Service Bulletin aimler
Contents
1. NS Service Bulletin JAGUAR DATE MARCH 1991 PAGE 1 of 8 REF JD 02 91 It has been decided to re issue sheets 1 of 5 and 2 of 5 of Service Bulletin JD 15 89 The first issue instructs fitters to lubricate the crankshaft rear oil seal The seal supplier however recommends that the seal is fitted dry to avoid contamination These amended sheets are included at the end of this Bulletin and are clearly identi fied as Issue 2 Would Service Personnel concerned please remove and destroy the original copies and replace them with the amended sheets ERRATUM With reference to Service Bulletin JD 01 91 Item 06 1 Please note that the restrictor valve detailed in kit JLM 2295 reads CCC 3587 this should read CCC 3537 2 An error has also been noted whereby the installation details for valve CCC 3587 nave been omitted Please refer as follows With the right hand side centre console panel removed locate the centre vent re strictor valve blue ident A See illustration on following page Note which direction the blue ident is positioned Jaguar Cars Limited Jaguar Cars Limited 2005 TN JD 02 91 JAGUAR 12 Remove the blue restrictor and replace with the yellow restrictor CCC 3537 install the restrictor in the same orientation ALL V12 ENGINES ITEM 10 ADDITIONAL USE OF RTV SEALANT Removing Replacing Sump Sandwich Plate Gasket When removing or replacing the sump sandwich plate g2. Time allowance 1 80 hrs XJS AND S 1IV12 ITEM 13 80 AIR CONDITIONING HEATER MICROPROCESSORS 82 Some confusion has recently occurred over the interchangeability of Mk 3 Air Condi tioning Heater Microprocessors due to the incorrect issue of supersession informa tion concerning Part Nos CAC 8032 and DAC 7601 This information has subsequent ly been corrected with Part No CAC 8032 being re instated To clarify the situation CAC 8032 and DAC 7601 are NOT interchangeable CAC 8032 was the original microprocessor and was fitted in conjunction with a red water temperature switch Part No JLM 763 DAC 7601 replaced CAC 8032 as a running change around November 1989 and was fitted in conjunction with a black water temperature switch Part No JLM 2121 If the identification or compatibility of the microprocessor narness and water tem perature switch is suspect identification can be determined as follows a DAC 7601 may be identified by a blue edge connector colouring and a DAC 7601 label b CAC 8032 was only identified using the supplier part number on the rear of the microprocessor Part No 36900200 c With the Air Conditioning Heater unit switched on disconnect the water tempera ture switch and measure the harness voltages These should be nominally 0 volts or 5 volts If they are the same voltage the ECU and harness are incompatible a switch between them will have no effect Measure Pin 21 of the microprocesso
3. refitting a dash tiner the only fixings that should currently be used are the stud fastener push in fixings Part No AGU 1425 These should be used in conjunction with the stud anchor plastic retainers Part No AJU 1736 NB The fixings identified above are the only ones that should be used to secure dash liners Any other fixing currently being used for this purpose should be discarded IM MEDIATELY 6 Jaguar Cars Limited 2005 JD 08 92 CU 76 JAGUAR WARRANTY CODES 8RG Dash Liner Driver s side SRH Dash Liner Passengers side REPAIR OPERATION CODES SRO 76 41 11 SRO 76 46 15 XJ 5 ITEM 34 BONNET LOCKING GAS FILLED SUPPORT STRUTS To provide a positive method of supporting the XJ S bonnet when in the fully open position a locking support strut is now fitted to the L H side of all bonnets from VIN 184672 This revised strut has been designed to be retrofittable to all XJ S vehicles PROCEDURE FOR OPENING CLOSING The method of opening the bonnet has not changed however the bonnet should be opened fully to engage the locking strut To close the bonnet pull the bonnet down slightly then push it fully open to disen gage the lock then lower the bonnet and close as normal SERVICE REPLACEMENT To fit this new strut to existing vehicles the following parts will be required PARTS BEC 15544 L H gas strut locking 1 off BEC 13584 Ball pin 2 off BEC 17641 Label underbonnetctosing 1 off FITTING
