Jaguar XJ40 1995 1996 Workshop Manual

TECHNICAL BULLETIN

Poor Hot Start – Tank Pressure

Control Valve – Check Operation

MODEL XJS Range 1995-96 MY

VIN 194775 - 226645

DATE

Remove and destroy Bulletin 17-8, dated 5/96.

Replace with this Bulletin.

5/96

17-8

Amended

1/97

When investigating a customer complaint of poor “hot start” on 1995-96 MY XJS

Range vehicles within the above VIN range, verify that the fuel tank pressure control valve (Rochester valve) is operating properly.

After verifying a customer complaint of poor “hot start” (extended cranking) on

1995-96 MY XJS Range vehicles within the above VIN range, check the fuel tank pressure control valve as follows:

1.

Raise vehicle on hoist.

2.

Remove the left front wheel.

3.

Remove the liner from the wheel well.

4.

Disconnect the vacuum hose from the control valve.

5.

Connect a vacuum tester to the pressure control valve fitting.

6.

2.94-14.7 in. Hg. (0.1-0.5 bar)

7.

Disconnect the vacuum tester from the control valve.

8.

If the valve held vacuum, reconnect the vacuum hose and lower the vehicle.

9.

If the valve is faulty, cut the retaining strap from the fuel tank vent hose.

Remove the retaining clip and disconnect the vent hose of fuel tank from the valve.

10. Loosen the retaining clip and disconnect the hose of the carbon canister from the valve.

11. Remove the defective valve.

as in step 4.

13. Install the new valve after checking.

14. Reconnect the hose of the carbon canister to the valve.

15. Reconnect the vent hose of the fuel tank to the valve. Install a new tie strap.

Bulletin Number 17-8 Date of issue 1/97 Page 1 of 2

16. Reconnect the vacuum hose.

17. Reinstall the wheel well fender liner.

18. Reinstall the left front wheel and lower the vehicle.

P AR TS INFORMA TION:

Fuel tank pressure control valve

Tie strap

P AR

CBC 7714

ADU 9028

W ARRAN TY INFORMA TION:

F A U L T

BK BB HM 17.15.48

Remove & install fuel tank pressure control valve

1

1

A L L O W A N C E

0.55 hrs.

Page 2 of 2 Date of issue 1/97 Bulletin Number 17-8


AIR Pump Clutch –

Intermittent Operation –

Service Action S458

MODEL 1993-94 MY 4.0L Sedan & XJS DATE 5/97

17-9

Amended

8/97



Some 1993-94 MY Sedan (4.0L) Range and XJS (4.0L) Range vehicles may experience intermittent operation of the AIR pump. The operation of the AIR pump clutch is controlled by a relay located in the engine compartment. The contacts of this relay may become contaminated by the entry of water or cleaning solutions containing silicones.

Jaguar Cars will contact all customers with 1993-94 MY Jaguar vehicles within the above VIN ranges to advise them to make dealer service appointments to verify proper operation of the relay.

A CTION:

The 1993-94 MY Sedan (4.0L) Range and XJS (4.0L) Range vehicles must be checked as described below.

AIR pump clutch as described below.

relay with a sealed unit and verify the operation of the AIR pump clutch as described on the following page.

VEHICLES REGISTERED AND SERVICED OUTSIDE CALIFORNIA

1.

Open hood and observe the AIR pump clutch while an assistant starts the engine. The clutch should engage as cranking begins.

On a hot engine, the clutch should disengage after a few seconds.

On a cold engine, more time will elapse until the clutch disengages at a coolant temperature of 34°C (95°F). Do not wait until the clutch disengages.

2.

If proper operation is observed, no further action is required. Stop the engine and close the hood.

3.

If the AIR pump clutch does not engage, follow normal diagnostic procedures

(refer to AJ6 4.0L Engine Management System/OBD I Diagnostic Guide) and repair. Submit a claim under normal warranty procedures.

(red mounting base on S edan;

Bulletin Number 17-9 Amended 8/97 Date of issue 5/97 Page 1 of 5

6703AA under the terms of this service action.

VEHICLES SERVICED OR REGISTERED IN CALIFORNIA

1.

(red mounting base on S edan;

2.

Observe the AIR pump clutch while an assistant starts the engine. The clutch should engage as cranking begins.

