Service Bulletin - Terry`s Jaguar Parts
Contents
1. JA GUAT aimler Service Bulletin Date MARCH 1984 Sheet 1 of 3 Bulletin JD 03 84 ITEM 14 00 AMENDMENT SERIES Ili XJ6 With reference to Item 76 JD 12 83 crankshaft and bearing failures Please note the intro duction points for B emission sursulf hardened crankshafts should read as follows 8L 148896 XJ6 7M 4796 Limo ITEM 15 SERIES III 4 2 5 3 XJS HE 00 WARRANTY CODES WHERE APPLICABLE During recent monitoring of Service Warranty Claims Returns in particular problems relating to Air Flow Meter Hoses split or adrift and headlamp adjustment investigations have been impeded by incorrect warranty codes being quoted Will Dealers please note that for the above mentioned problems the correct codes to be utilized are as follows Air Flow Meter Hose Adrift 2F2B Air Flow Meter Hose Split 2F2E Headlamp Unit Adjusted 7J1 A Jaguar Cars Limited Jaguar Cars Limited 2005 03 12 12 ITEM 16 REPAIR OPERATION TIMES XJ S 3 6 XJ SC 3 6 Service Times and Option Service Times for the new XJ S 3 6 and XJ SC 3 6 are quoted below There are no differences in Service Times or Option Service Times between the two models INTERVAL SERVICE TIME OPTION SERVICE TIME 1 000 miles 3 45 hrs 7 500 miles 3 20 hrs 0 90 hrs 15 000 miles 4 45 hrs 0 25 hrs 22 500 miles 3 20 hrs 0 90 hrs 30 000 miles 5 35 hrs 0 25 hrs 37 500 miles 3 20 hrs 0 90 hrs 45 000 miles 4 50 hrs 0 25 hrs 52 500 miles2. 25mm N B A kitis required to fit the new squab covers according to the following procedure This can be obtained from Jaguar Parts Supply by quoting Part No JLM 1787 PROCEDURE FOR DRILLING HOLES 1 Refer to therelevant figure for hole size location mark and punch the hole centre 2 Drilla pilot hole NOTE A pilot hole is necessary to prevent any possible frame damage ie bending which may result from the excessive pressure required to drill a fuil size hole 3 Open out the holes to full size NOTE When drilling the 7mm holes set the drill stop to allow the drill to penetrate 10mm ONLY The drill MUST NOT be allowed to contact the recline motor 4 Ensure that no drilling swarf debris enters the gear recline mechanism Jaguar Cars Limited 2005 FIG 3 FIG 4 TRIMMING THE SQUAB USING MECHANICAL FIXINGS E Place the new squab cover on the bench Trim off excess foam and piping where necessary Figs 5 and 6 3 Al A A KN SA K A s gt JS 930 FIG 5 FIG6 Attach fine malleable draw wires to the yellow elasticated support cables A Fig 7 Starting at the top feed the draw wires down through the calico material tubes that are fixed to the vertical inner edges of the squab cover Fig 7 Leave approximately 200mm showing at the upper end Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 89 SHEET 4 of 7 NW JU CT PEST A amame JSI 9268 FIG 7 Feed the inner
3. The HSLP switch is designed to monitor pressure drop on the high side line At a low pressure condition of 25 psi 5 psi the HSLP switch contacts which are normally closed open circuit thus breaking the earth circuit to the compressor clutch coil resulting in the clutch drive disengaging Where a definate fault is present in the air conditioning system e g low refrigerant restriction etc the HSLP switch will remain open circuit until such time as the problem is corrected Following rectification and recharging of the system the HSLP switch will return to a closed state once again completing the clutch circuit The need for the thermal fuse has been obviated with this system and significant benefits are gained especially where a transient fault occurs This condition has been experienced in service and in some instances has resulted in vehicles being returned several times to a Dealer for the fuse to be replaced although at the time the air conditioning system appeared to be fault free Jaguar Cars Limited 2005 J 86 510 1l Clutch Relay 3 HSLP Switch 2 Compressor Clutch 4 Diode Suppression FIG 17 SOME VEHICLES MAY STILL BE EQUIPPED WITH THE SUPEHEAT SWITCH THERMAL FUSE SYSTEM FOLLOWING MK III LAUNCH THE OPERATIONAL DETAILS ARE AS FOLLOWS SUPERHEAT SWITCH AND THERMAL FUSE A superheat switch is included in the compressor clutch circuit to provide a compressor protection system The superheat switch and thermal
4. assemblies are closed preventing outside air from entering the system In the LOW AUTO and HIGH positions information regarding the range of fan speeds is received by the control module from the control switch temperature selector and the various sensors Should a low fan speed be selected the control module will maintain the speed of the fan motor within a range of low speeds depending on the temperature requirement of the vehicle There are no steps between the fan speeds The fan speeds are electronically controlled and by selecting LOW AUTO or HIGH a level of speed in the range selected is received dependent on the vehicle requirement When DEFROST is selected the fans are electronically controlled to operate at maximum speed the screen vents open maximum heating is obtained and the lower level flaps fully close this operation can take up to a maximum period of 30 seconds Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 5 of 9 SWITCH POSITIONS A OFF B LOW C AUTO D HIGH E DEFROST l Pin Zs Pin 3 Pin 4 Pin 13 14 15 27 control control control control module module module module 5 Pin 5 Pin L Pin 8 Pin control control control control module module module module FIG 13 MODE CONTROL DIAGRAM BLOWER MOTOR SPEED DRIVE CONTROL Mounted in the outlet of the blower motor units are heatsink assemblies each of which consist of an interference suppressor diode 11 F
5. 0 200mV Water Valve Vacuum Solenoid 17 0 200mV Centre Vent Vacuum Solenoid 18 O0 200mV Select Norm Med or Auto On mode Switch Low Input 13 3 SV Medium Input 14 150 350mV High Input 15 3 25V Defrost Input 27 3 5V Select High On Mode Switch Maximum Temperature Demand Ensure Servos Are Stationary Jaguar Cars Limited 2005 Pin No Voltage Low Input 13 3 5V Medium Input 14 3 5M High Input 15 150 350mV Defrost Input 27 i 3 5V Select Defrost Low Input 13 3 5V Medium Input 14 3 5V High Input 15 3 5V Defrost Input 27 150 350mV Temperature amp Diff Potentiometer Ranges Temperature Demand Maximum 35 2 665 3 105V Temperature Demand Minimum 35 0 200mV Diff Demand Maximum 28 4 750 5 250V Diff Demand Minimum 28 0 200mV Set Temperature Demand to Mid Range 35 1 53 L 45V Select Norm Recirc Input 9 3 SV Servo Drive Lower Flap 37 4V Servo Drive Lower Flap 41 4V Servo Drive Upper Flap 40 4V Servo Drive Upper Flap 42 4V Recire output 3 0 500mV Reference voltage 7 2 875 2 895V Defrost Output Ll 0 500mV High Speed Relays 16 0 500mV Lower Feedback Potentiometer 29 0 60 0 90V Upper Feedback Potentiometer 30 1 15 1 45V Coolant Temperature Input 21 260 460mV Defrost Output 11 QO 500mV Clutch Output Evaporator above 2 745V 20 10 3 13 3 RH Blower Feedback 33 10 13V LH Blower Feedback 22 10 13V RH Blower Control 32 G D 3V LH Blower Control 31 0 0 5V Water Valve Solenoi
6. fuse guards against a low refrigerant charge or blockages causing extreme superheated refrigerant vapour conditions resulting in compressor damage The thermal fuse is a sealed unit containing a heater and a meltable fuse The superheat switch is located in the rear of the compressor in contact with the suction side refrigerant vapour With a low refrigerant charge or a blockage the pressure drops and the temperature rises This condition closes the superheat switch contacts which completes the thermal fuse heater circuit melts the fuse disconnects the battery supply to the compressor clutch winding and the thermal fuse heater The compressor ceases to operate and damage from insufficient lubrication will be avoided The thermal fuse melts at 157 to 182 C Time taken 2 minutes 14V system voltage 5 5 minutes 11 5V system voltage The heater resistance cold 8 to 10 ohms CAUTION After a thermal fuse melt establish and rectify the cause before replacing the thermal fuse unit complete FAULT FINDING WARNING THE MICRO PROCESSOR IS AN EXTREMELY SENSITIVE AND EXPENSIVE UNIT AND SHOULD ONLY BE TESTED USING A DIGITAL TYPE MULTI METER WITH NO LESS THAN A 3 5 DIGIT DISPLAY AND A RESISTANCE OF NO LESS THAN 2 MEGS OHMS ANY OTHER FORM OF MULTI METER WILL IRREVERSIBLY DAMAGE THE MICRO PROCESSOR THE CONTROL PINS ARE MOUNTED VERY CLOSE TOGETHER THEREFORE THERE IS A HIGH RISK OF SHORTING TWO PINS TOGETHER WHEN USING A TEST PROBE T
