Home

Service - Terry`s Jaguar Parts

Contents

1. 47 PROPSHAFT XJ S 3 6 XJ SC 3 6 When fitting the propshaft into the Getrag manual gearbox care must be taken not to disturb the oil sealing plug A by pushing the propshaft too far into the gearbox see diagram The only stop when sliding the propshaft into the gearbox is the sealing plug at the bottom of the propshaft reverse spline and if any force is used the plug can be disturbed and allow oil to leak out from the gearbox x AS SN eA e SON BC UY A hoy Crd ITEM 57 60 64 FRONT REAR SHOCK ABSORBERS SERIES II XJS The supply of front and rear shock absorbers has been changed from Girling to Boge Front and rear Boge shock absorbers were introduced on Series III saloons at VIN 391800 At present on XJS models only front Boge units have been introduced and Girling rear units are still fitted A further bulletin will be issued advising the introduction of rear Boge units on XJS models Boge shock absorbers can be identified by an all black paint finish which replaces the dark blue grey finish used by Girling and are fully interchangable with the Girling unit Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 84 Sheet 2 of 2 70 76 82 ITEM 58 FRONT BRAKE DISC PROTECTION XJS S III Difficulties have been encountered in production concerning the fitment of brake disc protection covers and anti rust paper This has resulted in the fitment being suspended from the following VIN s 388191 Series Ill 116764
2. GS arvice Rulletir AGUA Qaimled DATE FEBRUARY 1988 SHEET 1of6 BULLETIN JD 01 88 Due to additional information received after Service Bulletin JD 10 87 was issued it has been decided to re issue two pages of item 99 The amended version of Sheets 15 and 16 Service Bulletin JD 10 87 is included in this Bulletin and is clearly identified 2nd Issue Will Service personne concerned please remove and destroy the original copy and replace with the amended sheets 03 03 ITEM 01 REPAIR OPERATION TIMES XJ6 2 9 3 6 Repair Time Supplement JJM 10 01 05 S1 lists operation 26 25 11 Fan Cowl Renew as 0 60 hrs This replaces operation 26 40 07 Radiator Cowl Renew 0 55 hrs which appears in JJM 10 01 05 and should be deleted No other repair times are affected ITEM 02 REPAIR TIME AMENDMENT XJ6 2 9 3 6 Following a review of procedures could you please alter the following repair times in Repair Operation Times Supplement Part No JJM 10 01 05 S1 60 35 26 Suspension Unit Rear Mounting Bush Renew to read 6 10 hr 60 35 27 Suspension Unit Rear Mounting Bush Vehicle Set Renew to read 6 25 hr 86 70 20 Fuel Pump Link Harness Renew to read 0 70 hr The repair times shown above are for all XJ6 2 9 3 6 models and variants No other repair times are affected Jaguar Cars Limited Jaguar Cars Limited 2005 ITEM 03 XJ6 3 4 Where crankshaft main bearing failure is exp
3. XJS When the protection covers and anti rust paper are re introduced the introduction points will be advised in a future Service Bulletin ITEM 59 ELECTRIC DOOR MIRROR S III XJS HE To improve the reliability of the electrical door mirror assembly mirrors are now equipped with a new Kienzle motor unit Units to the latest condition being progressively introduced at VIN s 390466 Series Ill 117350 XJS HE ITEM 60 BLOWER FAN ASSEMBLIES S 1iI XJS HE AIR CON MODELS ONLY To overcome noise vibration problems experienced with the current blower fan units new fan assemblies incorporating Smiths Motors have been re introduced on air conditioned models only from VIN s 382821 Saloon 115478 XJS For normal service replacement purposes the new Smiths Motor will be supplied complete with a balanced fan assembly mounting bracket and link harness Part No s JLM 232 RH JLM 233 LH This kit may be used to service all previous fan assemblies incorporating either Smiths or Delanair type motors Should replacement of complete blower assemblies be required units to the latest condition are available under Part No s CAC 8710 RH CAC 8711 LH Jaguar Cars Limited 2005 ee JAGUAR Service Bulletin aimler Date SEPTEMBER 1984 Sheet tof 3 Service Bulletin JD 09 84 ITEM 71 12 ENGINE STALL S I 4 2 XJ6 All Markets except North America Australia Can
4. ut _ _C BC 5961supercedes CBC 4214 050 S The following guide lines MUST be adhered to when fitting replacement parts 1 Replacement of old with new specification units must always be in axle sets i e Units of different ride specification must not be mixed on an axle 2 Where front shock absorbers are replaced with new ride specification units then the rear shock absorbers ride level struts must also be renewed with new specification a units However it is permissible to fit new ride specification rear shock absorbers ride level struts with old specification front shock absorbers ITEM 07 66 ACCUMULATOR SWITCHES XJ6 2 9 3 6 To avoid the necessity to replace the whole accumulator assembly when investigating fiuid leaks from the accumulator switches the Low Pressure and Charge switches have been made available as separate items These parts can be ordered using the following Part Numbers Girling Part No Jaguar Part No Charge Switch 74968666 JLM 1562 Low Pressure Switch 74968667 JLM 1563 The following procedure should be adhered to when renewing either or both of these amp switches CAUTION EXTREME CLEANLINESS MUST BE OBSERVED AT ALL TIMES Jaguar Cars Limited 2005 Remove Jepre E e the rower rraraku syvstemt e s off the ignition and reneated depress the brake pedal until no further assistance is felt 2 Cut the tie strap securing connector RS25 green PM4 Disconnect the connector and feed the accumula
5. C higher subtract 0 007 7 points for every 10 C lower add 0 seg 0 points 8 8 a 267 at 18 C equals t 260 at 25 C ii ITEM 16 6 BATTERY XJS XJS models from VIN 145730 are now fitted with a Chloride battery Part No DAC 4545 This incorporates an integral vent system eliminating the previous vented cap and hold down zvan To accommodate this battery the fol lowing components are also introduced Battery Tray BCC 9561 Battery Cover BCC 9764 Battery Tie Rods DAC 4754 Battery Clamp DAC 4727 P sitive Battery Lead DAC 5608 Vent Pipe C43502 E in conjunction a slave battery system similar to that used for XJG models has also been introduced and a hew fully charged battery is Now fitted to all Vehicles at the point of despatch To nsufe the battery drainis Kept to a minimum during the transit period it has beer necessary to remove certain fuses on vehicles shipped to export markets Fuses rernuved are as s follows g Fuse No Location t 6 way fuse box passenger footwell component plate 1 2 3 15 17 passive restraint Main fuse box driver s footwell component plate 18 passive restraint Displaced fuses will be placed ina Plastic bag and stored in the glovebox These should be refitted at F D I Jaguar Cars Limited 2005 amp Service Bulletin JAGUAR amler DATE DECEMBER 1989 SHEET 1of4 REF JD 19
6. Electric Accessories Redor 10Aor sa ii jr gt aad row 5 20A 10 Yellow 20A Radio sun roof heated door locks where fitted glove SPE Fic gH compartment lamp map light interior headrest lamps ae aes am db see state illumination 11 Light blue 15A Cooling fan air conditioning compressor clutch where aT lt itted under bonnet lamps 12 Violet 3A Right hand rear lamps tail number plate and side marker 13 Ligth blue 15A Right hand rear door window door guard lamp 14 Red 10A Right hand dip headlamp fog lamp where fitted Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 88 Left Hand Side Fuse Box Dn eee O SHEET 5 of 6 No Colour Code l Light blue 154 Left hand front door window door guard ilamo and mirrors if driver s door 2 Violet 3A Instrument pack 3 Yellow 20A Left hand air conditioning where fitted heater fan 4 Light blue 15A Left hand main beam headlamp 5 Tan 5A _ Left hand frontlamps side side marker direction indicators and repeaters 5 6 Violet 3A Ride levelling where fitted power brakes fs Brown 7 5A Left hand rear lamps stop reverse direction indicators and fog where fitted 8 Natura 25A Right hand seat movement where fitted and seat White heater where fitted g Tan 5A Electric Accessories Redor 10A or Yellow 20A H VE A a ae Nane eaLmMmovemern yhere fittec AL ate White heater where fitted Ti Yellow 20A W
7. 1984 switches to the latest condition have been introduced from Vehicle Identification Number 381034 Parts Division stock is to the latest condition Jaguar Cars Limited 2005 26 37 Ag ITEM 48 LOW COOLANT PROBE XJ12 XJ S Further to Service Bulletin JD 10 83 Item 66 which detailed the method of relocating the low coolant probe in the header tank to overcome the involuntary flashing of the warning light this Service Fix has now been incorporated on all production vehicles from the Vehicle Identification Numbers quoted below The low coolant probe will be situated in the header tank 384477 Saloon 115816 XJ S ITEM 49 77 MM TRANSMISSION 5TH GEAR RETENTION SERIES II XJ6 Several reports have been received of the 5th speed gear and synchromesh hub coming adrift due to failure of the retaining circlip to secure the assembly to the main shaft Investigations have revealed the problem to be due to operator error in not ensuring that the circlip was fully seated in its groove Assembly instructions have been amended to ensure that circlip retention is correct This has been introduced at TRANSMISSION NO ENGINE NO 036688D 8L 158819 ITEM 50 GM400 SUMP GASKET LEAKAGE XJ12 XJ S LIMOUSINE To overcome the problem of oil leakage from GM400 transmission sump gaskets the following modifications have been introduced 1 Thicker gauge material for the sump pan Zi improved gasket material These modifications were i
8. 8914 EAC 9186 7P 55854 USA Champion RS5C Champion RS9YC 8S 42817 Australia Canada Japan V12 EAC 8914 EAC 8554 P 93272 All Models Champion RS5C NGK BR7 EFS 8S 41339 except USA Australia Canada Japan Please note Any warranty claims resulting from use of non approved spark plugs will be rejected Jaguar Cars Limited 2005 SERVICE BULLETIN JD 05 86 SHEET 3 of 3 ITEM 39 86 SUNROOF MOTOR ASSEMBLY S III Various internal design modifications have been incorporated into the current sunroof motor assembly to improve the performance of the motor Production fitment commenced at VIN 449846 Further improvements to the sliding roof panel adjustment together with a modified seal are to be introduced shortly and will be announced in a future Service Bulletin 1016F Jaguar Cars Limited 2005