On a hot engine, the clutch should disengage after a few seconds.

On a cold engine, more time will elapse until the clutch disengages at a coolant temperature of 34°C (95°F). Do not wait until the clutch disengages.

2.

If proper operation is observed, no further action is required. Stop the engine and close the hood.

3.

If the AIR pump clutch does not engage, follow normal diagnostic procedures

(refer to AJ6 4.0L Engine Management System/OBD I Diagnostic Guide) and repair. Submit a claim under normal warranty procedures.

L OCA TION OF SED AN (4.0L) RANGE AIR PUMP RELA Y

FRON T OF FRON T OF VEHICLE

1 993 MY

Page 2 of 5 Date of issue 5/97

ILLUSTRATION 1

1 994 MY

Bulletin Number 17-9 Amended 8/97

L OCA TION OF XJS (4.0L) RANGE AIR PUMP RELA Y

AIR PUMP RELA Y

FRON T OF VEHICLE


Sealed relay

ILLUSTRATION 2

P AR T NUMBER

LHF 6703AA 1


Service Action S458

SUMMAR Y

4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

ST Replace AIR pump relay

-without drive-in/out time

(performed with another repair)


ALL O W ANCE

0.10 hrs.

Date of issue 5/97 Page 3 of 5

SUMMAR Y

4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

SU Replace AIR pump relay

-with drive-in/out time

Check operation of AIR pump relay no fault found



4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

SW

4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

SX

4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

SY

Check operation of AIR pump relay no fault found


Check operation of AIR pump relay fault determined, replace relay



ALL O W ANCE

0.25 hrs.

0.10 hrs.

0.25 hrs.

0.20 hrs.

Page 4 of 5 Date of issue 5/97 Bulletin Number 17-9 Amended 8/97

SUMMAR Y

4.0L 1993-94 MY

Sedan

MODEL CODE

4064, 4082

4.0L 1993-94 MY

XJS MODEL CODE

200 0, 2030, 3000,

3030, 4234, 4235

SZ Check operation of AIR pump relay fault determined, replace relay


ALL O W ANCE

0.35 hrs.

NO TE:

‘ST’ or ‘SU’ regardless of vehicle’s state of registration. Non-

California dealerships must claim either summary code ‘ST’ or

‘SU’ on vehicles registered in the state of California.

CLAIM SUBMISSION PROCEDURE:

Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the parts and labor time allowance as indicated.

DCS DEALERS

Submit claims using the appropriate summary code for the vehicle model and work performed. Follow standard campaign submission procedures.

NON-DCS DEALERS

Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the Repair Code column. Do not use the W-1 warranty claim form.



Insufficent AIR Flow – AIR Pump

(AIRP) – Diagnosis

MODEL 1995-96 MY XJS (4.0L) Range

VIN 194775-199152

DATE 8/97

17-10

A revised AIR pump which is more heat resistant is now available.

The pump can be identified by a Julian date code of 002/*/96 or later. (The * in the date code indicates the shift during which the pump was assembled which is not relevant to the design of the pump.)

This technical bulletin provides a diagnostic procedure to aid diagnosis when DTC

P0411 has been flagged. Replacing the ECM will not solve the complaint of flagging DTC P0411.

A CTION:

In case of a customer complaint on a XJS (4.0L) Range vehicle, within the above

VIN range, of MIL illumination, with DTC P0411 flagged, follow the diagnostic flowchart located on the last page of this bulletin. The following text provides additional information.

The statements in boxes correspond to boxes in the flow chart.

Perform diagnosis with the engine at normal operating temperature to ensure that the HO2S feedback is operating.

Does AIR pump operate?

The pump can be heard running and a light vibration can be felt.

The AIR pump operates for a short period of time following every engine start. It typically operates for approximately 10-20 seconds at normal operating temperatures, then switches off for approximately 5-10 seconds, and then restarts to allow the system diagnostic check to occur. This check also takes approximately

5-10 seconds. See Illustration 1, sample of PDU trace. This complete cycle takes

This is the re-test refer red to in the flow c har t.


PDU TRA CE SHO WING CORRECT AIR PUMP OPERA TION

JSI-3154

ILLUSTRATION 1

Zone ‘A’ shows the initial operation of the air pump (air flow causes lean reading).

Zone ‘B’ shows the pump switched off, prior to the diagnostic test (stopping air flow causes rich reading).