7. of sheet 2 states that the high compression 12 5 1 will be discontinued This should read was discontinued and replaced by the standard 11 5 1 compression engine We apologise for any confusion caused and affirm that all engines fitted with Marelli ignition will run on unleaded fuel ITEM 11 O3 REVISED REPAIR TIMES XJS3 6 XJ62 9 amp 3 6 Since the deletion of drive in drive out allowance all modifications issued in Service Bulletins have now been revised Please amend your Bulletins where applicable using the D following list TIME SRO No MODEL PREV NEW ITEM 82 91 05 XJ62 9 3 6RHD 1 70hr 1 55hr Air Con Heater in car sensor 82 91 05 XJ62 9 3 6LHD 1 05hr O 90hr AirCon Heater incar sensor 86 91 14 XJ6 2 9 3 6 O 3Ohr 0 15hr Bonnet Chassis Earth 86 91 13 XJ62 9 3 6 O 45hr 0O 35hr Electric Aerial 30 94 65 Ad OA O o 7 J A 9 40 n watals Heatshield Rz 76 91 84 XJ62 9 3 6 O 85hr 0 75hr Sliding Panel Seal Adjustment 76 91 63 XJ62 9 3 6 1 50hr 1 40hr Door Panel Resonance 76 91 14 XJ6 2 9 3 6 O 3O0hr 0 15hr Boot Connector Rattle 76 91 15 XJ6 2 9 3 6 0 30hr O 20hr Centre Console 76 91 16 XJ6 2 9 3 6 Q 75hr O 60hr Radio Panel Creaks 76 91 67 XJS XJ6 3 6 1 45hr 1 30hr ZF Transmission 1 2 shift Jaguar Cars Limited quality Jaguar Cars Limited 2005 i ry SRO No MODEL PREV NEW ITEM 76 91 26 XJ62 9 3 6 O 65hr 0 55hr Passenger SW Pack and Ashtray Assy 76 91 25 XJ62 9 3 6 O 25hr O 15hr Door Wood
8. prevent these leak paths and modifications will be advised in a future Bulletin issue As a result of water entry vehicles equipped with the Hirschmann Electric Aerial Assembly from VIN 123281 JD 07 Item 55 refers have experienced contamination of the aerial relay causing aerial operation to be affected To prevent this relay assembly DAC 1820 has now been inverted This ensures that the relay terminals are positioned downwards and are therefore not vunerable to water splash Introduced at VIN 132955 Jaguar Cars Limited 2005 Vehicles in service prior to the safe VIN where water ingress has affected the aerial relay may be modified accordingly a Disconnect the battery and remove aerial trim panel b Release the excess relay harness from the clips beneath the inner wing panel c Remove the relay from the mounting bracket lug invert and relocate onto lug d Ensure the harness is routed as Fig 1 and is clear of the mounting bracket A JST 478 FIG 1 1112F Jaguar Cars Limited 2005 A A ih Qaimlen DATE MARCH 1989 SHEET 1 of 7 REF JD 03 89 ERRATA Bulletin JD 02 89 Section 19 Item 07 Modification procedure Paragraph 19 shouldread 19 Remove auxiliary air valve and replace with new unit supplied in kit Repair Operation amp 19 20 16 refers Not 12 20 16 as stated Please amend your copy accordingly NOTE Bulletin JD O 1 89 item O 1 Marelli Digital Ignition Paragraph 1
9. receives data signals from driver operated switches then by comparing this data with data received from various temperature sensors and feedback sensing devices it calculates the output voltages needed to operate the blower motors flap servo motors compressor and vacuum solenoids to achieve the temperature requirement selected for the vehicle Although the control module cannot be repaired in service a set of test pins are accessible for testing the various circuits by the use of a digital multimeter GREAT CARE MUST BE EXERCISED WHEN USING THE TEST METER THE CONTROL MODULE WILL BE IRREPARABLY DAMAGED SHOULD ANY OF THE TEST PINS BE MOMENTARILY SHORTED TOGETHER Th s technique should only be used until the new Jaguar Diagnostic System is available which is designed to test Mk III Air Conditioning fully and comprehensively Jaguar Cars Limited 2005 J 194 Upperfeed Back Potentiometer 6 Differential Temp Control Lowerfeed Back Potentiometer 7 Temp Demand Control Water Temp Switch 8 Temp Demand Potentiometer Recirc Vacuum Solenoid 9 Condensate Drain Tube Water Valve Vacuum Solenoid 10 Recire Solenoid Vacuum Restrictor FIG 1 AIR CON UNIT LH SIDE 49 185 Control Unit 6 Defrost Vacuum Solenoid Upper Servo Motor 7 Mode Switch Lower Servo Motor 8 Mode Control Evaporator Sensor 9 Condensate Drain Tube Centre Vent Vacuum Solenoid 10 Centre Vent Solenoid Vacuum Restrictor FIG 2 AIR CON UNIT RH SIDE Jagua
10. retainer cable through the upper horizontal calico material tube Feed the yellow support cables through the inner retainer cable eyes Fig 8 Fit the cover to the foam squab feed the 200mm of support cable through the slits in the foam andthrough the holes in the rubber diaphragm Fig 9 Locate the support cable hooks into the upper frame 4mm holes Fig 9 Carefully align the cover over the squab frame ensuring a good shape and tailored fit Ensure that the headrestraint cover holes are aligned correctly Pull the draw wires support cables around the recline pivot tube Hold one support cable under tension remove the draw wire and locate the hook into the lower frame 4mm hole Fig rtneother draw wire support cable Feed the harnesses through the holes in the lower cover Secure with new ratchet straps where necessary Fig 11 Jaguar Cars Limited 2005 FIG 10 FIG 11 Fit the side borders into position and align the 7mm holes Secure with fir tree plastic studs Fig 12 Fit double sided tape to the pivot flanges Fig 13 FIG 12 FIG 13 Remove the backing from the tape and position the cover lower trim onto the tape Secure the plastic retainer onto the frame flange Fig 14 Secure the cover to the frame using steel clips Fig 15 NOTE Spacing of clips is determined by a series of small holes in the cover material Locate the clips at these holes Jaguar Cars Limited 2005 SERVICE BULLET
11. suspension has identified that a creak can occur where the upper shock absorber assembly mounting bracket jocates into the bod aperture To eliminate further instances of this fault a spacer has been fitted Fig 1 on all XJ6 vehicles built from VIN 57 1642 This spacer is now available via Parts Supply and may be used as aretrospective in service fix on vehicles with this fault Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 89 SHEET 2 of 7 J511036 Rectification Referring to XJ6 Service Manual Pages 6 1 1 to 64 7 for non ride level suspension or 66 9 to 66 10 for ride level suspension displace road spring shock absorber assemblies Fit spacer BEC 1184 over shock absorber Assemble upper mounting bracket Ref to Fig 1 Reassembie suspension and road test vehicle NOTE Road spring shock absorber assemblies should notbe dismantled The operation numbers descriptions and times for the above procedures are as follows 64 9 1 01 Rear Shock Absorber Upper Spacer Modification 1 15 hrs 66 9 1 08 Ride Levelling Strut Upper Spacer Modification 1 70 hrs ITEM 14 RJ EA the DK HANL S 2 o Ithas been established that extreme force applied to an interior door handle can cause the clip securing the operating cable to become disconnected Whilst the clip is simple to refit it is recommended that it should be replaced by fitment of a new improved clip AGU 2678 RH and AGU 2679 LH which will remain in position The new