4. INSTRUCTIONS Unlock the bonnet and support it in the fully open position use a wooden wedge Unbolt and remove the L H strut Discard this strut and its securing bolts E ae a ISi 1740 Jaguar Cars Limited 2005 m Service Bulletin JAGUAR L aimler ISSUE NO JD 18 92 NOVEMBER 1992 SHEET 10F2 S R 0 86 25 04 76 31 44 76 31 45 MODEL XJS ALL MODELS SUBJECT WINDOW LIFT MOTOR REGULATOR ASSEMBLIES CUSTOMER CONCERN Poor operation sticking noisy ADVICE TO CUSTOMER Installation of a revised motor or a motor regulator assem bly which incorporates a new motor will overcame stick ing or noisy operation New window lift motors have been introduced in produc tion from VIN 184117 DEALER ACTION Yes REPAIR METHOD Window lift assemblies incorporating the new motor are fully interchangeable with previous assemblies All mo tors will be supplied with the necessary additional parts for fitment to vehicles prior to VIN 184117 If the new motor is required to be fitted to vehicles after VIN 184117 the additional parts supplied with the kit should be discarded For details of part numbers and components relative to VIN please refer to Parts Information below Replacement of window lift motors and or regulators should be carried out in accordance with the Service Man ual instructions This Bulletin contains relevant informa tion on the fitment of the additional parts sup
5. MOVED TO LOOK FOR THIS CONDI TION THE ABOVE SHOULD ONLY BE NECESSARY WHEN THE CONDITION IS NOTICED ON REMOVAL OF A CYLINDER HEAD FOR OTHER REPAIR WORK AJ6 ENGINES ITEM 32 DISTRIBUTOR ROTOR ARM SETTING GAUGE Initial setting of the distributor body and rotor arm may be carried out with Service Tool JD 189 as foliows Unclip and remove the distributor cap H T leads remain connected Set the engine to T D C firing an No 1 cylinder rotor arm at approx 5 0 clock slacken the distributor clamp bolt Fit service Tool JD 189 setting gauge Fig 1 to the distributor body Adjust the distributor body to enable the tool to engage the distributor body and rotor arm Fig 2 Tighten the distributor clamp bolt Jaguar Cars Limited 2005 JD 08 92 JAGUAR 16 FIG 1 FiG 2 Remove tool JD 189 setting gauge Fit the distributor cap and clamp with the securing clips XJ6 ITEM 33 DASH LINERS R H amp L H Problems associated with the cosmetic appearance fit and removal of the dash liners have prompted the following corrective actions To assist removal and prevent damage to the dash liner pads a removal tool JD 188 and Service Bulletin JD 02 92 tem 13 have been issued to all Jaguar Dealers Im porters The visual appearance of the facia glovebox lid hinges has been improved on all ve hicles built from VIN 658676 Hinges fitted to cars from this VIN are now finished in black FIG 1 When renewing
6. No C30075 2 WARRANTY CODE 1EA REPAIR OPERATION CODE SRO 12 60 26 ALL AJ6 ENGINES ITEM 31 12 CYLINDER HEAD EROSION On removal of AJ6 cylinder heads for service work it has been reported that in some cases a certain amount of erosion exists on the gasket face around the inlet side water jacket holes As a guide to whether the cylinder head should be changed dealers should proceed as follows Clean the gasket mating face using fine emery cloth or a soft wire brush NOTE CARE SHOULD BE TAKEN NOT TO SCORE OR DAMAGE THE SURFACE Make a paper template of the cored holes in the cylinder block that correspond with the affected water holes in the head To orientate the template to the head water holes include the cylinder head bolt holes on the template See Fig 1 FIG 1 Position the template on the cylinder head by aligning the cylinder head bolt holes on the template to those on the head 3 Jaguar Cars Limited 2005 12 Sate JD 08 92 ae JAGUAR ONLY IF THE EROSION ON THE HEAD OVERLAPS THE CORED HOLE CUT OUTS SHOULD THE HEAD BE CHANGED If the erosion is within the cut out the cylinder head should be refitted in the normal manner 47 1771K FIG 2 Dealers should ensure that Jaguar coolant anti freeze corrosion inhibitor is used in the cooling system at the correct concentration or where this is nat available phosphate free anti freeze to BS 6580 should be used NOTE CYLINDER HEADS SHOULD NOT BE RE
7. RH motor Parts required for regulator fault BEC 22008 9 LH RH regulator 4 From VIN 184117 Parts required for motor fault JLM 11002 3 LA RH motor Parts required for regulator fault BEC 22008 9 LH RH regulator Convertible 5 Up to and including VIN 179736 Parts required for motor and or regulator fault JLM 10578 9 LH RH regulator assembly DBC 11503 adaptor fink lead BD 48949 3 bolts 6 VIN 179737 to 184176 inclusive As Coupe 3 7 VIN 184117 onwards As Coupe 4 Jaguar Cars Limited 2005