9. Cylinder Head Rear Blanking Plate Renew 1 40 Hrs Please amend your Repair Operation Time Schedule accordingly No other Repair Times are affected XJ6 XJS ITEM 21 10 BRAKE SYSTEM SERVICE RECOMMENDATIONS With the introduction of new brake components on the above models the brake servicing recommendations have changed No routine replacement of system seals is necessary as the seals are designed to last for the life of the vehicle The braking system must still be inspected for satisfactory operation and condition at the regular service intervals Brake fluid to be renewed at 2 years or 30 000 miles 48 G00 km intervals whichever is the sooner For North America only 18 months or 30 000 miles 48 000 km Note Service Manuals will be up dated at the next reprint Jaguar Cars Limited Jaguar Cars Limited 2005 aoe JD 03 92 JAGUAR 26 80 82 84 ALL AJ6 ENGINED VEHICLES ITEM 22 WATER PUMPS A revised water pump assembly has been introduced on AJ6 engines The assembly now has a gasket between the two halves instead of RTV sealant as previously used The revised assembly is fitted from the following engine numbers 3 2 107696 4 0 157275 The part number of the new assembly is EBC 8550 and replaces EBC 4437 The part number of the gasket is EBC 9220 Note THE GASKET CANNOT BE RETRO FITTED TO RTV SEALED WATER PUMPS IF ALEAK BETWEEN THE TWO HALVES IS APPARENT THE OLD STYLE PUMP ASSEMBLY MUST BE REPLA
10. arrow E Fig 1 until the pawl ceases to move Rotate the nut one further full turn or until free play is identified at the exterior handle Secure the locknut using two spanners and recheck the free play Refit all trim etc 381 854 SECTION THREE Where door closure problems are identified and checks have shown that the lock linkage is set correctly the door should be examined initially for profile and adjusted as necessary Should a closure problem exist after profile setting and it is established that the striker is correctly set the aperture should be examined for contact marking Potential contact areas and corrective actions are detailed below 1 Draught welt flange Should hard contact be noted where possible the flange should be dressed carefully inboard to effect clearance Tread plate contact Where this is identified remove the tread plate and using a suitable file remove sufficient material from the tread plate to obtain clearance Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 88 SHEET 4 of 6 3 Door seal wrinkling This usually occurs at the top of the C post and inhibits rear door closure To rectify fit a new seal Repair time aliowances Front Door Exterior Handle Linkage Adjustment Operation No 76 37 10 Time allowance 0 55 hrs Rear Door Exterior Handie Linkage Adjustment Operation No 76 37 11 Time allowance 0 55 hrs NOTE Any repair time allowance for Secti
11. attached to the inside of the boot side reinforcement pane drainage channel L H Fig 1 N Y yang A JSI 1687 FIG 1 Prior to VIN 179737 90MY XJS the module is located beneath the centre console veneer finisher attached to a bracket in front of the stowage compartment Fig 2 386 1319 FIG 2 3 Jaguar Cars Limited 2005 JD 03 92 JAGUAR XJ6 ITEM 26 88 EXTERNAL SPEED SENSOR BRACKETS IDENTIFICATION Two external speed sensor brackets are available for use on XJ6 models To avoid any confusion they are identified as follows Bracket Description Of Use Part No CAC 9884 For al Drive Units prior to the introduction of EBC 9750 and EBC 9751 no colour identification EBC 9820 For all Drive Units from the introduction of EBC 9750 and EBC 9751 identified by a spot of blue paint 4 Jaguar Cars Limited 2005 00 00 Service Bulletin TEENS JAGUAR Date JUNE 1984 Sheet 1of3 Bulletin JD 06 84 ITEM 42 DISTRIBUTION POLICY UK MARKET ONLY In future the Dealer distribution of this Bulletin will be confined to JAGUAR DAIMLER Dealers only The circulation to Fleet and other recipients will remain unchanged Any non JAGUAR franchise holder who still has cause to require the Bulletins will be reinstated to the circulation upon application Customer Service Department Jaguar Cars Limited Browns Lane Allesiey COVENTRY CV5 9DR ITEM 43 REPAIR OPERATION TIM
12. from its mounting bracket BBC 6724 Front Door BAC 5430 31 Rear Door by removing two self tapping screws To fit a new motor unit reverse operations 2 to 4 Do not fully tighten the setscrews at this stage SETTING PROCEDURE FRONT PASSENGER DOOR LOCK MOTOR UNIT j Set the door lock to the full closed position 2 Slide the lock motor assembly towards the door lockface to take up all free movement Tighten the setscrews 1 Fig 4 a 3 Operate the exterior door handle Close the door 4 Check the setting by operating with the key from the driver s door Jaguar Cars Limited 2005 JS 4 JA SETTING PROCEDURE REAR DOOR LOCK MOTOR UNIT p P w Set the door outer lock to the full closed position Slide the lock motor assembly away from the door lockface to take up all free movement Tighten the setscrews 1 Fig 4 Operate the exterior door handle Close the door Check the setting by operating with the key from the driver s door SERVICE REPLACEMENT BOOT LID LOCK MOTOR UNIT F Ww Disconnect the lock motor block connector from the boot lid harness Remove the two setscrews securing the lock motor assembly to the boot lid inner panel Release the locking link BBC 6727 from the motor and remove the motor assembly from the boot lid Separate the motor from its mounting bracket BBC 6725 To fit a new boot lock reverse operations 1 to 3 Do not fully tighten the setscrews at this stage SETTING PROCEDURE
13. operation but as the adjustment procedure is identical for both front and rear doors repair methods are included for both This Bulletin Item details in Section One a method for checking if free play exists at the exterior handle Section Two provides a procedure for setting the lock linkage and Section Three identifies a number of potential contact areas which can affect closure SECTION ONE 1 Ensure the sill link is in the fully unlocked position and the latch claw is in a partial closed position A Fig 1 2 Place a finger into the striker slot B Fig 1 where the upper part will make contact with the lock pawl C Fig 1 Jaguar Cars Limited 2005 HE D 3 Use the other hand to check the exterior handle for free play If set correctly the pawl will remain stationary during the initial movement of the handle i e 1 2mm Should pawl movement be identified move to Section Two NOTE Excessive play at the exterior handle can also cause door closure problems and will necessitate adjustment Refer to Section Two and adjust to attain the correct setting SECTION TWO 1 Remove the door veneer panel and upper and lower trim pads Remove the taped plastic moulding from the door inner panel to aliow access to the lock assembly Release the locknut at the top of the handle link barrel nut D Fig 1 Place a finger into the striker slot to contact the pawl and with the other hand rotate the barrel nut in the direction of the
14. primers available or Schutz gun BERGER STANDOX STONE RESISTANT PRIMER 3M s BODY CAULKING 8568 Water resistant thumbing compounds for sealing DUNLOP SEMSTRIP 2208 openings in body panels 3M s BOLTED PANEL SEALER 8574 Water resistant sealers for jointing between bolted DUNLOP SEMSTRIP GP rivetted panels 3M s SUPER SEAM SEALER 8537 A brush on sealer ideal for footwells and floor seams ITEM 53 SERIES lil 6 CYLINDER MODELS WINDSCREEN WASHER PUMP NON HEADLAMP WASH WIPE To improve the windscreen wash facility on Series III 6 cylinder non headlamp wash wipe models a larger capacity washer reservoir incorporating a Tudor heavy duty pump assembly has been introduced from Vehicle Identification Number 385665 Jaguar Cars Limited 2005 26 37 TENS JAGUAR aimler Service Bulletin Date JULY 1984 Sheet 1 of 2 Bulletin JD 07 84 ITEM 54 COOLING SYSTEM ALL MODELS Instances have been reported of sludge contamination in the cooling system resulting in poor heater performance or overheating Samples of this contaminant have been analysed and identified as a phosphate based substance probably caused by the use of non approved anti freeze Only anti freeze recommended in the workshop manual copy shown below should be used for topping up and re fill purposes RECOMMENDED ANTI FREEZE BP Type HS25 Bluecol U Union Carbide UT 184 or Unipart Universal if these are not available phosphate
15. the fitment of production build USA Canadian specification high mounted stop lamp assemblies Will Dealers please note that the fitment of such lamps in both the U K and European markets is strictly governed by legislation High mounted stop lamp assemblies as fitted to USA Canadian specification vehicles do not comply with this legislation and SHOULD NOT BE FITTED Jaguar Cars Limited 2005 Exu ata ITEM 12 86 FUSES FUSEBOXES XJ6 2 9 3 6 Revised fuse box and failure modules have been introduced into production from VIN 931170 The fuse ratings and colour codes are given on the following charts Right Hand Side Fuse Box Fuse Fuse Value Circuit No Colour Code L Lightblue 15A Right hand front door window door guard lamp and ete He es mirrors if driver s door 2 Light blue 15A Door lock control luggage compartment lock petrol filler flap seba a Yellow 20 A Right hand air conditioning where fitted heater fan 4 Light blue 15A Right hand main beam headlamp 5 Tan 5A Right hand front lamps side side marker direction indicators and repeater 6 Yellow 20A Heated rear screen luggage compartment lamp electric aerial heated door mirrors rear quarter reading lamp R H where fitted SANTEE HAN 7 Red o 10A Right hand rear lamps stop reverse direction indicators and fog where fitted 8 Yellow 20A Front and rear cigar lighters where fitted 9 Tan 5A