12. 3 20 hrs 0 90 hrs 60 000 miles 5 3b hrs 0 25 hrs 67 500 miles 3 20 hrs 0 90 hrs 75 000 miles 4 45 hrs 0 25 hrs 82 500 miles 3 20 hrs 0 90 hrs 90 000 miles 5 40 hrs 0 25 hrs 97 500 miles 3 20 hrs 0 90 hrs Use current Supplementary Job Sheets for these services No other Services Times or Option Services Times are affected ITEM 17 ENGINE GROAN ON INITIAL START UP 5 3 MODELS Reports have been received of an engine noise on V 12 engines described as a groan on initial start up when the engine is cold This is a standard feature although it may not affect every engine It is caused by the oil pump purging air out of the lubrication system which can enter the system after the engine has stopped It is not detrimental to the running performance of the engine and disappears very quickly after starting NOTE Any noise which persists for a significant length of time should be investigated further ITEM 18 E EMISSION ENGINES SERIES III XJ6 MIDDLE EAST MARKETS BAHRAIN KUWAIT LEBANON OMAN QATAR SAUDI ARABIA UNITED ARAB EMIRATES To accommodate the introduction of the evaporative loss system detailed in Service Bulletin JD 01 84 Item 01 all XJ6 vehicles supplied to Middle East markets are now fitted with E emission specification engines In addition to a thermal vacuum valve and throttle edged vacuum source for the evaporative loss system E emission engines also incorporate standard compression pistons Part
13. 441593 S III V12 127879 XJS V12 Interchangeability with the previous type control unit is not affected A further Service Bulletin will be issued advising part number allocation and parts stock availability ITEM 18 DIFFERENTIAL PINION SEAL S III XJS 3 6 LIMO Further to Service Bulletin JD 08 85 Item 57 the new pinion seal Part No JLM 527 has now been introduced on all remaining GKN axle ratios from unit number 85N 5701 and progressively introduced at Jaguar from VINs 129526 IS 3 6 446153 S III 200821 Limo ITEM 19 GEAR LEVER GAITER S III AXJ5 To prevent gear lever sizzle on manual transmission XJ6 vehicles a revised gear lever gaiter incorporating a rubber O ring and retaining ferrule was introduced on 1986 M Y vehicles This gaiter is available under Part No BBC 8602 ITEM 20 PAINT RECTIFICATION CRAZING CHECKING ALL MODELS This Bulletin has been prepared primarily to provide Jaguar Dealers Importers with guidelines for use when carrying out paint rectification on vehicles affected by crazing checking Jaguar are aware of the need for the refinisher to repair first time any damaged paint work so the correct approach and diagnosis is vital if this is to be achieved This is particularly important where major rectification is necessary as errors can prove costly GENERAL POINTS 1 Film build depth is critical on thermo plastic acrylic T P A finishes Jaguar recommend 150 200 microns total film
14. 7 5V High 2 3V 2 2V 2 3V 2 2V 3 0 5V 4 1V 3 0 5V 4 0V Pin No Voltage Set Temperature to Maximum 28 2 08 J LOV Mode Switch RH Control LH Control RH Feedback LH Feedback Position Pin No 32 Pin No 31 Pin No 33 Pin No 22 Low 1 2V 1 67V 1 2V 1 63V 6 5 9V 6 25V 6 5 9V 6 1V Med 2 3V 2 17V 2 3V 2 1V 3 0 5V 4 25V 3 0 5V 4 2V High 2 3V 2 37 2 3V 2 3V 3 0 5V 3 79 3 0 5V 3 5V Pin No Voltage Open The Water Temperature Switch Leads Set Temperature to Mid Point 35 1 43 1 45V RH Control 32 0 0 5V LH Control 31 0 0 5V Short the Water Temperature Switch Leads Select Low On Mode Switch Jaguar Cars Limited 2005 Clutch Output RH Control LH Control Set Diff to Minumum Set Temperature to Minimum Recire Output High Speed Relays Water Valve Solenoid Centre Vent Solenoid Defrost output Select Defrost On Mode Switch High Speed Relays Lower Feedback Upper Feedback Select Off On Mode Switch Recire Output Pin No Voltage 20 9 43 12 3V 32 1 2V 31 1 2V 28 0 200mV 35 0 200mV 3 9 3 12 3V 16 0 200mV 17 9 3 1243 18 9 3 12 3 35 0 500mV 27 150 350mV 16 93 2 43V 29 2 709 3 100V 30 1 714 2 014V 44 0 lv 3 9 3 12 3V eee sopa Pon n mom p Control module In car temperature sensor Defrost vacuum solenoid Mode control switch WO OOo J Q uin P Co h2 High speed relays Compressor clutch relay Differential control iu Ambient temperature s
15. 8 Time allowance 1 60 hours ITEM 16 RECOMMENDED TREATMENT OF ELECTRONIC CONTROL DEVICES IN AN ACCIDENT REPAIR ALL MODELS Electronic components are manufactured and designed to withstand damage or stress which may arise during the manufacture and fitment to the vehicle Similarly electronic control devices are positioned in or on the vehicle so as to survive most accidents relatively undamaged The replacement of electronic control devices after an accident is therefore only necessary when one or more of the following criteria are met 1 Thehousing is damaged or distorted 2 Themounting position or bearing surface is damaged or distorted 3 Theharness connector is damaged or corroded as aresult of moisture 4 Thevehicle self diagnosis facility or functional test indicates a fault ITEM 17 BODY REPAIR WELDING BRAZING PRECAUTIONS ALL MODELS Due to the sensitive nature of certain electrical electronic components on XJ6 XJS SIII essential precautions are necessary before carrying out welding or brazing 1 DISCONNECT THE BATTERY BEFORE CARRYING OUT ANY BODY REPAIR WORK OBSERVE HEALTH AND SAFETY PRECAUTIONS 2 Electric Arc Welding CAUTION UNDER NO CIRCUMSTANCES MUST ELECTRIC ARC WELDING EQUIPMENT BE USED ON JAGUAR VEHICLES Due to the high voltages produced electric arc welding can cause irreparable damage to the microprocessor ECU controlled systems therefore this method of body repair must not be used Jaguar Cars
16. 83 English AKM 4051 83 Italian AKM 4446 83 Dutch AKM 4447 83 French AKM 4448 83 German AKM 4494 83 Spanish ITEM 13 12 CRANKSHAFT FRONT SEAL S III XJ6 LIMO A new crankshaft front seal incorporating a PTFE sealing lip has been introduced on all 3 4 and 4 2 litre engines from Engine Nos 8A 16541 S III 3 4 8L 203238 S III 4 2 7M 5211 Limo Jaguar Cars Limited Jaguar Cars Limited 2005 LZ 12 12 The new seal is available under Part No EAC 8815 and is supplied on a mandrel which should not be removed until immed ately prior to fitting the seal This seal should now be used for all XK crankshaft front seal replacements and should be fitted in conjunction with a new distance piece Part No C40147 and O ring When fitting the new seal please note the following and refer to Repair Operation 12 21 14 in the Workshop Manual 1 This seal is designed to operate without an oil flinger behind the seal and it will therefore be necessary to remove this where fitted As the flinger cannot be withdrawn from the crankshaft with the timing cover in place cut into the notches with suitable metal shears and discard the segments 2 Fit the seal dry as supplied taking care to avoid contact with the sealing lip Do not degrease the seal as this will damage the material 3 When fitting the new distance piece lubricate with clean engine oil Do not use grease 4 When refitting the sump apply a small bead of RTV sealant
17. ACUUM SOLENOID The vacuum supply to the recirculate fresh air flaps and the centre vent have built in restrictors so that the operation of these flaps is slowed down to avoid the risk of the system hunting due to the rapid change caused by fast operation time The recirculation flaps can take up to 30 seconds to change state COMPRESSOR CLUTCH CONTROL The output from pin 20 of the control module is used to energise the compressor clutch relay 2 Fig 16 which will result in the relay contacts closing allowing battery voltage to the clutch via the thermal fuse 3 Fig 16 The control module has protection circuits built in to protect the micro processor from damage in case of incorrect connections which may be made to the compressor clutch relay Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 6 of 9 1 S ge 8 S i L SS ORES 6 J86 299 L Positive Battery Supply 5 Pin 20 Control Module 2 Clutch Relay 6 Superheat Switch 3 Thermal Time Fuse 7 Negative Pin Control Module 4 Compressor Clutch FIG 16 COMPRESSOR CLUTCH DIAGRAM HIGH SIDE LOW PRESSURE HSLP SWITCH Together with the introduction of the Mk III unit a new compressor clutch protection system will be introduced The thermal fuse and superheat switch are deleted and replaced by a high side low pressure switch HSLP The superheat switch design was such that it detected pressure drop and superheated refrigerant vapour on the low pressure line