8. The dished serrated washer C 30075 2 should not be used Sump sandwich plate gasket EBC 9637 replaces EAC 7252 EBC 9637 should be fitted without RTV sealant on split lines between the cylinder block and the timing cover and must only be used with fasteners JZS 100034 and JZS 100035 in place of SH50508 1 3 and BH 505141 J respectively The fasteners should be torqued to 21 27 Nm The dished serrated washer C 30075 2 should not be used A bank cam cover gasket EBC 9627 replaces C 29428 EBC 9627 should be fitted without RTV sealant and must only be used with M6 bolts Pt No FS 106251 J in place of SN 106251 J torqued to 9 5 11 5 Nm B bank cam cover gasket EBC 9628 replaces C 29429 All other details are as for the A bank cam cover gasket NOTE RTV sealant should continue te be used on the rubber half round seal located at the rear of the cam carrier Water rail gasket EBC 9634 replaces C 30344 EBC 9634 should be fitted without RTV sealant Throttle body gasket EBC 9635 replaces EAC 9759 EBC 9635 should be fitted without RTV sealant and with the tab on the gasket facing downwards Water pump elbow gasket EBC 9636 replaces EAC 9805 The gasket should be fitted without RTV sealant and with the black side of the gasket to the pump body This makes disassembly easier shoutd it be necessary Water pump gasket Between the 2 halves of the water pump EBC 9630 replaces C 36542 EBC 9630 should be fitted without RT
9. V sealant and grease should not be used to retain the gasket during assembly Jaguar Cars Limited 2005 FEE JD 08 92 JAGUAR Water pump gasket pump assembly to timing cover EBC 9629 replaces C 29626 EBC 9629 should be fitted without RTV sealant and grease should not be used to retain the gasket during assembly Top cover gasket Also known as Valley gasket EBC 9631 replaces C 29485 EBC 9631 should be fitted without RTV sealant or grease with the black side of the gasket to the cylinder block This makes disassembly easier should it be necessary A bank timing cover gasket EBC 9632 replaces EBC 3280 B bank timing cover gasket EBC 9633 replaces EBC 3281 Timing cover top gasket EBC 9625 replaces EBC 3282 The three timing cover gaskets above must be fitted without RTV sealant or grease After fitting the timing cover the ends of the gaskets should be trimmed flush with the block using a sharp knife All fixing bolts screws and their torques not mentioned above remain as before XJ S amp S I V12 ITEM 30 12 OIL PUMPS To improve quality Jaguar is now using an alternative supplier for the V12 oil pump In most cases the new pump can be used as a direct replacement with no modifica tion to the block however in some cases a foul condition may exist between the pump and certain areas of the old sand cast block To check for any foul condition the pump should be offered in the correct position to th
10. asket Engine Set Renew 1 15 Hrs 30 15 20 Front Exhaust Manifold Gasket Renew 0 95 Hrs 30 15 21 Rear Exhaust Manifold Gasket Renew 1 00 Hrs 30 15 36 Front Exhaust Manifold Renew 0 95 Hrs 30 15 37 Rear Exhaust Manifold Renew 1 00 Hrs 30 15 38 Exhaust Manifold Engine Set Renew 1 15 Hrs Please amend your Repair Time Schedules accordingly No other times are affected Jaguar Cars Limited Jaguar Cars Limited 2005 haan JD 08 92 JAGUAR ALL V12 ENGINED VEHICLES ITEM 29 12 REVISED GASKET AND FIXING BOLT FASTENER PACKAGE A revised gasket and fastener package has been introduced on production for Y12 en gines to overcome complaints of oil leaks in service The package was fitted from the following engine numbers 7P 67281 S Hl 85 86317 XJ S BYW 10641 XJR 5 6 0L The gaskets and fasteners are available from Jaguar Parts Operations and are all able to be retro fitted to earlier engines Where specified below the correct fasteners MUST be used The new fasteners are designed to reduce torque relaxation Part numbers and fitting details are as follows Oil filter mounting gasket EBC 9624 replaces EAC 6337 EBC 9624 should be fitted without RIV sealant Sump gasket EBC 9623 replaces EAC 7251 EBC 9623 should be fitted without RTV sealant and must only be used with fasteners JZS 100033 and JZS 100035 in place of C 37175 4 and BH 505141 J respectively The fasteners should be torqued to 214 27 Nm