16. 2 BS 2 E l aS be ITEM 14 n ip 5 z a bo aa 3 By MT a oh ONES riiag E a G5 2 ga P pye go am nt 2 E E pa 86 BRAY HEATER vooo eag ks SMN VI2 XJS V12 XJ6 3 6 a TQ provide access to the connector on the cylinder block heater it has been re positioned in the radiator bottom hose The heater cable is now fitted prior to shipment and strapped as indicated by Fig 1 XJ6 3 6 and Fig 2 S II V12 and XJS sii acihis modification has been introduced from Engine Nos CEN voy xo 7P59268 SMV12 0 o 9DP 133250 XJ636 4 f A uu We seg 88 55854 XJS V12 see a vials ae i a pe vox Ma N e bate can a Fae a ger EAS Bh ta ar na t x at j eee ea a t i use 7 J ER SSE A ent ia A 2 E pee miis torte mm o oes es Kaki t ORE TY i a Ee ig y Ww pa Pre z FEAE in ate aes me eal t s 4 cate EE eee aS wad w TE EN TLS She t wie E O rt spa r gt e 4 x Se S ai Pe PAR tos took E ae ees ar aye n a yi N 4 Diir ie Len q lt r J b n varies Pod SEIN S E es ir gt whee ibe vN l Ser e ene at i Ay fs ee ony for meitai op s Mags ob toe vE wae 7 ERE Ny FIG 2 a wt wed f ey py i g JS1 B26 go b Es m a ve Liptay are ey PSS N genbe y oot cs A Sgi Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 88 SHEET 6 of 6 STS LT NS TS a Pe 9 I SN wee ee ITEM 15 86 CHLORIDE DRY CHARGED BATTERY COMMISSIONING XSS XI
17. 4 Bulletin JD 09 85 ES ar 12 OIL PRESSURE TRANSMITTER S III XJ S Investigations into oil loss from the oil pressure transmitter have revealed that in the majority of cases the leak is via the sealing washer To ensure that the washer seals correctly the tightening torque has been increased to 20 3 to 27 1 Nm 15 20 lbs ft This change was introduced at the following engine numbers 8L 187777 4 2 84 16096 3 4 7M 5084 Limo 8S 36329 XJS 7P 53368 XJ12 ITEM 63 12 ENGINE OIL COOLER PIPE SAI 3 4 4 2 To eliminate the possibility of oil loss from the engine oil cooler hoses a new hose material has been introduced which has been designed to withstand higher temperatures _ This has resulted in Part Number changes for the hoses CBC 1437 replaces CAC 4557 CBC 1438 replaces CAC 4558 These new hoses were introduced at VIN 432926 ITEM 64 26 IDLER PULLEY ASSEMBLY y12 MODELS Following reports of fracturing of the idler pulley assembly used for tensioning the water pump drive belt on V12 engines the material of the pulley arm has been changed from aluminium to G iron This modification has resulted in Part Number changes which will be advised when the new parts are available The modification was introduced at engine numbers 7P 53808 S III V12 8S 37231 XJS V12 jaguar Cars Limited Jaguar Cars Limited 2005 26 76 ITEM 65 THERMOSTAT XJ S 3 6 XJ SC 3 6 To improve heater output on XJS and XJ S
18. 77 82 AIR CONDITIONING IN CAR SENSOR ALL XJS MODELS To improve in car sensor response on XJS HE and XJ 3 6 models a Blown Aspiration System similar to that currently fitted to Series models is shortly to be introduced Introduction vehicle identification numbers will be advised in a further Service Bulletin Should Distributors Dealers receive customer complaints of a slow sensing action i e the air conditioning unit irrespective of what automatic mode it is set at blows either too hot or too cold for a prolonged period before stabilizing the in car temperature then vehicles may be modified in accordance with the following procedures Parts required are as follows Part No Description Qty per Car CAC 8362 Aspirator Choke 1 C15150 8 Hose 1 CAC 3398 Elbow Pipe 2 RHD 1 LHD Please note that hose part number C15150 8 is supplied in a 1 metre 4Qin length however this will require cutting to the following lengths for RHD and LHD applications RHD 279 0 mm 11 0 in 1 off RHD 38 0mm 1 5 in 1 off LHD 889 0 mm 35 0 in 1 off Jaguar Cars Limited 2005 Labour Allowances RHD 0 75 hrs LHD 1 55 hrs Should be quoted utilising Warranty Code 8R4U IN CAR SENSOR MODIFICATION RIGHT HAND DRIVE RHD REFERENCE FIG jf Disconnect Battery 2 Remove the passenger side underscuttle trim panel and glove box assembly 3 Remove the in car sensor assembly and associated pipe work PLEASE NOTE The existing in car sens
19. 89 ITEM 89 26 WATER PUMPS COOLANT LEAKS AJ6 ENGINES A high percentage of returned water pumps replaced under warranty for leaks have been tested and have been found fault free itis important that before condemning the water pump other areas of the cooling system are eliminated first i e 1 The hose clips securing the hoses to the water pump and the thermostat housing 2 The thermostat housing joint ITEM 90 64 REAR SUSPENSION A FRAME MOUNTING BUSHES XJG 2 9 3 6 4 0 service Repair Operations are now available for renewing the rear suspension A frame mounting bushes on XJ6 2 9 3 6 and 4 0 litre models The following bush renewal procedure should be adopted Remove A Frame Mounting Bushes Raise the vehicle on aramp Ensure the vehicle is positioned on the ramp with one of the differential drive flange spider legs lowermost see Fig 1 Ps Remove the tuel numon mountinga oracke 0 A ame se nan Remove the A frame to differential rear bracket securing bolts Remove the A frame to differential front bracket inner securing nuts and bolts Place a jacking channel on the ramp bed and mount a suitable bottle jack on the jacking channel Align the channel and jack under the previously positioned lowermost differential drive flange spider teg Insert a suitable block of wood approx 25x 50x 100mm 1x2 x 4in between the jack and the differential drive flange spider leg see Fig 1 Operate
20. C 3 6 the cooling system thermostat has been changed from 82 C to 88 C The new Part Number will be advised when parts are available The new thermostat was introduced at Engine Number SDPAMA 102481 ITEM 66 CENTRAL LOCKING S III Commencing with 1986 M Y a new electric locking system has been introduced onto S III vehicles from VIN 428715 L H D and 429455 R H D In general terms the main change from the previous system introduces electric motor operation to the locks on all passenger doors and boot in place of the electric solenoid operation used on earlier vehicles The whole system is activated by a control unit DAC 3529 situated inside the driver s door Fig 1 J 86 gt 384 KEY 1 Door Lock Control Module 2 Door Boot Lock Motor FIG 1 The change in locking systems allows deletion of the lock relays but necessitate harness changes which will preclude conversion of existing vehicles The driver s door control unit and the lock motors are mounted onto brackets welded onto door rails in the same way as the lock solenoids The boot lock motor is mounted on the lid inner panel adjacent to the lock mechanism This Bulletin lists component changes setting procedures and fault finding Jaguar Cars Limited 2005 SERVICE BULLETIN JD 09 85 1 2 3 ke SHEET 2 OF 4 COMPONENT CHANGES Part No s Quanity per Vehicle Description DAC 3529 Driver s Door Control Unit DAC 3530 4 Motor Unit DAC 3609 l B
21. CED BY EBC 8550 When EBC 8550 has been fitted to an engine the bolts securing the two halves to gether must be re torqued to 21 5 Nm 28 5 Nm to overcome the possibility of gasket relaxation XJ6 XJ S S l ITEM 23 AIR CONDITIONING HEATER MICROPROCESSOR Refer to Service Bulletin JD 09 91 Item 62 To improve the retention of the air conditioning heater servo drive motor ICs inte grated circuits secured to the microprocessor unit heatsink the supplier has now changed the process to Rivscrews This modification commenced during mid November 1991 and replaced the previ ous bolt type fixings Air conditioning heater units fitted with revised microprocessors were progressively introduced from VINs XJ6 659029 XJS 1783501 S III 486299 XJ6 ITEM 24 WINDSCREEN WIPER ARM AND BLADE From VIN 657725 all XJ6 vehicles have been fitted with a revised wiper arm and blade assembly These new parts are tnterchangeable with cars built prior to this VIN when changed as an assembly only Dimensional changes prevent the fitment of a mixed condition of arm and blades Dealers are reminded that wiper blade replacement remains a part of the 7500 mile 12000 km service schedule for all vehicles Jaguar Cars Limited 2005 JD 03 92 JAGUAR XJS ITEM 25 86 STOP LIGHT FAILURE SENSOR MODULE LOCATION From VIN 179737 92MY Facelift XJS the stop tight failure sensor module is located in the boot of the vehicle
22. Conditioned models JD 04 85 Item 30 refers FUEL GAUGE Seddi Incidents of fuel gauge needles sticking have been found to be due to a foul condition existing between the needle and dial face cut out To overcome this problem the dial face cut out has been enlarged with effect from supplier date code 19 85 The date code can be located on the label adhered to the instrument case Jaguar Cars Limited 2005 12 26 44 JAGUAR Daimler Service Bulletin aimler Date MAY 1986 Sheet l of 3 Bulletin JD 05 86 ITEM 34 TORQUE CONVERTER DRIVE PLATE S III XJ6 An improved full diameter drive plate has been introduced on 3 4 and 4 2 engines to overcome complaints of drive plate noise The new part number EAC 8973 was introduced at the following engine numbers 8A 16666 3 4 8L 207464 4 2 ITEM 35 COOLANT PRESSURE CAP S III XJS To prevent contamination of the coolant pressure cap seal during initial coolant fill Barrs Leak pellets are now used in place of Barrs Leak solution These pellets which are inserted into tbe bottom hose during vehicle build were introduced at VINs 454031 S TJ1 I3 loss XJS TTEM 36 TRANSMISSION INHIBITOR SWITCH S ITI 4 2 Instances of vehicle failure to start in either Park or Neutral plus failure of the Reverse light function have resulted in transmission inhibitor switch DAC 4155 being replaced Following investigation of warranty returned units a significantly
