lines will drop The TCU will diagnose this as an open circuit failure Therefore when fauit codes 17 and 08 are seen together the supply to the engine management ECU shouid be checked It is also possible that this fauit may be caused by any non approved security alarm systems which immobilise the engine management system by cutting its power sup ply Jaguar Cars Limited 2005 26 51 86 JD 05 93 i JAGUAR ALL MODELS ITEM 04 DELETION OF BARRS LEAK When draining and refilling the cooling system during vehicle maintenance itis no longer necessary to add Barrs Leak radiator leak sealer
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