11. asket would Dealers please note that to help prevent the possibility of oil leaks additional RTV sealant should be applied as follows A bead of RTV sealant approximately 3 mm wide and 10 mm lang should be applied in the middle of the joint line between the cylinder block and the rear main bearing cap in two positions Fig 1 before the sump sandwich gasket is fitted ae I g i ase ANN 39 1435 FIG 1 A small spot of RTV approximately 3 mm diameter should be applied in the middle of the split line between the timing cover and the sump face Fig 2 after the paper timing cover gasket has been shaved and just before fitting the sump sandwich gasket 15l 436 Jaguar Cars Limited 2005 76 one JD 02 91 JAGUAR XJR S AND XJR SALOON ITEM 11 76 SATIN BLACK EXTERIOR FINISHERS WHERE FITTED When polishing vehicles equipped with satin black exterior finishers during PDI showroom preparation or service valeting care should be exercised to avoid excess ive rubbing particularly with power tools otherwise the satin finish may become glossy in appearance detracting from the original specification tn order that owners are discouraged from similar practices in service reference in the form of a caution note will be contained within future editions of the vehicle hand book under Section 9 Vehicle Care AJS COUPE ITEM 12 DOOR GLASS INCORRECT OPERATION Service reports have identified some incidence of d
12. e mounting bosses If it lies flat against the bosses the condition is correct If the pump lies proud of the bosses material should be removed from the foul area of the block refer to shaded areas in Fig 1 for possible foul areas by careful use of a rotary file or similar implement WARNING PROTECTIVE EYE WEAR MUST BE WORN WHEN USING ROTARY FILES FIG 1 Care should be taken when removing material to ensure that swarf produced by the operation is completely cleared from the area and that no other part of the engine i e crank main bearing is damaged during the operation Jaguar Cars Limited 2005 JD 08 92 seit JAGUAR In some cases the new pump may appear to be seized or difficult to turn This can be explained by stiction arising due to storage and does nat mean that the pump is damaged in any way If the pump does appear to be seized 10 ccs of engine oil should be poured into the suction port and the inner rotor of the pump turned using a suitable implement The repair method is as outlined in the relevant Service Manual Note the torque for the fixing bolts remains the same at 21 5 28 5 Nm Service Too s are as outlined in the relevant Service Manual The new part number is EBC 3163 for the pump and EBC 4240 for the adaptor collar which must be used in conjunction with the pump In addition shorter fixing bolts must be used 4 off Part NoSH505071J The washers for the bolts remain the same Part
13. oor glass sticking and juddering whilst it is being powered up and down The reports also point out that the adjust ments incorporated within the window lift assembly do not in all cases provide an effective means of eliminating the problem To redress this situation and prevent further occurrences of the fault a modified lower door glass guide channel and improvements to the door assembly have been intro duced on all XJS coupes manufactured from VIN 176860 Coupes built prior to VIN 176860 which are affected by this problem can be corrected by carrying out the fol lowing procedure Rectification Procedure 1 Remove the door trim refer to S R O 76 34 01 to gain access to the door glass window litt regulator assembly 2 Disengage the regulator assembly from the door glass and allow it to rest in the lower door panel 3 Place hands on either side surface of the door glass then move the glass up and down Refer to Fig 1 Point A The glass movement becomes restricted at this point as full contact is made between the glass and upper to lower guide channels Close observation of the glass channel seal at the foul point A will in variably show signs of pressure marking and wear Jaguar Cars Limited 2005 E JD 02 91 JAGUAR dJ5il42 7 FIG 1 Note When excessive wear is apparent on the inner surface of the seal t MUST be renewed 4 Remove the lower door glass channelfrom the door and place it on a
14. plied with the kit when fitting to vehicles prior to VIN 184117 Prior to the replacement of parts Dealers must ensure that on vehicles built priorto VIN 176860 the customer concern is not the result of poor channel guide setting and action as detailed in Service Bulletin JD 02 91 Item 76 must be carried out before parts are removed from the vehicle A Service Bulletin will be issued shortly detailing the set ting procedure for Facelift vehicles to ensure that the align ment of the door glass is suitable to allowsopregt saalaibos JD 18 92 SERVICE TOOLS PARTS INFORMATION aoe JAGUAR When the motor is confirmed as being the cause of con cern it should where possible be removed from the regu lator and be replaced as a single part Refer to Parts Infor mation below N A As a result of changes during production to the connector the channel guide regulator arm and the quadrant it is im portant that VINs are accurately recorded before parts are obtained Coupe 1 Up to and including VIN 174361 Parts required for motor and or regulator fauit JLM 11002 3 LH RH motor JLM 11018 9 LH RH regulator DBC 11503 adaptor link lead 2 VIN 174362 to 179736 inclusive Parts required for motor fault JLM 11002 3 LH RH motor DBC 11503 adaptor link lead Parts required for regulator fault JLM 11018 9 LH RH regulator 3 VIN 179737 to 184116 inclusive Parts required for motor fault JLM 11002 3 LH