23. EPTEMBER 1985 yz 2nd ISSUE Sheet 1 of 4 12 12 26 Bulletin JD 09 85 ITEM 62 OIL PRESSURE TRANSMITTER S III XJ S Investigations into oil loss from the oil pressure transmitter have revealed that in the majority of cases the leak is via the sealing washer To ensure that the washer seals correctly the tightening torque has been increased to 20 3 to 27 1 Nm 15 20 lbs ft This change was introduced at the following engine numbers 8L 187777 4 2 8A 16096 3 4 7M 5084 Limo 8S 36329 XJS 7P 53368 XJ12 ITEM 63 ENGINE OIL COOLER PIPE S III 3 4 4 2 To eliminate the possibility of oil loss from the engine oil cooler hoses a new hose material has been introduced which has been designed to withstand higher temperatures This has resulted in Part Number changes for the hoses CBC 1437 replaces CAC 4557 CBC 1438 replaces CAC 4558 These new hoses were introduced at VIN 432926 ITEM 64 IDLER PULLEY ASSEMBLY V12 MODELS Following reports of fracturing of the idler pulley assembly used for tensioning the water pump drive belt on V12 engines the material of the pulley arm has been changed from aluminium to S G iron This modification has resulted in Part Number changes which will be advised when the new parts are available The modification was introduced at engine numbers 7P 53808 S III V12 8S 37231 XJS V12 Jaguar Cars Limited Jaguar Cars Limited 2005 yz 2nd ISSUE 5 ITEM 65 26 THER
24. ES SERIES II1 XJ S Would any franchise holders who have experienced difficulty in obtaining AKM 9038 83 Series III Repair Operation Times and AKM 4412 83 XJ S Repair Operation Times from Unipart please note that matters have been rectified and no further trouble should be encountered Jaguar Cars Limited 2005 Jaguar Cars Limited 03 09 ITEM 44 SERIES tll REPAIR OPERATION TIMES SERIES III 3 4 4 2 There is an alteration to the Series I Repair Operation Times AKM 9038 83 to three operations concerning six cylinder vehicles The Operation Numbers are 82 50 53 82 20 54 and 82 20 55 The alteration concerns changing the entry in the Repair Time column from NA to NT thus allowing the time in the 5 3 column to be claimed The Repair Time columns for these three operations should now be altered to the foliowing 3 4 4 2 5 3 82 20 53 NT gt NT gt 1 90 82 20 54 NT NT 1 65 82 20 55 NT gt NT gt 1 60 No other Repair Times are affected ITEM 45 APPROVED LUBRICANTS ALL As part of our programme to evaluate and test oils the following list of SCN Te i oils has been given approval by Jaguar Cars PRODUCT NAME SAE VISCOSITY RATING Motul 300V 15w 50 Agip Sint 2000 10w 50 Mobil SHC 10w 50 20w 50 Mobil 1 10w 30 Shell Gemini 15w 40 shell Gemini Quadro 10w 40 Mobil 1 Rally Formula 5w 50 Generally synthetic oils are superior in performance under extreme operating conditions at higher engine temp
25. MOSTAT XJ S 3 6 XJ SC 3 6 76 To improve heater output on XJS and XJ SC 3 6 the cooling system thermostat has been changed from 82 C to 88 C The new Part Number will be advised when parts are available The new thermostat was introduced at Engine Number 9DPAMA 102481 ITEM 66 CENTRAL LOCKING Sed LE Commencing with 1986 M Y a new electric locking system has been introduced onto S III vehicles from VIN 428715 L H D and 429455 R H D In general terms the main change from the previous system introduces electric motor operation to the locks on all passenger doors and boot in place of the electric solenoid operation used on earlier vehicles The whole system is activated by a control unit DAC 3529 situated inside the driver s door Fig 1 J85 364 KEY 1 Door Locking Control Module Driver 3 Rear Door Lock Motors 2 Front Door Lock Motor Passenger 4 Boot Lock Motor FIG 1 The change in locking systems allows deletion of the lock relays but necessitate harness changes which will preclude conversion of existin vehicles The driver s door control unit and the lock motors are mounted onto brackets welded onto door rails in the same way as the lock solenoids The boot lock motor is mounted on the lid inner panel adjacent to the lock mechanism This Bulletin lists component changes setting procedures and fault finding Jaguar Cars Limited 2005 Service Bulletin JAGUAR Date SEPTEMBER 1985 Sheet l of
26. O 2 5 amp 3 6 E Investigations into premature Dattery failure on XJ6 Chloride replacement batteries Part Nos DAC 4120 0BC 3135 and DAG 4545 Nave emphasized the need to comrmissiori th se units in accordance with the manufacturers iristructions Failure to do so will result in the battery not achieving a full state of charge in service Full commissioning instructions are attached to Parts suppiied teplaceni nt Chiorid batteries and ar reproduced below for reference we Sp EM Noain E rg w Eg Stig rae A gt 3 yee n R a GS e Sa tet eye ee i Piragts ot INSTRUCTIONS FOR COMMISSIONING DRY CHARGE Si BATTERIES Aua aor FA 6 ait a FILLING 1 Remove vent plugs with each cell to the levels indicated in para 2 below with the correct specific gravity acid as given in Table 1 2 The level of the filling in acid should be 6mm above the separators or where applicable fiush with the tops of the ribs of the separator guards or to ta TVS Ah e 3 acid level indicator bar at the bottom of the filling tube 3 After a few minutes the ievel of the initial filing acio will fall and his SHUI the be amp restored by adding more acid until the levels a re agan asii para 2 2 above 307 SAT P Sta DU Yo See lar SA ie PUTTING INTO SERVICE p E 7 After filling the battery should be ailOwed to stand for apcroximateiy 20 minutes before charging l 2 Itis essential prior to fitment to give a battery a conditioning charge
27. S BOOT LID LOCK MOTOR UNIT 1 2 Ensure that latch BBC 3283 is in the unlocked position Slide the motor assembly towards the latch to take up all free movement Tighten the setscrews 1 Fig 5 Close the boot lid and check the setting by locking with the key from the driver s door FIG 5 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 09 86 i SHEET 4 OF 4 86 86 FAULT FINDING All Locks Inoperative 1 Check the fuse mounted above the passenger s side fuse box 2 Fuse intact Check feed to A post block connector at purple wire 3 Feed established check feed to control unit at the block connector inside the door See cautionary note 4 Feed established Reconnect the connector inside the door connect a test Lamp across the door harness connector located within the A post as previously described and operate the door lock If the lamp does not light momentarily change the control unit Passenger Door Motor or Boot Motor Inoperative 1 Check feed through system at block connectors at positions shown Fig 2 2 If a feed is established at the motor block connector change the motor Dealers carrying out warranty repairs using operations detailed in this Bulletin must refer to the relevant R O T listed below Number Description Time 86 25 46 Front Passenger Door Lock Motor Renew 0 55 86 25 47 Rear Door Lock Motor Renew 0 50 86 25 48 Rear Door Lock Motor Bracket Renew 0 50 86 25 49 Boot Lid Lock Mot
28. Sweden Switzerland Xie From 7P 50514 to 7P 50749 KS From 8S 29899 to 8S 30614 ITEM 75 TOP WATER HOSE XJS 3 6 amp XJ SC 3 6 Investigations into the failure of a top water hose part number CAC 5100 have revealed that the material at the centre of the hose was not fully cured The suspect hoses have the date code 13 83 moulded into the outer covering of the hose along the centre line It is essential that all vehicles are inspected and if found to have a top hose CAC 5100 with a date code 13 83 fitted then the hose must be replaced This inspection is to be carried out during normal vehicle servicing NOTE All vehicles produced after VIN 118692 are assured and do not need checking ITEM 76 SUNROOF PANEL STICKING S i Investigations reveal that where sunroof sliding panels stick in a closed position damage to the sunroof motor can result The sticking condition is caused by a white grease which is smeared around the sunroof aperture to assist smooth panel operation Under certain conditions the grease becomes very sticky and causes the lid seal to stick to the aperture To ensure smooth sunroof operation this grease MUST BE COMPLETELY REMOVED If the sunroof subsequently fails to operate smoothly a suitable alternative lubricant can ve applied The grease detailed above was deleted from new vehicles from VIN 396121 Rectification 1 Remove sunroof panel as follows a Fully open the sunroof b Remove four scr
29. ada Japan Sweden Switzerland Further to Service Bulletin JD 08 84 Item 65 isolated reports have been received of engine stall idle dip on vehicles not fitted with AIR CONDITIONING Such vehicles may be modified as detailed in JD 08 84 but terminal 6 Fig 3 need NOT be connected to the green brown GN compressor feed C Fig 2 and should be taped back into the harness ITEM 72 12 EXCESSIVE OIL CONSUMPTION S 111 4 2 A further modification has been introduced on 4 2 XK engines to improve engine oil consumption This modification concerns a new piston ring pack and was introduced at engine number 8L 167619 Part numbers will be advised when stocks are available ITEM 73 12 EXHAUST VALVE GUIDES S I XJ6 A modification has been made to the exhaust valve guide to overcome sticking valves This modification involves relieving the valve guide bore at the exhaust port end This was introduced at engine numbers 8L 167200 _ 4 2 8A 15507 _ 3 4 7M 4927 Limo New part numbers will be issued when stocks are available Jaguar Cars Limited Jaguar Cars Limited 2005 ITEM 74 SPARK PLUGS V12 HE ENGINES Due to supply difficulties with the copper cored resistive spark plug recently introduced see JD 05 84 Item 39 it has been necessary to revert to the old spark plug in certain markets for a limited period Detailed below are the markets and Engine numbers affected All Markets except North America Australia Canada Japan
30. 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 RE a ee se es SS SS aS TY 70 74 76 82 ITEM 05 BRAKE BEDDING IN PROCEDURE 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 sati