18. IN JD 03 89 SHEET 5of 7 FIG 14 FIG 15 Place a suitable support block on the bench Cover the block to prevent damage to the seat facing Place the seat on the bench with the support block directly below the relief line the relief line is arrowed in Fig 16 Position the outer retainer cable as shown in Fig 16 Press down the diaphragm until the inner retainer cable inside the calico tube meets the outer retainer cable Secure both cables with hogrings Fig 16 JS 925 FIG 16 Refit the headrestraint Refit the squab back finisher Refit the lumbar support handwheel escutcheon Refit the seat recline handwheel escutcheon manual seat only NOTE Use a bradawl to mark hole positions in the squab side cover for the lumbar support escutcheon Refit the recline tube side covers two on powered seats one on manual seats Refit the seat to the vehicle 76 70 01 Jaguar Cars Limited 2005 77 77 REPAIR OPERATION TIMES ELECTRICALLY OPERATED FRONT SEAT SQUAB MECHANICALLY FIXED COVER RENEW S R O 76 70 15 Time allowance 1 45 hours MANUALLY OPERATED FRONT SEAT SQUAB MECHANICALLY FIXED COVER RENEW S R O 76 70 25 Time allowance 1 40 hours ELECTRICALLY OPERATED FRONT SEAT SQUAB ADHESIVE FIXED COVER RENEW USING MECHANICALLY FIXED COVER S R O 76 91 29 Time allowance 1 65 hours MANUALLY OPERATED FRONT SEAT SQUAB ADHESIVE FIXED COVER RENEW USING MECHANICALLY FIXED COVER S R O 76 91 2
19. L V12 AUSTRIA GERMANY AND SWITZERLAND To satisfy legislative market requirements a revised engine specificiation for the above markets has been introduced This incorporates an emission type F engine with stellite seat valves and emission equipment cbanges to suit unleaded fuel A summary of the emission equipment by market is tabulated below Germany A B C D Sct 5 2 X X X S III V12 XJS V12 X X Austria Switzerland S III 4 2 X X X X S III V12 XJS V12 X X X X A Underfloor Catalyst B Downpipe Catalyst C Air Injection D Oxygen Sensor To rationalise build Fitted to first cars only not required on subsequent builds The engine idle and ignition setting should be checked against the following values S III 4 2 Idle speed 750 850 rev min Austria Germany Ignition Timing 16 189 BTDC at 800 rev min and Switzerland with vacuum disconnected S III V12 XJS V12 Idle speed 650 850 rev min Austria Germany Ignition Timing 15 179 BTDC at 3 000 rev min and Switzerland with vacuum disconnected These changes have been introduced from engine numbers 8L 209816 S III 4 2 FP 55737 8 III VIZ 8S 43250 XJS V12 Further details and part numbers will be issued as parts are available Jaguar Cars Limited u Jaguar Cars Limited 2005 ITEM 46 74 ALLOY ROAD WHEELS SIII XJS 76 80 small batch of vehicles fitted with alloy road wheels and Pirelli tyres recently despatched from the factory are subject to r
20. Limited 2005 SERVICE BULLETIN JD 03 89 SHEET 6 of 7 Resistance spot welding can only be carried out on bare metal it is assumed therefore that all trim and electrical components in the locality of the repair will have been removed prior to panel removal replacement It is however the responsibility of the technician to ensure that ALL sensitive electrical electronic components in the locality of the repair are disconnected and removed before commencing work 4 MIG welding brazing including MIG plug tack seam butt welding As with resistance spot welding MIG welding and brazing will only be carried out when all trim and electrical components have been removed prior to painting Again it is recommended that ALL sensitive electrical electronic components in the locality of the repair are disconnected and removed before commencing work Always observe Health and Safety precautions see the relevant Service Manual Section 77 Body Repair These methods of welding and brazing are the only ones recommended by Jaguar Cars Ltd ITEM 18 o 84 WIPERMOTORS XJS To improve the wiper system performance on XJS models a new wiper motor has been introduced from VINs 15251 1 RHD 154405 LHD Interchangeability between the previous wiper motor and the new system is affected Should it become necessary to replace the earlier motor a conversion is possible utilising the parts listed and following the detailed proce
21. Motor Grille Assembly Remove the old motor and grille assembly replace with the new motor and grille unit Wiper Arm Blade Setting Procedure Reconnect battery With the ignition switch on switch on the wiper system and switch off with the wiper switch This procedure ensures that the wiper motor is in the parked position Note that with the new wiper system there is no suppressed wiper blade parking Switch the ignition off Fit the wiper arms and blades as shown in Fig 2 Diagrams C and D Tighten the wiper arm fixing nut s to a torque of 9 10 Nm Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 89 SHEET 7 of 7 JS1103c DIAGRAM C Passenger side RH Drive shown LHD is symmetrically opposite 191 1033 DIAGRAM D Driver s Side LH Drive shown RHD is symmetrically opposite 1888F FIG2 Jaguar Cars Limited 2005
22. No EAC 2042 E emission 6 cylinder engines were introduced for the above markets at VIN 380366 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 84 Sheet 2 Of 3 19 26 ITEM 19 CRUISE CONTROL SERIES III 4 2 EFI Would Distributor Dealers please note that if they are involved with the installation of an Econocruise after sales cruise control kit Part No 2 5042 as specified for Jaguar Series III 4 2 EFI Models it is ESSENTIAL that the instructions regarding the fitment of the Econo cruise throttle lever and bowden cable brackets reference kit part number 236 are followed carefully See Fig 1 IMPORTANT FOLLOWING INSTALLATION IT IS ESSENTIAL THAT A FULL OPERATIONAL CHECK IS CARRIED OUT THIS IS TO ENSURE THAT THE MOVE MENT OF THE ECONOCRUISE THROTTLE CABLE DOES NOT COME INTO CONTACT WITH THE FUEL INJECTION FUEL RAIL HOSES AS EXPLAINED IN THE FITTING KIT INSTRUCTIONS SHOULD ANY PROBLEMS ARISE THROUGH A FAILURE TO COMPLY WITH THE FITTING INSTRUCTIONS OR OTHERWISE THE RESPONSIBILITY LIES SOLELY BETWEEN THE DISTRIBUTOR DEALER AND ECONOCRUISE LTD Jl 42 ITEM 20 RADIATOR HOSE 5 3 MODELS Several reports have been received of radiator hoses splitting on the above models especially the top hose Investigations with the supplier have attributed this to delamination of the hose material resulting in bursting of the hose All suspect hoses have been removed from production and Unipart stocks Radiator hoses are quality a
23. Veneered Panels 76 91 19 XJ62 9 3 6 O 3Ohr O 15hr Front Door Sill Button Bezel 76 91 20 XJ62 9 3 6 O 25hr 0 15hr Rear Door Sill Button Bezel 76 91 21 XJ62 9 3 6 O 2b5hr 0 10hr Coinbox Driverside Underscuttle 76 91 23 XJ62 9 3 6 O 45hr 0 35hr Rear Parcel Shelf 76 91 13 XJ62 9 3 6 O 45hr O 35hr Sunroof 76 91 24 XJ62 9 3 6 0 25hr Q0 10hr Sunvisor Vanity Mirror 76 91 78 XJ62 9 3 6RHD 1 35hr 1 30hr Sanden Compressor Noise 76 91 78 XJ62 9 3 6 LHD 1 55hr 1 50hr Sanden Compressor Noise 76 91 77 XJ62 9 3 6 1 60hr 1 25hr Blower Motor Assy Mod 76 91 80 XJ6 2 9 3 6 2 00hr 1 90hr Front Windscreen Condensation 76 91 81 XJ62 9 3 6 O 60hr 0 50hr FrontWindscreen Condensation 76 91 72 XJ6 2 9 3 6 O 55hr 0 40hr Rear TailLight 76 91 83 XJ62 9 3 6 O 40hr 0 30hr Oil Pressure Transmitter 76 91 64 XJ62 9 3 6 0 45hr O 30hr Fuel Tank Element 19 91 08 XJ62 9 3 6 1 00hr O 9O0hr Fuel Tank Internal Hose Clipping 76 91 82 XJ6 2 9 3 6 0 30hr 0 20hr FuelFiller Flap 76 91 08 XJS C 1 85hr 1 75hr Boot Ventilation NOTE No other Repair Times are affected ITEM 12 57 P A S RACK FIXINGS TORQUE SETTINGS XJ6 The torque settings quoted in the XJ6 2 9 3 6 Service Manual for the rack mounting securing amp nuts and bolts have been changed from 26 29 Nm to 45 55 Nm Please ensure that all Service staff are made aware of this change ITEM 13 64 REAR SUSPENSION CREAKS 2 XJ6 2 9 3 6 66 Investigation into noises emanating from the rear