Zone ‘C’ shows the pump operating during the diagnostic test cycle.

Zone ‘D’ shows the pump switched off when the test is complete.

Zone ‘E’ shows the lambda voltage switching under normal lambda operation.


PDU TRA CE SHO WING INADEQ UA TE AIR FL O W

JSI-3155

ILLUSTRATION 2

Illustration 2 shows a PDU trace where there is inadequate air flow from the air pump.

Zone ‘A’ shows the initial operation of the air pump (air flow causes lean reading).

Zone ‘B’ shows the pump switched off, prior to the diagnostic test (stopping air flow causes rich reading).

Zone ‘C’ shows the pump operating during the diagnostic test cycle.

Zone ‘D’ shows the lambda voltage switching to normal feedback, as there is insufficient air flow to sustain the voltage at 5v.

Zone ‘E’ shows the air pump switched off at the end of the diagnostic cycle.

Zone ‘F’ shows the lambda voltage switching under normal lambda operation.

Check outlet port of pump for strong air flow

The air flow from the air pump should be strong enough to almost prevent the palm of the hand from staying pressed against the outlet port of the pump. In situations where DTC P0411 is flagged, the air flow from the pump outlet will be very weak.

Check ports of pump for signs of overheating or excessive build-up of carbon.

This check should be performed when the voltage trace is correct, in case of intermittent operation of the pump. Look for excessive buildup of carbon on the outlet port, and check if the foam filter in the inlet port has melted or is out of position. In such cases, replace the outlet check valve also.


Follow electrical diagrams in XJS Electrical Guide

If the AIR pump does not operate as described on page 1, refer to Fig. 25 of the

XJS Range 1995/6 Electrical Guide.

Is “bleed nipple” hose fitted?

On vehicles from VIN 194775 - 199153, check that the hose between the air pump and check valve is the type incorporating an anti-vacuum bleed nipple, as introduced in production from VIN 199154 (refer to Technical Bulletin 18-47

Amended 4/95.) If not, install the appropriate later-design hose.


Air Injection Pump

Check Valve

P AR T NUMBER

LHE 1545AC

EBC 11499

Hose, pump to check valve, Normally aspirated NBC 4798AA


F A UL T

BG BB ** 17.25.07

17.25.21

86.99.01

Air pump - renew

(including diagnostic time)

Check valve - renew

Read and clear DTCs.

Fill out Form S93.

ALL O W ANCE

0.60 hours

0.20 hours

0.50 hours

1

1

1


DIA GNOS TIC FL O WCHAR T

With the engine at normal operating temperature, connect the PDU and read DTC P0411. Fill out form S93.

Clear DTC.

Is ‘bleed nipple’ hose installed?

YES NO

Install ‘bleed nipple’ hose. Retest

Return vehicle NO Defect still present?

YES Does AIR pump operate?

NO

YES

NO

Refer to electrical diagrams in

XJS Electrical Guide

Circuit OK?

YES NO

Repair

Retest

OK?

YES Return vehicle In PDU Datalogger, run engine while monitoring HO2S voltage.

Is voltage trace correct?

YES

Check ports of pump for signs of overheating or excessive buildup of carbon.

Pump OK?

YES

NO

NO

Check outlet port of pump for strong air flow.

Strong air flow?

YES

Replace pump

NO

Retest OK?

NO

YES

Return vehicle

Return vehicle

Replace check valve

Retest OK?

YES NO

Contact Technical Hotline

Check pipe for blockage.

Clear/replace as necessary.

Retest, OK?

NO YES

Return vehicle



Throttle Difficult to Open on Cold Engine

– Normally Aspirated Engines –

Modify Crankcase Breather System

MODEL 1995-96 MY XJS

VIN 194775-226643

DATE 12/98

17-11

On some 4.0L XJS vehicles, owners may experience slight difficulty in opening the throttle from the closed position after the vehicle has been sitting for some time. Under certain circumstances, oil mist from the crankcase may collect and harden on the throttle body and plate when the engine is cold, where it may cause this condition.

A CTION:

Perform the following modification to include an oil separator in the crankcase when there is a history of customer complaint of the condition described above.

MODIFICATION PROCEDURE

1.

Open the hood and install fender covers.

2.