31. but do not tighten the mounting bush to body securing bolts Align the outer bracket to body securing bolt holes fit and tighten the securing boits and finally tighten the mounting bush to body securing bolts NOTE New self locking bolts should be used DO NOT re use old bolts Lower the bottle jack remove the block of wood bottle jack and jacking channel Lower the vehicle on the ramp The following Service Repair Operation numbers apply 64 25 09 Rear Suspension A Frame Mounting Bush Vehicle Set Renew 1 60 hrs 64 25 10 Rear Suspension A Frame Mounting Bush One Side Renew 1 35 hrs When making warranty claims Complaint Code 5HB should be used using the appropriate Ath digit ITEM 91 POWER STEERING RIDELEVELSYSTEMRESERVOIR XJ6 2 9 3 6 90 MY ONLY A new power steering ride level system reservoir incorporating a revised filier neck and cap design has been introduced on XJ6 models from VIN 601983 The new reservoir is identified by the filler cap having six semi circular finger grip indents equally spaced around the outer diameter compared with the four lugs used on the earlier design The new filler cap must not be used with the old type reservoir lf H M S O fluid leakage from the reservoir filler cap seal is experienced on 1990 MY vehicles prior to VIN 601983 an alternative cap seal available from Jaguar Parts Operations should be fitted This seal is available under Part No CCC 2782 and should be fitted
32. d tighten the nut and washer to hold the tool in position see Fig 2 JD 143 N gt D ama FIG 2 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 19 89 SHEET 2 of 4 Position the A frame mounting bush housing on to tool JD 143 ensuring that the weld nut boss of the A frame locates in the cut out of the tool Align the mounting bush with the hydraulic press ram then keeping the A frame level operate the press to remove the bush Remove the A frame assembly from the hydraulic press Remove tool JD 143 6 from the mounting bush by removing the nut and washer Discard the bush if required the other mounting bush can be removed in the same manner After removal of bush es refit the nut and washer to tool JD 143 6 then store the tool ina safe place ready for future use Fit New A Frame Mounting Bushes Invert the A frame Position the mounting bush housing on to tool JD 143 Position the new mounting bush flange uppermost on to the A frame bush housing Align the new bush to set the centre line of the bush rebound stops with those of the opposite bush see Fig 3 A t NEET E HOTS EHS FIG 3 E NOTE Bush to be within 5 degrees of position shown Place a suitable flat steel plate centrally on to the mounting bush The steel plate should be sufficiently large enough to cover the rubber flange of the new bush see Fig 4 E FIG 4 Jag
33. elt RENEW DISCS PADS AS NECESSARY NOTE On higher mileage vehicles any tendency for brake judder will be excited by wear in the suspension joints Z upper lower ball joints wishbone bushes BRAKE PULL This condition is sometimes confused with the tendency of certain vehicles to follow the camber of the road ENSURE CORRECT TYRE PRESSURES ENSURE CORRECT STEERING GEOMETRY DEGLAZE PADS AND DISCS CHANGE FRONT ROAD WHEELS SIDE TO SIDE Jaguar Cars Limited 2005 yx 2nd ISSUE yx BRAKE RUMBLE HARSHNESS CLEAN DISCS PADS Remove all brake dust debris and lightly emery the disc and friction pads RENEW DISC PADS BRAKE SQUEAK NOTE Squeak squeal is generated by the SQUEAL accumulation of brake pad debris DO NOT replace pads CLEAN DISCS PADS Remove all brake dust debris and lightly emery the dise and friction pads WARNING SOME BRAKE LINING DUST MAY CONTAIN ASBESTOS WHICH IF INHALED CAN DAMAGE YOUR HEALTH ALWAYS USE A VACUUM BRUSH TO REMOVE DRY BRAKE LINING DUST NEVER USE AN AIR LINE 86 ITEM 38 SPARK PLUGS S 1II V12 XJS V12 Following Service Bulletin JD 03 86 Item 28 which advised introduction of NGK BR7 EFS spark plugs in specific markets on V12 a revised Champion spark plug has now been introduced in the remaining markets to overcome a possible cold fouling condition from the following VINs 346920 peli VIZ 105048 XJS V12 Model Old Part No New Part No Engine Intro No V12 EAC
34. eratures Although all the above SYNTHETIC oils are approved by Jaguar Cars it is essential that the temperature chart detailed in the Owner s Handbook and Workshop Manual reproduced below for reference is referred to An oil with a viscosity rating which falls within the ambient temperature scale which the vehicle is operated in MUST be used e g 10w 30 or 10w 40 MUST NOT be used if the ambient temperature EXCEEDS 16 C 60 F Jaguar Cars Limited 2005 SERVICE BULLETIN JD 06 84 Sheet 2 of 3 The above SYNTHETIC oils and normal mineral oils meeting BLS 22 0L 02 are compatible As such should synthetic oil not be available it is acceptable to top up with a normal mineral oil providing it meets BLS 22 0L 02 Engine Oil Recommended S A E Viscosity Range Ambient Temperature Scale See i ces eee aap er A 5 F 20 10 10 20 30 40 50 60 70 80 490 100 J09 001A ITEM 46 19 POOR HOT START WARRANTY ADMINISTRATION V12 MODELS Reference Service Bulletin JD 11 83 Item 72 please note the following warranty coding should be utilised against this operation 7G4A ITEM 47 19 CRUISE CONTROL BRAKE PEDAL SWITCH SERIES III Further to modifications detailed in Service Bulletin JD 02 84 Item 12 the supplier of the brake pedal switch which disconnects the speed control system when the brake is applied has introduced additional quality improvements From Manufacturing Date Code A4 A January 4
35. erienced on 3 4 and 4 2 models it is possible for some distortion to occur within the cylinder block as a result of the heat generated To enable effective repairs to be carried out with confidence new short engines consisting of a cylinder block crankshaft pistons con rods and oil pump are now available using normal parts ordering procedures These are supplied under the following Part Numbers and should be used when repairing engines which have suffered crankshaft main bearing failure particularly rear main bearing failure JLM 1411 N 3 4 JLM 1412 N 4 2 H Comp JLM 1413 N 4 2 S Comp USA JLM 1414 N 4 2 S Comp Middle East ITEM 04 12 STRIPPED ENGINE ASSEMBLY XJS 3 6 A revised XJS 3 6 engine Part No JLM 1564 N with a redesigned crankshaft eliminating the need for balance weights on the crank damper and drive plate has been introduced from Engine No 9DP 128811 This engine which supercedes JLM 1338 N can also be used as a replacement for Part Nos JLM 104 N JLM 569 N and JLM 1046 N provided the necessary modifications are also included To determine the full list of modifications applicable to individual vehicles reference should be made to the application chart after first determining the original engine number fitted to the vehicle APPLICATION CHART REPAIR OPERATION NEW PARTS REQUIRED JLM 104N PER VEHICLE up to Engine DP102538 Modify Power Assisted 1 off EAC 7081 D
36. ews from the front edge of the sliding panel c Operate the sunroof towards a closed position at the same time lifting the front of the sliding panel away from the undertray d After full travel lift the sliding panel clear by releasing from two clips at the rear end 2 Clean sunroof aperture and sliding panel seal THOROUGHLY using white spirit SBP3 or a similar suitable solvent which will NOT damage T P A Paint 3 Apply lubricant seal if desired See Note 4 Refit lid Jaguar Cars Limited 2005 SERVICE BULLETIN JD 09 84 Sheet 2 of 3 aS ee eee en eee eee eee ee eee ee ee ee ee ee Warranty claims for this rectification should be submitted using Code 9C9F Labour allowance 0 45 hours Notes on Lubricants In the absence of universally approved lubricants it is permissible for Dealers to use a proprietary silicone based lubricant However it must be emphasised that whilst fully cured paint is not affected by silicone sprays such sprays MUST NOT be discharged near vehicles undergoing paint rectification or silicone cratering may result U K Approved Lubricants iP Hellerine Hellerman Electric Pennycross Close Pennycross Plymouth Devon PL2 3NX Application Smear lightly on to the rubber seal vs A O T Superlube A O T Limited Immex House Imperial Way Watford Herts Telephone Watford 33477 Application Spray lightly on to seal It is important to remove any spray from painted surfaces or marking may result ITEM
37. f the setting is correct the lamp will flash momentarily just before the flap reaches full travel When the flap is moved back towards the lock position the lamp will flash again just before the flap reaches full travel Disconnect the test lamp and reconnect the harness block connector 9 Operate the outer door handle to release the latch 10 Close the door and recheck the operation of all doors using the key in the driver s door lock 11 Refit trim panels to A post and door CAUTION Should it be necessary to connect an independant battery feed to the control unit whilst in situ the following connections must be observed Positive feed to purple wire Negative feed to black wire A wrong connection can destroy the control unit and it is recommended that this operation is carried out with the unit removed from the vehicle SERVICE REPLACEMENT OF CENTRAL LOCK MOTOR UNIT FRONT AND REAR PASSENGER DOORS 1 2 Remove door trim casing 76 74 01 Front Door 76 34 04 Rear Door With the door glass in the fully closed position disconnect the door lock motor block connector from the door harness NOTE it may be necessary to remove the plastic strap from around the harness for access Remove two setscrews securing the lock motor assembly to the mounting plate on the intrusion member release the locking link BBC 4580 Front Door BAC 4583 Rear Door from the motor and remove the motor assembly from the door Separate the motor
38. fOF approximately 4 hours at the charge rate of 6 amps to ensure peak performance oc 3 Where batteries are stored for a period exceeding one year in a temperate climate of 3 months or more in temperatures greater than 30 C and or humidity exceeding 80 they must be charged for 12 hours at the rate indicated 4 Check the electrolyte levels after charging and adjust accordingly as instructions given in section a Wher Fitti ng the battery to the vehicle ensure that it is properly securea by the hold down devices that the terminals are lightly smeared with petroleum jelly and that the cables are serrectly ane d sea ely connected to the battery terminals BATTERY MAIN TENANCE Keep the top of ihe battery ina clean and dry condition and the vent plugs securely screwed or pushed hema 2 Keep terminals and connections free from corre ion and coated with petroteum je It is important to note that overtopping can result in a wet battery top which edna es corrosion Ae 3 Maintain electrolyte to the levels indicated in section va para 2 by the addition of distilled or de ionised water 4 lf batteries are used on applications Without an engine driven charging unit uian recharging shouid take place when the specific gravity drops to 1 220 or 1 180 when low gravity acid has been used for hot climates until the specific gravity in all the celis rises and remains constant for 3 hours In any event such batteries should be put ona mon