15. r if this is 0 volts a red water temperature switch should be fitted If this is 5 volts a black water temperature switch should be fitted Jaguar Cars Limited 2005 JAGUAR aimler DATE JULY 1992 PAGE 1 of 10 REF JD 08 92 ERRATA WITH REFERENCE TO SERVICE BULLETIN JD 02 92 ITEM 16 THE FOLLOWING ISA CORRECTION TO THE FAULT DIAGNOSIS PROCEDURE ITEM FUEL GAUGE ALWAYS READS EMPTY PLEASE NOTE DURING THE CHECK PROCEDURE DETAILED THE LOW FUEL WARN ING LIGHT WILL ALSO REMAIN ILLUMINATED WHEN THE UPPER WIRE IS CON NECTED TO GROUND TO CHECK THE GAUGE NEEDLE MOVEMENT THE CURRENT BULLETIN ONLY STATES THAT THIS WILL OCCUR WHEN DISCONNECTING THE UPPER WIRE TO CHECK IF THE GAUGE READS EMPTY XJ6 amp XJ S ITEM 27 00 WARRANTY CODE BOOK To enable dealers to diagnose customer concerns of brake pull accurately a new Ath digit code of R has been introduced into sections 6E and 6J of the XJ6 Warranty Code Book and section 6J of the XJ S Warranty Code Book Dealers should amend their code books immediately to reflect this addition XJ63 2 amp 40 ITEM 28 03 REPAIR OPERATION TIME AMENDMENT An error has been discovered within the XJ6 Repair Time Schedule Section 30 15 Ex haust Manifolds The incorrect times have been issued and affect 3 2 and 4 0 catalyst non EGR vehicles only The correct times are as follows 30 15 09 Exhaust Manifold Heatshie d Renew 0 20 Hrs 30 15 12 Exhaust Manifold G
16. work bench 5 Refer to Fig 2 which shows the lower guide channel being measured at the posi tion it must be opened outto prevent the door glass sticking The nominal dimen sion at this position should be 19 8 to 20 8 mm subsequentiy the channel should be opened up to 26 0 to 28 0 mm FT dS 1228 FIG 2 6 To open up the channel using soft face jaws secure it firmly in a vice Fig 3 Using a pair of pliers equally bend each side of the channel outward until the in creased channel width of 26 0 to 28 0 mm is achieved A Fig 3 Jaguar Cars Limited 2005 aN JD 02 91 JAGUAR wie we A 1i 1 Siig FIG 3 7 Refer to Fig 4 using an engineer s steel rule measure the external width of the frame as shown The correct dimension shauld be 19 5 to 20 5 mm fn a ISIE 24 FIG 4 8 lf this dimension is less than 19 5 mm the door glass movement will still be re stricted at this point Shouid this dimension be correct items 9 to 11 can be disre garded When this width is less than 19 5 mm the doorfwindow frame channel will have to be opened out 9 Toopenoutthis channel inserta 15mm thick steel drift approximately 12cm long x 25 mm wide into the channel as shown in Fig 5 Jaguar Cars Limited 2005 EN JD 02 91 JAGUAR JS 25 FIG 5 10 Using a pair of pipe grips secured to the drift twist the drift in the direction shown in Fig 6 This action should be repeated until a dimension of appro
17. ximately 21 mm ts achieved at the position shown in Fig 4 This 0 5 mm increase above the upper limit of 20 5 mm will compensate for any spring back of the channel due to integral latent stresses FIG 6 11 On completion of the previous action the steel drift should be removed and the inner surface of the channel inspected for damage paint removal Any area of the tnner channel where bare metal is found should be repaired in line with Jag uar s current full paint specification This will require the application of i A brush applied air dry anti corrosive primer etch primer 11 A brush applied air dry black top coat e g BASF synthetic Code No L21 K013 12 When the paint ts fully dried refit the door glass lower guide channel and the glass channel seal Reset the channel so that the door glass moves freely up and down Ensure there is no excess sideways movement which may allow the glass to tilt and subsequently jam Jaguar Cars Limited 2005 hone JD 02 91 JAGUAR 13 Refit the regulator and motor assembly and check for correct functioning of the door glass during powered operation 14 Refit all door trim then carry out a final test for correct functioning of the door glass Warranty repairs should be claimed quoting the following details R O T Single Door 76 92 04 Window Lower Guide Channel Repair Time Allowance 0 90 hrs Both Doors 76 92 05 Window Lower Guide Channel Repair
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