24. WO PINS SHORTED TOGETHER EVEN MOMENTARILY WILL CAUSE IRREPARABLE DAMAGE TO THE CONTROL MODULE Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 7 of 9 To avoid shorting two pins together an insulated sleeve or shroud must be fitted over the probe so that it overlaps the end of the probe by approximately 3 mm 9 125 ins The insulation stripped from a piece of cable will provide a suitable sleeve Always allow time for servos to come to rest An automatic check will require setting all sensors to a known condition i e in workshop area at 24 C 75 F for at least 30 minutes Sensor inputs will relate to ambient temperature ie at 24 C 75 F sensor voltage readings will be 2 97V lmV 10c 33 89F This technique should only be used until the new Jaguar Diagnostic System is available which is designed to test Mk III Air Conditioning fully and comprehensively SYSTEM OFF POWER SUPPLY ON Pin No Voltage Ignition in 1l 11 14V Recire Input 9 2 6V Grounds 2 0 40mV 6 0 40mV 10 0 40mV 38 0 40mV 45 0 40mv From On Off Switch 44 0 12mV To ON OFF Switch 12 10 13 3V Set in Manual by shorting pin 19 To Ground Select Low On Mode Switch Maximum Temperature Demand Low Input 13 150 350mv Clutch Output Evap Sensor below 2 720V 20 0 6 11 4V Medium Input 14 3 5V High Input 15 3 5V Defrost 27 3 5V From On Off Switch 44 10 3 13 3V Output 43 4 73 5 2V Recire output 3 O 200mV High Speed Relay 16
25. at original exterior however refinishers can allow up to 250 microns on a sound substrate 2 Refinishers must use recommended materials from Jaguar approved suppliers Jaguar Cars Limited 2005 United Kingdom and Europe Inmont I C I Ault and Wiborg Sikkens Dupont Berger P P G United Kingdom and Glasurit U S A and Canada Inmont Rinshed Mason I C I C I L Ltd Sikkens and Dupont Australia Spartan and Dulux R O W Approved supplier materials from the above via importers or local agents These materials may be marketed under an alternative trade name 3 Paint supplier data sheets must be referred to with regard to viscosity application surface preparation and Spray booth temperatures DEFINITION Crazing checking can be categorised into three types of which one or two may be present on a vehicle 1 Fuel Crazing Forms a local run pattern of fine crazing due to fuel spillage onto newly applied paint 2 Fine Cracking Checking Evident on early cars emanating from around the front and rear screens of direct glazed thermo plastic acrylic T P A vehicles Small areas of fine crazing checking are usually apparent adjacent to the cracking Material and process changes have eliminated this problem 3 General Crazing Checking Mainly affecting horizontal panels this fault may develop in the post warranty period if the paint film deteriorates This fault is caused by excessive film build incompatible mat
26. clip should be fitted on a Complaint Only basis using the Repair Operation Number and Time allowance quoted in this Bulletin Jaguar Cars Limited 2005 Procedure amp Remove the door trim veneer panel Separate the retaining clip from the operating cable Fit the new clip AGU 2678 RH or AGU 2679 LH to the interior handle Insert the cable end into the clip and lock the clip into position on the cable Operate the handle to ensure it does not foul the clip Clear as required by relieving the handle Refit the veneer panel O AWN Repair Operation Times as follows 76 91 37 Door Remote Operating Cable Retaining Clip Modification 0 10hrs 76 91 38 Door Remote Operating Cable Retaining Clip Vehicle Set Modification 0 40 hrs e ITEM 15 76 MECHANICAL FIXING OF FRONT SEAT SQUAB COVERS XJ6 2 9 3 6 INTRODUCTION A change in the method of securing the front seat squab trim covers to the squab foam frame is being introduced on XJ6 2 9 3 6 models Introduction is progressive achieving 100 across al colour derivatives in cloth and leather by commencement of 1989 MY build The new method eliminates the use of adhesives in favour of a mechanical fix Future parts supply of squab trim materials willbe to the new design condition and it is therefore necessary to describe how these materials may be fitted to pre 1989 MY models should the need arise METHOD Remove the seat XJ6 Service Manual Section 76 70 01 e Place
27. compound to both sides of the sump face at the seal aperture joint and torque the sump fixing nuts and bolts to 20 nm 15 lb ft ITEM 14 CYLINDER HEAD GASKET S III XJG STA To overcome instances of external coolant seepage from the cylinder head cylinder block joint an improved cylinder head gasket Part No EAC 8349 has been introduced on 3 4 litre engines from Engine No 8A 16376 ITEM 15 ENGINE REAR MOUNTING SPRING S tITL XJb Due to instances of a knock from the prop shaft area caused by excessive movement of the transmission rear mounting a revised gearbox rear mounting spring has been introduced This spring Part No C45902 l is now painted black and replaces the previous plastic coated spring Part No C45902 It was introduced at VIN 442669 ITEM 16 ENGINE STALL S III XJ6 4 2 ALL MARKETS EXCEPT USA AUSTRALIA CANADA JAPAN SWEDEN SWITZERLAND Further to Service Bulletin JD 08 84 Item 65 the modification incorporating the supplementary air valve to overcome engine stall has now been introduced on production built vehicles from VIN 443387 Jaguar Cars Limited 2005 SERVICE BULLETIN JD 02 86 SHEET 2 of 4 19 51 76 79 ITEM 17 ELECTRONIC CONTROL UNIT S III V12 XJS V12 EMISSION B ONLY To improve the reliability of the fuel injection system a new digitial microprocessor electronic control unit has been introduced on S III V12 and XJS V12 emission B models only from VINs
28. d 17 0 500mV Centre Vent Solenoid 18 O0 500mV Select Low On Mode switch Minimum Temperature Demand Set Diff to Mid Range 28 2 45 2 55V Servo Stopped 37 4V 40 4V 41 4V 42 4V Lower Feedback 29 0 0 2V Upper Feedback 30 O 02V Set Temperature to Mid Position 35 1 43 1 45V Servo Stopped 37 4V 40 4V 41 4V Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 8 of 9 Pin No Voltage 42 4V Lower Feedback 29 0 57 0 87V Upper Feedback 30 0 60 0 9V Set Temperature to Maximum 35 2 665 3 105V Lower Feedback 29 0 979 1 279V Upper Feedback 30 1 518 1 818V Set Diff to Maximum 28 4 750 5 20V Lower Feedback 29 0 979 1 279V Upper Feedback 30 1 340 1 640V Blower Test Set Diff To Minimum 28 0 200mV Set Temperature to Minumum 35 0 200nmV Note After setting allow servos to come to rest Typ cal voltage f gures are in the brackets Mode Switch RH Control LH Control RH Feedback LH Feedback Position Pin No 32 Pin No 31 Pin No 33 Pin No 22 Low l 2V 1 77V 1 2V 1 7V 4 6V 5 8V 4 6V 5 63V Med 2 3V 228V 2 3V 2 27v 3 5V 3 7V 3 5V 3 4V High 1 2V 1 17V 1 2V 1 19V 1 2V 1 22V 1 2V 1 27V Pin No Voltage Set Temperature to Mid Point 28 1 43 1 45V Mode Switch RH Control LH Control RH Feedback LH Feedback Position Pin No 32 Pin No 31 Pin No 33 Pin No 22 Low 1 2V 1 24V 1 2V 1 27V 6 5 9V 8 7V 6 5 9V 8 7V Med l 2V 1 4V 1 2V 1 41V 6 9 9V 7 5V 6 5 9V