39. free anti freeze conforming to specification BS 3150 or 3152 may be used Concentration UK and RHD export markets only 40 sp gr 1 065 In North America use Jaguar Part No ZVW 244101 All other markets 55 sp gr 1 074 In territories where anti freeze is unnecessary the cooling system must be filled with a solution of Marston Corrosion Inhibitor Concentrate SQ36 Always top up the cooling system with recommended strength of anti freeze or corrosion inhibitor NEVER with water only N B When investigating overheating problems on vehicles fitted with air conditioning a check should be made to ensure that there is no road debris trapped between the radiator and the condenser ITEM 55 MANUAL GEARBOX SERIES III XJ6 Several reports have been received of 77mm 5 speed gearboxes jumping out of gear Sample gearboxes returned for investigation have been tested and found to be functioning correctly It is known that if the transmission tunnel cover plate or gear lever gaiter are incorrectly fitted the gear lever movement can be restricted to prevent the gears engaging fully lf any manual XJ6 vehicles are encountered which are jumping out of gear or suffering difficult gear engagement then the centre console should be removed to check that the gear lever movement is not restricted by either the gaiter or the cover plate before the transmission is removed Jaguar Cars Limited Jaguar Cars Limited 2005 ITEM 56
40. high proportion have been confirmed satisfactory However close examination showed that in the majority of cases there are indentations in the switch body possibly due to overtightening of the fixing bolt Any subsequent repositioning for adjustment purposes only has a temporary effect as the switch is liable to move In doing so the fixing washer again positions itself in the indentation Jaguar Cars Limited 2005 Jaguar Cars Limited 70 To overcome this problem the fixing washer size has been increased together with the addition of a shake proof washer Torque Figure 16 5 to 18 5 lbf ins Production fit to the modified condition commenced at VIN 453381 If a problem is encountered in service prior to the above VIN and the switch contact operation is coinfirmed satisfactory then the following procedure should be implemented Note If the indentation mark on the original switch is very severe then the switch should be renewed 1 Remove the inhibitor switch fixing nut and retain Discard the plain washer Check indentation mark 2 Fit a new plain and shake proof washer to the following nominal dimensions and replace the fixing nut do not tighten Outside Internal Bore Diameter Diameter Thickness Plain Washer 12 5 mm 5 3 mm 1 0 mm Shakeproof Washer 9 0 mm 5 3 mm 0 5 mm 3 Adjust the inhibitor switch as detailed in Service Bulletin JD 08 85 Item 61 and tighten fixing nut to torque of 16 5 to 18 5 lbf ins 4 If the
41. in accordance with the procedure detailed below Remove the filler cap from the reservoir and using a suitable implement remove the seal from behind the retaining flange AFig 1 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 19 89 SHEET 3 of 4 76 ISI 5207 FIG 1 Discard the seal Clean the cap andreservoir neck Locate the new seal in the cap seating the seal against the retaining flange as shown inB Fig 1 Do NOT locate the new seal behind the retaining flange Check the fluid level and top up as necessary Replace the filler cap Warranty claims should be submitted quoting Warranty Complaint Code 6FXZ and Repair Operation No 66 9 1 09 A labour allowance of O 1 hrs may be claimed ITEM 92 ROOF PANEL RESONANT NOISE BOOM XJ6 NON SUNROOF VEHICLES ONLY Resonant boom emanating from the roof pane non sunroof cars only has been recognised as affecting XJ6 cars fitted with headlinings manufactured using compressed felt as the backing material To prevent further instances of this problem a new moulded polyurethane headlining has been introduced on all non sunroof cars built from VIN 595794 To address this problem on vehicles built prior to the above VIN the following rectification method should be applied VIPOR TANT isTrepal ould be carried out after customer comptaintonkh a Position front seats fully forward with the squabs fully reclined b Detach and lower the head
42. indscreen wiper horns 12 Violet 3A Left hand rear lamps tail number plate and side marker i Light blue 15A Left hand rear door window door guard lamp fuel filler amp flap rear quarter reading lamp L H where fitted 14 Red 10A Left hand dip headlamp fog lamp where fitted Centre Fuse Box Fuse Fuse Value Circuit No Colour fF Code Ta Violet 3A Lamp modules right hand rear and left hand front aiternator control 2 Violet 3A Lamp modules right hand front and left hand rear 3 Tan 5A Speed contro where fitted 4 Violet 3A Power brakes ride levelling where fitted amp 5 Violet 3A Cooling fan heated washer jets 6 Violet 3A Radio illumination breather heater Jaguar Cars Limited 2005 ITEM 13 WARRANTY CODES EY a Ce a emam e O XJ6 2 9 3 6 Dealers have reported isolated incidences of excessive quiescent battery drain caused by gither the main central processor unit or ride height level sensor Unfortunately when submitti ng the warranty claim Dealers have been uncertain as to the codes to use a Ke 2 Forside height level sensor existi ng code reference 7UHJ should be used To identify quiescent drain caused by the main CPU Central Processor Unit Malfunction has been allocated to 4th digit code Y in Section 7B Therefore when submitting claims please quote 7BLY eet E eo 5 vie kiia Pn 3 w A e A e a 2 mK s gt 7 i 2 a if ey r wee o we f f G Apen ET
43. it block connector from the door harness Remove the two setscrews securing the control unit assembly to the bracket on the intrusion member release the locking link BBC 4580 from the unit and remove the unit from the door Separate the control unit DAC 3529 from the mounting bracket BBC 6724 by removing the two self tapping screws To fit a new control unit reverse operations 2 to 4 Do not fully tighten the setscrews at this stage Jaguar Cars Limited 2005 SETTING PROCEDURE DRIVER S DOOR ONLY 1 Remove the A Post lower trim panel driver s side Service Manual Operation 76 13 22 2 Locate the door harness multiplug connector within the A post with orange red and orange green leads Disconnect the connector 3 Connect a test lamp across the connector terminals on the door harness side 1 Fig 2 a FIG 2 J 1 420 4 Set the outer door lock to full closed position 5 Set the door lock inner flap to full locked position 6 Move the control unit by hand fully towards the lock assembly then carefully move the unit slowly in the opposite direction until the test light flashes momentarily The unit should now be positioned correctly tighten the setscrews 1 Fig 3 LE i me ee eee og SS a FIG 3 JSi 213 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 09 85 SHEET 3 OF 4 Fa 8 To check the setting move the door lock inner flap slowly to the unlock position I
44. lant loss from the thermostat housing new gaskets have been introduced on 6 cy 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 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 Ibstt 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
45. lining allowing it to rest on the seats NOTE Itis not necessary to remove the headlining from the vehicle c Affix the anti resonance pads Part No BEC 9039 3 required per vehicle to the inner face of the roof panel the positions are indicated in Fig 1 Jaguar Cars Limited 2005 JSI 1959 FIG 1 NOTE Although these pads are self adhesive and magnetic they shouldbe firmly pressed along their length on to the panel using aroller or wooded block to ensure full adhesion d Refit the headlining and road test the vehicle for elimination of resonant boom Ve i stian nould DE olat ad auotinc ONmMnplain ode MR AE aie ry 1 2 labour allowance of 1 75 hrs ITEM 93 86 WATER TEMPERATURE SWITCH XJ6 2 9 4 0 1990 MY Revised operation of the air conditioning heater water temperature switch in conjunction with circuitry changes to the electronic control module have been incorporated at 1990 Model Year VIN 594576 The water temperature switch performs the following function lf warm air is required and the coolant temperature is less than 30 C the fans are switched off This avoids large amounts of cold air being blown into the car From 1990 MY the operation of this switch has changed from normally open when the coolant temperature is below 30 C to normally closed and open when the coolant is above 30 C Operation gt When the coolant is below 30 C the switch is closed thus supplying an earth to the ECU this
46. ntroduced on Transmission Numbers 84ZU 4057 84ZD 1164 The first engines to have modified transmissions fitted were 8S 28242 XJ S 7P 49806 XJ12 Saloon The introduction point for Limousines will be given when it is available The part number of the new gasket will be given when parts are available Jaguar Cars Limited 2005 SERVICE BULLETIN JD 06 84 Sheet 3 of 3 76 79 84 ITEM 51 AIR EXTRACTOR NOISE SERIES III Rectification of rattles emanating from the flaps of the air extractor tray was detailed in Service Bulletin JD 07 83 Item 49 Self adhesive plastic caps BAC 3859 are now available for use instead of the self adhesive strips previously recommended NOTE Plastic caps are packaged in strips of 56 When ordering one off BAC 3859 56 caps will be supplied which is enough for 7 vehicles 2 caps per flap 8 caps per vehicle BAC 3859 was introduced at Vehicle Identification Number 376790 ITEM 52 REPAIR CONSUMABLES SERIES ti XJ S LIMOUSINE Continuing the policy of evaluating consumable products for use on Jaguar vehicles the following products have been approved for service use and are additional to products previously approved NOTE When using any of the products recommended by Service reference should be made to the appropriate data sheet supplied by the manufacturer P955 3001 in one litre containers for use with suction feed spray gun ICI AUTOCOLOUR ANTI STONE RESISTANT Y Water based