Disconnect the multiple connectors from the intake air temperature sensor

(IATS) and from the mass air flow sensor (MAFS).

3.

Disconnect the convoluted hose from the throttle body.

4.

Remove the nut that secures the rubber mounting bobbin to the induction elbow; release the air cleaner to MAFS retaining clips and remove the MAFS/ induction elbow assembly to provide further access.

5.

Unscrew by ONE turn the throttle stop adjustment screw, so that no air gap exists on either side of the throttle plate. It will be necessary to shorten a standard hexagon wrench (Allen wrench) for access to this screw.

6.

Hold the throttle closed and remove the screws that retain the throttle plate to the shaft.

7.

Note the direction of assembly to assist during reassembly and then remove the throttle plate after opening the throttle shaft.

pulled out of the potentiometer. If this occurs, removal of the potentiometer will be required to permit reassembly.

8.

Gently return the shaft to the ‘closed’ position.

9.

Use a suitable solvent and shop towel to carefully remove all residual


contaminants from the throttle plate and throttle body air passage. Use care not to allow excess solvent to run down the throttle shaft or enter the intake manifold. Use a mirror to assist in checking that all deposits have been removed. Dry off any residual solvent/deposits.

10. Using care not to disengage the throttle shaft from the potentiometer below, and noting the correct orientation, reinstall the throttle plate in the shaft.

Apply thread locking compound to the threads of the securing screws and start, but do not fully tighten, the two securing screws.

11. Check with a mirror that the throttle plate is centered with the throttle fully closed, as the retaining screws are tightened enough to grip the plate. Open the throttle against spring pressure, then allow it to snap closed - this will help center the throttle plate on the shaft and to the venturi. Repeat if necessary, then fully tighten the throttle plate retaining screws.

plate screws. Tighten them appropriately for brass screws of this size.

12. Check that the locking patch of the throttle stop screw is still effective.

Sufficient drag must remain to ensure that any setting will not be disturbed by vibration, otherwise apply fresh locking compound. Adjust the screw to open the throttle plate until a narrow 0.002 inch feeler blade can fit between the throttle plate and the venturi.

13. Remove the screws that retain the fuel rail cover and remove the cover.

14. Loosen the clamps and remove the breather hose from the engine.

MODIFYING EXIS TING BREA THER HOSE

A

1 6 MM (5/8 INCH)

B

DET AIL FOR CUTTING

EXIS TING BREA THER HOSE

LOCA TION FOR RES

JSI.3438

ILLUSTRATION 1

15. Cut the existing breather hose as shown in Illustration 1. Make sure that a clean cut is made, maintaining the 22 mm (7/8 inch) dimension consistently.

16. Insert the larger diameter of a restricter (Part No. NNB 3956AA ) into the cut upper end of the hose. Push the restricter fully into the hose, until the lower end is 16 mm (5/8 inch) from the cut end, as in Illustration 1.


17. Install a worm drive hose clamp (Part No. JHC 200401) and connect the upper portion of the breather hose to the top stub of the oil separator (Part No. NNB

2102AA), as in Illustration 2.

ASSEMBL Y OF HOSES T

V APOR SEP ARA T OR

EXIS TING HOSE

JSI.3432

ILLUSTRATION 2

18. Installing a worm drive hose clamp (JHC 200401) to the lower portion of the existing breather tube, connect it to the side stub of the oil separator, and with a hose clamp (JHC 200101) install the drain hose (NNB 5961AA) to the lower stub of the oil separator, as in Illustration 2.

It is impor tant that the worm housing of the hose clamp is installed facing the engine ’ side of the hose and oil separator

19. Tighten the hose clamps with the hoses positioned as in Illustration 2.

20. Remove the dipstick from the dipstick tube. Wipe it clean and place it aside in a clean location until reinstalled later.

21. Remove the retaining screw at the support bracket and remove the existing dip stick tube from the engine. Remove the existing ‘P’ clip for reuse before discarding the existing dip stick tube.

22. Ensure that the rubber sealing tube for the dip stick tube remains on the engine.

23. Transfer the ‘P’ clip to the replacement dip stick tube (NNB 3908AA), install the dip stick tube on the engine (ensuring that it is fully seated). Reinstall the retaining screw on the tube and bracket.