29. dure For information on the earlier wiper motor availability and supersession details please refer to Parts Technical Information Volume J8 Number J1 January 1989 Item 1 Parts Required RHD Part No Description e DAC 5504 Wiper Motor Grille Assembly DAC 6053 Intermittent Wipe Relay Green Case DAC6148 Wiper Arm RH Crank Driver DAC6150 Wiper Arm RH Straight Passenger LHD Part No DAC 5505 Wiper Motor Grille Assembly DAC 6053 Intermittent Wipe Relay Green Case DAC6149 Wiper Arm LH Crank Driver DAC 6150 Wiper Arm LH Straight Passenger A labour allowance of 1 45 hrs may be claimed quoting Repair Operation No 84 9 1 04 and Complaint Code 7KA B Modification Procedure Disconnect battery negative lead Jaguar Cars Limited 2005 Wiper Switch Access the wiper column switch cut andremove the black B cable from the switch harness at points A and B as indicated in Fig 1 JST1054 FIG 1 Intermittent Wipe Relay Locate the intermittent wipe relay see Service Manual Remove and replace with the new relay green case Part No DAC 6053 Model Manual Ref Key 3 6 RHD 86A 56 57 35 3 6 LHD 86A 58 59 23 Please Note 3 6 LHD key references Page 86A 58 are printed incorrectly to obtain correct e locations move all key descriptions up one number Key 1 air pump is deleted Key reference 23 detailed above is corrected reference 5 3 RHD 86A 60 61 43 0 B 3LHD 86A062 00 15b Wiper
30. ensor Evaporator temperature sensor Recirculation vacuum solenoid Water valve vacuum solenoid Coolant temperature switch FIG 18 AIR CONDITIONING J86 300 Centre vent vacuum solenoid Lower servo feedback potentiometer Upper servo feedback potentiometer LH blower motor assembly RH blower motor assembly Temperature demand control Upper servo Lower servo To compressor To fuse To fuse WIRING DIAGRAM Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 9 of 9 ITEM 50 84 WINDSCREEN WASHER FLUID S III XJS 86 86 Between the months of October and April commencing October 1986 windscreen washer fluid bottles will be filled with a solution giving frost protection to 159C This will apply to all markets except Canada which will continue to be shipped dry between the above period The inclusion of fluid providing protection to 159C is possible with the introduction of new paint technology FUEL TANK ELEMENT RECIRCULATION VALVE HARNESS S III Due to service network demand the fuel tank element and recirculation solenoid valve link harness Part No DAC 1744 is now available through the Parts Division DAC 1744 is routed clipped beneath the fuel tank and is utilised on both R H and L H side tank assemblies JSE 471 ITEM 52 ELECTRIC AERIAL RELAY XJS FROM VIN 123281 Instances of water entering past the boot lid seal have been experienced on XJS models Action is being taken to
31. eports of white staining of the protective lacquer This has been caused by the solvent used by the supplier to clean the wheel prior to application of the balance weights not being to specification This staining should be removed at P D I stage by buffing the area with a pad lightly moistened with Ethyl Methyl Ketone MEK When using this chemical the following precautions MUST be strictly adhered to Highly flamable DO NOT USE whilst standing near a naked flame or smoking DO NOT INHALE Only use in a well ventilated area Avoid contact with the skin and eyes wear protective clothing e g gloves glasses etc ITEM 47 SEAT BELT SLIDER BAR XJS To assist occupants with the fitting of XJS seat belts Jaguar have carried out a modification to the fixed anchorage point A bar has been installed which is secured to the sill at its forward position and is located in an aperture situated in the heel board panel at its rear location The seat belt has a stitched loop which passes over the slider bar prior to fitment into vehicle This loop allows fore and aft movement of the seat belt to be achieved 100 fitment to Coupe models is assured from VIN 131010 The Cabriolet will also be fitted with this modification from early August on 1987 M Y vehicles introduction VIN to be advised NOTE This is an Engineering Design modification and cannot be fitted to pre modification vehicles To fasten the seat belt pas
32. erials temperature changes etc DIAGNOSIS 1 Define the extent of the fault i e local extensive fine or heavy crazing 2 Examine the film build thickness of the existing finish 3 Take into consideration the vehicle colour prior to deciding the extent of rectification e g to achieve a satisfactory colour match on certain metallics local repair may have to be extended to envelop a section of the vehicle 4 Where the crazing is severe define the depth by flatting locally and examining with a magnifying glass 5 ALWAYS REMEMBER THAT WHEREVER POSSIBLE THE ORIGINAL FINISH I E ELECTROCOAT AND PRIMER SURFACER SHOULD BE LEFT INTACT WHERE A FAULT IS SEVERE BUT CONFINED TO HORIZONTAL SURFACES IT MAY BE ADVANTAGEOUS TO SAND OFF TO A SOUND SUBSTRATE INSTEAD OF COMPLETELY STRIPPING TO BARE METAL 6 The alternatives to a complete strip should always be given consideration when refinishing as an incorrect process from bare metal will almost certainly promote future problems Jaguar Cars Limited 2005 SERVICE BULLETIN JD 02 86 SHEET 3 of 4 RECTIFICATION 1 Local fine crazing checking P1200 wet flat compound and polish Fine cracking checking around screens Where this fault is evident and emanates from the screen apertures remove the outer lace and wet flat with P800 to remove all traces of the fault Apply an approved paint process to the affected areas NOTE where the cracking affects the top of the aperture a com
33. ess included should be returned through the normal Parts D Y Return System Jaguar Cars Limited 2005 86 88 SERVICE BULLETIN JD 02 86 SHEET 4 of 4 ITEM 22 ALTERNATOR Selll V12 A revised 4133 75 amp alternator and alternator harness have been introduced on S III V12 Models from VIN 425413 The revised alternator incorporates a single eyelet connector which replaces the previous Lucar terminals For introduction details on S III XJ6 Air Con Models Service Bulletin JD 04 85 Item 30 refers XJS V12 models Service Bulletin JD 09 85 Item 69 refers ITEM 23 SPEEDOMETER TRANSDUCER S III XJS Instances of electronic speedometer signal transducers becoming loose and possibly detached from the transmission housing have been identified in Service Production procedures have now been corrected and security of the unit assured from VINs 445458 S III 128950 XJS To ensure that transducer units are secured correctly on vehicles prior to the above vehicle identification numbers Dealers will be requiried to check all new vehicles at P D I and those in service at the next service interval The knurled locking ring may be GENTLY tightened using a suitable adjustable spanner Do not overtighten as this will result in damage to the transducer unit Jaguar Cars Limited 2005 Service Bulletin JAGUAR Daimler Date JULY 1986 Sheet lof 9 Bulletin JD 07 86 ITEM 45 17 EMISSION r S III 4 2 AL
34. ig 14 a feedback isolation diode 8 Fig 14 and a power transistor 9 Fig 14 The unit is supplied with positive battery voltage via an ignition controlled fuse With the fan motor running at high speed the relay 12 Fig 14 is energised with a voltage from pin 16 of the control module thus closing the relay contacts The negative circuit is therefore completed via the relay contacts On all the other fan speeds the negative circuit for the fan motor is via the power transistor and the control module The feedback diode 8 Fig 14 enables the control module to sense the voltage at the negative terminal of the fan motor and so calculate the speed of the blower motor VACUUM SYSTEM The components operated by the vacuum solenoids are l Defrost Demist flaps which are held closed by vacuum Identified by a green supply tube 2 Recirculation Fresh air flaps which are held closed by vacuum Identified by a blue supply tube 3 Centre vent which is opened by vacuum tube 4 Water valve which is closed by vacuum tube Identified by a black supply Identified by a red supply Jaguar Cars Limited 2005 S Z i T J86 297 l Pin 16 control module 7 Blower motor 2 t battery supply 8 Feedback diode 3 Pin 22 or 33 control module 9 Power transistor 4 Pin 31 or 32 control module 10 Resistor 5 Pin 45 control module 1l Protection diode 6 Earth 12 High speed relay FIG 14 BLOWER MOTOR DIAGRAM J82 115 FIG 15 V