47. on Three items are covered by normal warranty times where a component is replaced ITEM 10 86 TIME CLOCK XJ6 2 9 3 6 During July 1987 a new type of time clock was progressively introduced onto XJ6 with 100 fitment from VIN 521288 Visually the old and new clock look identical The difference between the two being the method of control the old unit obtained all its power and data signals from the central processor whereas the new unit generates its own timing signals hence its name being To ascertain which type of clock is fitted to a vehicle an inspection of connector RB LB30 must be undertaken The wire pin details are as follows CPU CONTROLLED STAND ALONE CLOCK PIN3 Slate Yellow Slate Yellow PIN 7 Slate White PIN 8 Slate PINS Biue _ PIN 12 White White PIN 13 Slate Brown Slate Brown PIN 14 Brown Green PIN 15 Orange Brown Orange Brown G It should also be noted that PIN 14 on the butkhead harness side of the connector should have a brown link wire going directly to the bulkhead positive terminal post If this wire is not connected then the clock will lose its memory when the ignition is switched off JDS Rotate Issue DBC 4004 covers the CPU controlled clock and not the stand alone AA AAA aTa A arsa 8 FTAA erte e HHG SOUHNY Sieg d ITEM 11 86 HIGH MOUNTED STOP LAMP XJS S 111 V12 XJ6 2 9 amp 3 6 NOT USA CANADA It has become apparent that Dealers have been approached by owners requesting
48. oot Lock Link Lead DAC 3509 1 Bulkhead Harness RHD DAC 3504 1 Bulkhead Harness LHD DAC 3503 1 Bulkhead Harness LHD DAC 3572 1 Driver s Door Harness DAC 3573 I Driver s Door Harness DAC 3571 1 Rearward Harness DAC 3570 1 Window Lift Sunroof Harness JLM 456 l Lockset BAC 8554 2 Edge Nut Boot Motor Bracket SH 504051 2 Setscrew y FW 104T 8 Washer Mounting Brackets BAC 5430 1 Motor Mounting Bkt Rear Door RH BAC 5431 I 2 3 LH BAC 4583 2 Link Motor to Latch Rear Door BAC 6728 T Link Bell Crank to Latch Rear Door RH BAC 6729 1 u 0 a LH BAC 6727 1 Link Boot Lock to Motor BBC 6725 i Boot Motor Mounting Bracket WF 600040 4 Spring Washer Mounting Bracket BBC 4580 2 Link Motor Control Unit to Private Lock Front Door BAC 6476 4 Anti Rattle Sleeve Rear Door DRC 1449 3 10 Grommet Doors and Boot BBC 6724 2 Mounting Bracket Motor Control Unit Front Door AB 608081 10 Self Tapping Screw Mounting Brackets CAC 1823 10 Insert Washer Mounting Brackets SH 604051 6 Setscrew Mounting Brackets l Except Canada 2 Canada only 3 Except Jaguar Sovereign VDP or Daimler 4 Jaguar Sovereign VDP and Daimler SERVICE REPLACEMENT OF CENTRAL LOCKING CONTROL UNIT DRIVER S DOOR kr 4 a Remove the door trim casing Service Manual Operation 76 74 01 With the door glass in the fully closed position remove the adhesive tape securing the control unit harness to the door interior and disconnect the control un
49. operation of either the inhibit or reverse light function is still incorrect loosen the fixing nut and adjust the switch until the correct position is obtained and re tighten ITEM 37 BRAKE FAULT DIAGNOSIS ALL MODELS To enable complaints particularly of noise or brake pull to be accurately diagnosed and repaired the following Bulletin item has been prepared It is important to clearly identify and establish the actual complaint a Judder is accompanied by pedal pulsation b Brake rumble noise this complaint normally occurs when braking heavily from high speed because of the frequency of the vibrations felt in the car it is sometimes confused with brake judder c Brake pull the vehicle has a tendency to pull to the right or left when the brakes are applied d Brake squeak occurs when braking at low speed or when coming to rest Jaguar Cars Limited 2005 yr 2nd ISSUE s SERVICE BULLETIN JD 05 86 SHEET 2 of 3 JUDDER Note This condition will usually exist if the variation in thickness of each individual disc exceeds 0 0lmm 0 0004 in Grooved discs are not detrimental to the operation of the brakes CARRY OUT A SHORT ROAD TEST COMPLAINT SEE TEST FOR CONF LRMED NO RUMBLE HARSHNESS YES TEST FOR FRONT OR REAR To check the rear discs do not exceed 40 km hr 25 mph and apply the handbrake If the judder is from the rear discs a pulsation through the handbrake lever will be f
50. or Renew 0 35 86 25 51 Front Passenger Door Lock Motor Adjust 0 40 86 25 52 Rear Door Lock Motor Adjust 0 35 86 25 33 Boot Lid Lock Motor Adjust 025 86 80 03 Door Lock Control Module Renew 0 85 86 80 04 Door Lock Control Module Adjust 0 65 ITEM 67 CENTRAL HIGH MOUNTED STOP LAMP S III XJ S V12 NAS ONLY To meet current legislative requirements USA Canadian specification S III and XJS V12 Models are now equipped with a central high mounted stop lamp introduced at VIN s 434936 S III 125881 XJS V12 The new lamp is mounted on the heated rear screen assembly and its operation controlled through the existing stop lamp circuit Illumination is provided by 4 x 5 watt capless bulbs ITEM 68 MERLIN ELECTRIC AERIAL SALL To improve electric aerial performance and reliability a new Merlin aerial assembly incorporating a permanent magnet motor has been introduced from VIN 430929 Interchangeability with the previous installation is affected A further Service Bulletin will be issued detailing parts and fitting procedures required for replacement purposes as and when parts stock is confirmed Jaguar Cars Limited 2005 ITEM 69 86 ALTERNATOR XJ S V12 88 A revised Al33 75 Amp alternator and alternator harness have been introduced on XJS V12 models from VIN 124308 The revised alternator incorporates a single eyelet connector which replaces the previous Lucar terminals For introduction details on S III Air
51. or E foam tube G and rubber elbow F should be retained when modifying both RHD and LHD conditions all other components removed may be discarded Also rubber elbow F should be shortened at the sensor connection end by 25 0mm 1 0in for both RHD and LHD applications 4 Utilizing the existing components referred to above and the new parts required pre assemble as shown in Fig 1 Locate the in car sensor harness connection H through the foam tube G before connecting to the sensor E Using suitable adhesive tape secure the sensor E to the choke D and slide foam tube G into position shown in Fig I am Relocate modified assembly into position ensuring that no kinks or twists are evident in rubber hose sections B and C 6 Using a suitable plastic self locking ratchet strap secure the lower rubber hose section B to the side of the air conditioning heater unit case as per original installation ts Replace under scuttle trim panel and glove box assembly 8 Reconnect battery Jaguar Cars Limited 2005 JSt 271 SERVICE BULLETIN JD 09 84 Sheet 3 of 3 IN CAR SENSOR MODIFICATION LEFT HAND DRIVE LHD REFERENCE Fig 2 Modified Hose Routing Fig 3 Sensor Component Assembly Wh oO Disconnect Battery Remove the driver and passenger side underscuttle trim panels Remove the instrument pack assembly and glove box compartment Carefully remove the existing choke assembly from the driver s side bl
52. ower fan ducting Cut off the plastic ratchet strap retaining the rubber hose to the air conditioning unit case and remove the choke assembly from the hose Remove the sensor assembly disconnect the sensor harness and disconnect assembly from the rubber hose Cut off the surplus rubber hose protruding at both the driver s and passenger side Extreme care should be taken to ensure that the sensor harness at both ends is clear before commencing cutting PLEASE NOTE Due to the original rubber hose section being secured to the main bulkhead harness and the securing points being inaccessible the route of the original rubber hose cannot be utilized The new rubber hose section B is to be routed forward of the bulkhead harness following the space created by the shape of the facia crash roll as shown in Fig 2 For ease of fitment it is advised that the new rubber hose is fitted from the driver s side FIG 2 Jaguar Cars Limited 2005 10 11 12 13 14 With the rubber hose B in position connect the hose to the driver s side blower motor duct aperture utilizing metal elbow A Using a suitable plastic self locking ratchet strap secure the rubber hose B to the main bulkhead harness as shown in Fig 2 Locate the in car sensor harness connections H through the foam tube G and connect to sensor E Connect sensor E to the new choke assembly D and secure using suitable adhesive tape Slide foam tube G into
53. position shown in Fig 3 Connect rubber elbow F to the sensor E Connect choke sensor assembly to hose B and fit to vehicle ensuring that no kinks or twists are present on hose B Replace under scuttle trim panels glove box compartment and instrument pack Reconnect battery JS 270 FIG 3 Jaguar Cars Limited 2005 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 coo
54. riving Dog JLM 569N Steering Pump Drive Dog 10ff AC 7107 Coupling X Engine Range 9DP102539 9DP103839 Fit Revised Heater 1 off CAC 9801 Heater JLM 1046N Feed Hose Feed Hose X X Engine Range 9DP 103840 9DF 108736 Modify Oil FillerDrain 1 off EAC 6889 Stud Bolt Cylinder Head Rear 2 off EAC 3215 1 Clips Engine Range Cover Stud 1 off EAC 7407 Hose X X X 9DP 108737 1 off EAC 7441 Oil Drain Pipe 9DP 128810 1 off EAC 4929 Olive 1 aff EAC 4927 Nut Refit Original Crank amp Damper Timing Disc None X X X X and Timing Indicator Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 88 SHEET 2 of 6 ITEM 05 tie ee mos All vehicles supplied to all markets now have a 50 anti freeze content in the cooling system from the following VIN Nos 478841 S IIV12 146964 XJS 533662 XJ6 201064 Limo 400303 Hearse This ensures cooling system protection to a temperature of 36 C ITEM 06 60 RIDE REFINEMENT DETAILS XJ6 2 9 3 6 64 66 Front Rear Shock Absorbers and Ride Level Struts Replacement Guidelines To overcome criticisms of poor ride characteristics revised settings for front and rear shock absorbers and ride level struts have been introduced on Production from VIN 527357 Parts stocks are available and parts can be ordered using the following part Numbers Front shock absorber CBC 5954 supercedes CBC 4197 Rear shock absorber CBC 5958 supercedes CBC 4186 amp CBC 5410