35. ins uncontaminated by fingermarks etc and apply an approved 2 pack etch primer to the bare metal h It is essential that a suitable primer surfacer is applied within one hour of the etch primer or blistering may occur i Following preparation apply an approved paint process NOTE These operations must be carried out in a temperature controlled spray booth Jaguar Cars Limited 2005 ITEM 21 XJS WINDSCREEN WIPER MOTOR PRE HE MODELS Following the conversion on Pre XJS HE Models of the windscreen wiper system using Service Kit AEU 1731 and motor assembly AEU 1738 Service Bulletin JD 11 81 Item 83 refers several Dealers have experienced the problem of the circuit fuse continually blowing Investigations have identified that certain AEU 1731 kits were equipped with an incorrect adaptor harness which caused a short curcuit to occur when fitted Parts stock of this component has now been checked and suspect stock removed In the event that stock may be held by Dealers kits should be checked to ensure that the correct harness has been supplied To clarify this Dealers should check the colours of the wiper motor plug connector wires Correct Condition 1 Red Light Green 3 2 White Light Green 3 Yellow Light Green 4 Blue Light Green 4 5 Light Green JSI450 Incorrect Condition 1 White a 2 Red 3 Yellow 4 Brown 4 5 Green JST 450 Kits identified with the incorrect harn
36. plete roof panel respray may be necessary Local Heavy Crazing Fuel Spilliage etc Wet flat locally P800 to remove the fault and apply an approved paint process Extensive Crazing affecting the colour coat Use one of two methods a Wash off the colour with acrylic thinners avoiding any spillage or runs onto adjacent panels or b Sand off the colour mechanically finishing off with a P600 P800 wet flat Following preparation apply an approved paint process Extensive Heavy Crazing of indeterminate depth a Apply a chemical stripper to remove all paint to bare metal NOTE strippers are most effective if used in two stages 1 Colour Removal 2 Primer and surfacer removal CAUTION DO NOT APPLY STRIPPER WITHIN 25mm of PANEL EDGES CHANNELS GLASS OF TRIM FINISHERS b Remove the paint with a scraper and or steel wool c Wash off the stripped vehicle with solvent SBP 3 or similar activating with steel wool to remove any residues d Flat off paint from the panel edges and around the finishers Blow off with an air gun and wash the complete vehicle with solvent e Apply a phosphoric acid metal conditioner to the manufacturer specifications This will remove surface contamination and etch the metal surface to assist paint adhesion NOTE this operation is most important f Wash off the activated conditioner with clean water and dry off thoroughly with chamois leather and air gun g Ensure the prepared surface rema
37. r Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 3 of 9 18 A e 5 J Cy f B e 3 15 6 4 C MOM 7 ON J85 290 1 Control Module 12 Blower Motor Feedback 2 Differential Temperature Control 13 High Speed Relay 3 Temperature Control Switch 14 Compressor Clutch 4 Mode Control Switch 15 Blower Motor 5 Ambient Temperature Sensor l6 Blower Motor 6 In Car Temperature Sensor 17 Servo Motor 7 Evaporator Temperature Sensor 18 Servo Motor 8 Coolant Temperature Switch 19 Defrost Vacuum Solenoid 9 Flap Feedback Potentiometer 20 Recirculation Flaps Solenoid 10 Flap Feedback Potentiometer 21 Centre Vent Solenoid ll Blower Motor Feedback 22 Water Valve Vacuum Solenoid FIG 3 TEMPERATURE DISTRIBUTION SYSTEM The air conditioning unit case consists of three parts the rear of which carries the evaporator the front is then split in two to enable the rotary flaps to be inserted The method used to achieve the required air temperature is known as a series parallel system All the air into the unit passes through the evaporator then depending on the position of the flaps either passes through the heater matrix to be heated or bypasses the heater matrix completely or a combination of both to achieve the air termperature required The system employs two flaps that are driven to the required position determined by the control system by servo motors and gear box assemblies The motor can rotate in either a clockwise o
38. r anti clockwise direction depending on the direction of current flow through the motor Jaguar Cars Limited 2005 JB2 14 JA2 16 1 J82 4 3 FIG 6 FULL COOLING FIG 7 AIR BLEND The flap positions are monitored by 2K2 ohm feedback potentiometers which supply voltage signals to the control module indicating the flap postions FIG 8 FEEDBACK POTENTIOMETER Jaguar Cars Limited 2005 sx 2nd ISSUE SERVICE BULLETIN JD 07 86 SHEET 4 of 9 TEMPERATURE SELECTOR The temperature requirement is selected by the setting of a 2K2 ohm potentiometer which is coupled to the temperature control switch 5 volts is supplied to the potentiometer from pin 43 of the control module The output voltage is from zero to 2 885 volts which represents a range of temperatures from 19 to 29 C 66 to 84 F The rotation of the potentiometer is restricted internally to 180 travel TEMPERATURE SELECTOR SWITCH AUTOMATIC OVERRIDE FUNCTION Incorporated within the temperature selector switch is the facility to override the automatic function This enables the temperature to be manually selected and is achieved by pulling the left hand knob Engaging the manual override mode and dialling the temperature switch within the range available allows the occupants to select the desired temperature of air entering the passenger compartment This is permanently maintained regardless of the ambient temperature TEMPERATURE DIFFERENTIAL CONTROL The slide
39. r control can be used to adjust the temperature of the air being delivered through the fascia end vents When the control is at the full right position the air being delivered to the fascia end vents will be slightly cooler than that at the footwell vents Moving the control to the left reduces the temperature of the air to the fascia end vents at the full left position the air is at its coolest This control does not affect the set in car temperature and is most effective during NORM normal operation of the air conditioning system When the system is in a heating mode this control allows warmer air to the feet than to the face A 10K ohm slide potentiometer used for this purpose is coupled to the thumbwheel Its supply voltage is from pin 7 and the signal voltage is then fed to pin 28 of the control module TEMPERATURE SENSORS There are three temperature sensors fitted into the system the ambient temperature sensor the in car temperature sensor and the evaporator temperature sensor All three sensors are electrically identical but the evaporator temperature sensor is physically different and is not interchangeable with the other two An input of 5 volts is supplied to the sensors from pin 43 of the control module The temperature sensing voltage from the sensor is then fed back into the control module At 09C 32 F the sensing voltage should be 2 732 volts and with a temperature rise or fall of 19 C 1 8 F the sensing vol