55. sfactory brake lining disc conditioning and lead to optimum brake life and performance ITEM 06 ALLOY WHEELS S 1M 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 now coated with Shell Retinax A grease This was introduced at VIN Nos 411159 S I 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 fit
56. the jack to just take up and support the axle assembly DO NOT overstress the differential drive flange and coupling with undue pressure NOTE Ensure the axle assembly is only supported with the jack under the lowermost differential drive flange spider leg DO NOT support the axle by using a propeller shaft drive flange spider leg as the drive flange coupling would almost certainly be overstressed Jaguar Cars Limited Jaguar Cars Limited 2005 JSi 1167 FIG 1 Remove the A frame mounting bush to body and bracket to body securing bolts and remove the mounting bush brackets Lower the jack approx 25mm 1in to give improved access Remove the A frame to differential front bracket intermediate securing bolts Remove the 4 LJ 2 ame to ditferentiantront mounting brackxetand terod outersecuring baits NOTE Ensure the outer securing bolt spacers remain in position captive in the differential front bracket after the removal of the securing bolts Remove the A frame to differential casing securing bolts applying hand pressure to support the A frame whilst the final bolt is removed Remove the A frame from the vehicle Position tool JD 143 on the bed of a hydraulic press Ensure the cut out in the tool is uppermost Remove the nut and washer from tool JD 143 6 and fit the toot assembly on to the A frame mounting bush Ensure the flats on the tool locate between the bush rebound stops Fit an
57. thly recharge schedule ensuring a fully charged condition is reached periodically 5 Stored batteries should be recharged every 2 to 3 months one to two months in hot climates until the fully charged condition has been reached c SAFETY PRECAUTIONS ake care When tilling oeatteries wi utphuric acid affected parts immediateiy with water Feta Bata a B E r ES ai i a 2 During the charging of a battery explosive gasses are given off Keep the top well ventilated and away from flames or sparks 3 Switch off the charger before disconnecting the charger leads 4 When putting the battery into service on a vehicle connect the earth iead last and when removing the battery disconnect the earth leac first on Keep the battery away from children ol Jaguar Cars Limited 2005 TABLE 1 i SPECIFIC GRAVITY AND TEMPERATURE OF ACID The specific gravities shown below are corrected to 25 C To correct the specific gravity reading for other temperatures apply the correction formula shown in the note on temperature correction a N CLIMATES WITH AIR TEM PERATU RE SPECIFIC GRAVITIES CORRECTED TO 25 C For Filling New AtEnd of Charge Calis Normallybelow32C 0 220 1 270 1 280 Frequently apove 32 C Low Gravity 1 240 1 240 1 260 Maxi mum Permissa ble Temperatu re of EI lectrolyte du ri ina rge m 45 C 45 C ie eae wee same mtse ten ay i Tem perature Correction To correct to 25 C for every 10
58. ting replacement Receiver Drier Bottles on Series I 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 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 approximately 15 degrees rearwards ITEM 10 DOOR POCKET WARNING LAMPS S II 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 B
59. together using suitable insulating tape 5 Feed the accumulator harness up through the engine bay to locate the socket NOTE Ensure that the plug and socket are clean and free of any contamination before connecting them together 6 Lower the vehicle and connect RS25 plug and socket Secure with a tie strap 7 Start the engine and allow the hydraulic system to pressurise 8 Check for any leaks 9 Check top up the power hydraulic fluid reservoir Repair Operation Number Lower Pressure Switch 66 30 11 Charge Switch 66 30 12 Labour Allowance 66 30 11 0 5hr 66 30 12 0 5hr ITEM 08 JURID 518 FRONT AND REAR BRAKE PADS XJ6 2 9 3 6 A revised brake lining material known as Jurid 518 was introduced on Production progressively from VIN 533084 and as 100 fit from VIN 533361 These pads can be identified by the wording JURID 518 printed on the top face of the pad material Part Numbers wili be advised in a Parts Information Builetin when sufficient stocks are available ITEM 09 DOOR CLOSURE XJ6 2 9 3 6 The Service network has identified a condition where during the closure operation a door latch may not fully engage causing the door to rebound open This is caused by either sa amp an A a af k amp aio ff nAnTA DETVY Ce P rye IE 128te TRE epee te naae A7 n a h L2 wt AA teva amp bf hell LA Ad kF ia k fittings which impedes closure This condition mainly affects rear door
60. tor harness and multi plug down through the engine compartment area 3 Raise the vehicle using either a jack and stands or a vehicle ramp 4 From below cut and remove the heat shrink sleeve securing the two accumulator switch harnesses together 5 Remove the anti back out plate from the rear of the muiti plug 6 Note the positions of the connections in the multi piug and remove the seal Remove the appropriate connector pins from the plug using Service Tool JD 137 NOTE Further details on pin removal can be found in Book 5 Section 86 Page 864 4 of the XJ6 2 9 2 6 Service Manual 7 Thoroughly clean the accumulator switch assembly ensuring that the surrounding area is free of all dirt and grit etc 8 Remove the leaking faulty switch from the accumulator body and discard Refitting 1 Fitthe new switch assembly to the accumulator body and tighten to the correct torque i e 31 39 Nm CAUTION DURING THIS OPERATION IT IS IMPERATIVE THAT NO FOREIGN BODIES ARE ALLOWED TO ENTER THE ACCUMULATOR 2 Position the harness pins through the anti back out plate and seal Fully seat the pins into their appropriate positions in the multi plug See Fig 1 As JLM 1563 0 CORDED e JS 8 47 B K B K FIG 1 Jaguar Cars Limited 2005 70 76 SERVICE BULLETIN JD 01 88 SHEET 3 of 6 3 Fully seat the seal and anti back out plate in the multi plug socket 4 Secure the two switch harnesses
61. uar Cars Limited 2005 66 Adjust the A frame assembly to centralise the new bush and steel plate with the ram of the hydraulic press Keeping the A frame level operate the press to fully seat the new bush Remove the steel plate Remove the A frame assembly from the hydraulic press When the new bush es has been fitted store the steel plate and tool JD 143 in a safe place ready for future use Position the A frame assembly at the correct location on the vehicle Fit but do not tighten the A frame to differential casing securing bolts Align and seat the fuel pump mounting bracket studs to the A frame then fit and tighten the securing nuts IMPORTANT Ensure the fuel pump wiring remains clear of the A frame clamping face Fit but do not tighten the A frame to differential front bracket outer securing bolts Ensure the spacers previously left in position in the differential front bracket are in the correct position before fitting the securing bolts Fit and tighten the A frame to differential rear bracket securing bolts Tighten the A frame to differential front bracket outer and intermediate securing bolts inner securing nuts and bolts and the A frame to differential casing securing bolts Raise the bottle jack ram approx 25mm 1in to seat the A frame mounting bushes on to the tapered body locations Place the mounting bush outer brackets in position and fit
62. ulletin 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 off Diode AAU 5034 D Jaguar Cars Limited 2005 SERVICE BULLETIN JD 01 85 Sheet 3 of 3 MODIFICATION PROCEDURE l 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 111 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 piama Service Bulletin JAGUAR aimler Date S
63. will inhibit the fan operation as for previous models When the coolant is above 30 C the switch will open and the ECU will see 5 Volts from its own pull up now incorporated into the ECU this will allow the fans to operate normally PLEASE NOTE The revised temperature switch and new electronic control module ARE NOT interchangeable with previous parts Fault Analysis The old system inhibits the fan operation if either the temperature switch or the harness become open circuit With the new system if the switch or the harness become open circuit the fans will continue to operate even if the coolant temperature is below 30 C Similiar modifications to XJS and S 1I V 12 will be introduced in the near future Introductory VIN s will be advised in a future Service Bulletin Jaguar Cars Limited 2005 iS Service Bulletin JAGUAR DATE APRIL 1992 PAGE 1 of 4 REF JD 03 92 Owing to revised information received from Engineering pages 11 of Service Bulletin JD 01 92 3 4 and 9 10 of Service Bulletin JD 02 92 are being re issued and are pro vided at the end of this Bulletin marked Ilssue 2 Existing pages of the above should be removed and discarded to be replaced with the revised version XJ6 3 2 amp 4 0 ITEM 20 03 ADDITIONAL REPAIR OPERATION TIME The following Repair Operation Times are now available 12 29 16 Cylinder Head Gasket Rear Blanking Plate Renew 1 40 Hrs Gasket 12 29 17

Download Pdf Manuals

Related Search

Related Contents

Auricular Bluetooth Nokia BH    User`s Guide - Rev.1.3 - Hawk-IIc  SMG-700 User's Guide V1.00 (Nov 2004)  Transcend Transcend TS4GHR72V1C memory module  Nilfisk-Advance America GU 305 User's Manual  消毒、滅菌総合ガイド - お客様相談センター  Télécharger la fiche technique  BUTLER 2551 DELUXE - CONRAD Produktinfo.  Contents  

Copyright © All rights reserved. Failed to retrieve file