40. s a hand back along the sill grasp the belt and pull forward Transfer the belt to the other hand pull across the body and fasten in the normal manner PLENUM GRILLE S III The plenum griile is located by two push fit retention pegs see illustration located in two friction bushes It is possible to damage the plenum grille using an incorrect method of removal i e levering the grille free at the extreme ends Jaguar Cars Limited 2005 SERVICE BULLETIN JD 07 86 SHEET 2 of 9 82 To avoid damage use a screwdriver with a narrow blade covered with cloth preventing damage to grille paintwork inserted at location A or B between the plenum grille and panel Gently lever the grille forward and up until the retention peg is free of the bush Repeat the above procedure for the remaining retention peg location to complete removal ITEM 49 MK III AIR CONDITIONING UNIT S III V12 XJS Jaguar will be introducing a new air conditioning system for the above modeis shortly The following information is provided to allow technicians to develop an early appreciation of its features and functions prior to the release of further documentation The concept of this sophisticated air conditioning system has been developed to increase performance and reliability To achieve this mechanical components are kept to a minimum ELECTRONIC CONTROL MODULE The control module is a computer at the heart of which is a digital micro processor It
41. ssured from VIN s 373192 Series 113471 XJS Jaguar Cars Limited 2005 26 44 82 ITEM 21 WATER PUMP LEAKAGE XJ6 SERIES II Investigations into XJ6 water pump leakage have revealed a problem with the machining of the seal seat in the water pump body which could allow movement of the seal This has now been corrected and water pump seal location is assured from Engine Nos 8L 146844 4 2 8A 14618 3 4 7M 4766 Limo ITEM 22 BORG WARNER MODEL 66 SUN GEAR SHAFT SERIES II1 XJ6 Further to Service Bulletin JD 03 83 detailing a material specification change of the sun gear shaft from SAE 8620 to EN 36B the sun gear shaft sealing ring grooves are now shot peened to relieve any possible stress points This modification was introduced at ENGINE NO TRANSMISSION NO MODEL 8L 143470 6066 39459 4 2 8A 14592 6067 4284 3 4 ITEM 23 SERIES III XJS HE AIR CONDITIONING EVAPORATOR AIR CONDITIONED MODELS Air conditioning units are now received from the supplier with the evaporator assembly dehydrated and pressurised Units to this condition were introduced at VIN 347244 Saloon 108046 XJS As a result of this improvement it has been necessary to modify the air conditioning unit case to enable the evaporator unit to be fitted by the supplier without disturbing the expansion valve assembly Modifications have entailed the relocation of the evaporator expansion valve mounting plate fixings on
42. tage should rise or fall by 0 01 volts for example if the temperature should rise to 5 C 41 F from zero the voltage will rise by 0 05 volts to 2 782 volts The sensor is a semi conductor device similar to a zenor diode in as much as it allows current to flow in reverse bias The current flow through the device varies with temperature and is very accurate over a wide range The sensor assembly has a built in potentiometer which is preset and should not be adjusted Jaguar Cars Limited 2005 se 2nd ISSUE 5x 5 6 j86 295 J82 117 Resistor FIG 10 EVAPORATOR SENSOR Semi conductor Potentiometer Pin 43 control module Sensing voltage Pin 43 ambient Pin 5 evap sensors Earth Pin i o CO N m a gs J2 118 FIG 9 SENSOR DIAGRAM FIG 11 AMBIENT SENSOR COOLANT TEMPERATURE SWITCH A water temperature switch is fitted to the lower side of the heater inlet pipe Its contacts are open at temperatures below 409 C this prevents the fans from operating until relatively hot coolant is flowing from the engine 182179 FIG 12 COOLANT TEMPERATURE SWITCH MODE CONTROL SWITCH This main control switch provides inputs to the control module giving information regarding the requirements of the operator The switch has five position OFF LOW AUTO HIGH AND DEFROST In the OFF position the system is not operational but a signal from the switch is sent to the control module to ensure the flaps in the fan motor
43. the air conditioning unit case see Fig 1 A Previous Condition Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 84 Sheet 3 of 3 B Latest Condition JST 240 For parts replacement purposes only evaporator expansion valve assemblies to the latest condition are available Should replacement be required on vehicles prior to the above VIN s the following modification will apply Evaporator expansion valve assembly part number remains unchanged AEU 1191 MODIFICATION PROCEDURE T Following removal of the air conditioning assembly and subsequently the evaporator unit carefully cut off the metal flanges see Fig 1 C 2 Mark and drill the unit case to the dimensions detailed in Fig 2 3 Following completion of procedures 1 and 2 ensure all swarf is removed prior to re assembly 4 Locate new evaporator expansion valve assembly and secure 31mm 31mm naiem C 1 218 in 1 218in JS1239 Jaguar Cars Limited 2005 Fig 2 84 88 ITEM 24 WINDSCREEN WASH WIPE RESERVOIR GAP XJS The metal cap Part No GWW 968 for the windscreen wash wipe reservoir was replaced by a plastic cap Part No GWW 933 at VIN 108985 The plastic cap is available from Unipart as a separate item It is interchangeable with the metal cap up to VIN 110190 at which time the windscreen wash wipe reservoir and cap were replaced by a revised design ITEM 25 OIL PRESSURE TRANSMITTER SERIES III amp XJS HE Inves
44. the seaton abench suitably covered to prevent damage to the seat facing Remove the lumbar support handwheel escutcheon Remove the seat recline handwheel escutcheon manual seat only Remove the recline tube side covers two on powered seats one on manual Remove the squab back finisher exposing all the trim cover fixings Remove the head restraint securing clip Cut the ratchet strap to release the harness and remove the head restraint Remove the steel spring clips A Fig 1 Release the fabric tie ribbons C Fig 1 Release the adhered edge of the cover from the frame B Fig 1 Tofullyrelease the cover pass one handbetween cover andfoam support at the areas shown in A Fig 2 and VERY CAREFULLY ease the cover away from the foam CAUTION ALTHOUGH THE COVER FOAM SHOULD SEPARATE EASILY EXERCISE GREAT CARE TO PREVENT IRREPARABLE DAMAGE TO THE FOAM SUPPORT Jaguar Cars Limited 2005 SERVICE BULLETIN JD 03 89 SHEET 3 of 7 t J91972 o spat FIG 1 FIG 2 Obtain the following tools 1 Air driven or electric hand drill 2 Hammer and centre punch 3 Pilot drill maximum 2mm diameter 4 HSS driil 4mm diameter 5 HSSdrill 7mm diameter 6 Drill stop 7 Measuring tape and scriber TNs i A ee ee Lom m 2 m c aie Ay a fil NOTE Dimension A Fig 3 6mm e Dimension B Fig 3 152mm Driil 2 x 7mm holes in the seat frame side in the positions shown in Fig 4 NOTE Dimension A Fig 4 39mm Dimension B Fig 4
45. tigations into isolated instances of oil pressure gauge inaccurate readings due to a malfunction of the engine pressure transmitter unit have identified the following fault During the manufacturing process the transmitter lock screw is secured by Parapan Lacquer Service units examined were found to have the internal diaphragm impregnated with this lacquer causing it to stick and subsequently result in an inaccurate gauge reading Action to correct this production assembly fault has been assured from supplier date code Wk 46 83 and progressively introduced from VIN s 378920 Saloon 114671 XJS Jaguar Cars Limited 2005 SSS RS Service Bulletin JAGUAR Date FEBRUARY 1986 Sheet of 4 Bulletin JD 02 86 ITEM 11 00 AKM 9006 SERVICE MANUAL a LLI An updated version of AKM 9006 Service Manual for S III Models in English language is now available from Jaguar Parts Operations Unlike the original Manual this is available only as a complete book Individual books within the manual are not available separately Individual books for Edition 1 of the Manual may still be porem from Jaguar Parts Operations while stocks last ITEM 12 03 PROPSHAFT REPAIR TIMES XJS CABRIOLET Please add the following Repair Operation Times to your XJS Repair Time Schedules V12 3 6 47 15 01 Propeller Shaft Renew 2 34 0 95 47 15 10 Propeller Shaft Overhaul 3 40 2 00 No other Repair Times are affected AKM 4412
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