FEEDING BREA THER

BREA THER HOSE

JSI.3433

ILLUSTRATION 3

24. As shown in Illustration 3, route the end of the longer breather hose (attached to the side stub of the new oil separator) under the fuel rail. When part-way under the fuel rail, route the thinner drain tube (attached to the bottom stub of the oil separator) between the runners of the intake manifold so that it can eventually be connected to the new dip stick tube.

HOSE INS T ALLED WITH V APOR SEP

V APOR SEP ARA T OR

BREA THER HOSE

JSI.3431

ILLUSTRATION 4

25. Continue to align the breather hose assembly until the upper breather hose can be reconnected to the stub pipe on the camshaft cover and the original hose clamp tightened, as in Illustration 4.

26. Install the drain hose on the side connection on the replacement dip stick tube, installing a worm drive hose clamp (JHC 200101) over the hose, and tightening the clamp once the hose is fully connected and free of any kinks.

27. Check that the dip stick is clean and reinstall it.

28. Reinstall the MAFS/induction elbow assembly and reconnect the multiplugs.

29. Connect the lower end of the breather hose to the stub on the induction elbow and tighten the hose clamp.


30. Reconnect the side hose above the oil separator to its original stub pipe and tighten the hose clamp.

31. At the PDU base station, load JTP 626/4. Select Diagnostics, Vehicle Setup, then select Engine Setup. Connect the PDU to the vehicle. Under Engine

Setup, select Throttle Position Sensor Adaption Test. Answer YES to the question, “Has a new throttle position sensor been fitted?” After the test passes, the idle speed will be correct.

32. Remove the fender covers and close the hood.


The following should be ordered from Jaguar Parts Operations:

Breather Kit

Screw, throttle plate retaining

* only needed if lost or damaged

P AR T NUMBER

JLM 20709

JLM 20936

CONTENTS LIST - BREATHER KIT JLM 20709 (For Information Only)

Breather-Oil Separator

Restricter - Part Load Breather

Tube - Dipstick

Hose - Oil Drain

Clamp, Hose, Worm Drive

Clamp, Hose, Worm Drive

P AR T NO

NNB 2102AA

NNB 3956AA

NNB 3908AA

NNB 5961AA

JHC 200101

JHC 200401

1

1

1

1

2

2

1

*


F A UL T

CD KF 69 17.91.33

Engine Breather System

Modification (includes throttle position adaption test)

ALL O W ANCE

0.85 hrs.



Recall T493 - 1995 MY/Recall

R493 - 1996 MY – AJ16 EGR System –

Replace PROMs and EGR Valve

MODEL 1995-96 MY XJS 4.0L

VIN 194775-226645

DATE 11/01

Remove and destroy Bulletin 17-12, amended 11/01.


This Recall supersedes Service Action S483.

17-12

Amended

08/02

action required on 1995 MY vehicles was temporarily suspended due to unforeseen problems with one of the components associated with this recall. Jaguar had requested that dealers cease conducting further actions on 1995 MY vehicles until the problem with the affected component had been resolved.

J aguar is now pleased to inform you that the issue with the

PROMs has been resolved, and that J aguar once ag ain will be

This version of the recall bulletin has a revised part number for the 1995 MY vehicle. Additional Warranty Information has been added for those 1995 MY vehicles previously re-worked under this Recall Action. Please destroy all previous versions of Recall

Action Bulletin R493 and replace it with this version.

Please note that the Recall number for 1995 MY vehicles is now

T493, R493 will continue to be used for 1996 MY vehicles.

Since the introduction of the AJ16 engine Jaguar has seen a high rate of replacement of EGR valves following illumination of the malfunction indicator lamp (MIL). This is understood to be a result of accumulated contamination within the EGR valve that can produce possible drivability issues such as rough idle, hesitation, and difficult starting.

Following consultation with the US Environmental Protection Agency (EPA) Jaguar has decided to recall all vehicles equipped with this engine and carry out a number of modifications including the introduction of a cleaning cycle to the EGR valve. The following actions apply to all vehicles within the above VIN ranges.

• Replace PROMs within Engine Control Module (ECM). Jaguar Cars has upgraded the PROMs within the ECM to provide a cleaning cycle of the EGR system.


• Replace EGR valve and gasket, to ensure that it is free from contamination.

• Replace throttle return spring. Some vehicles may experience customer complaints of high idle speeds.

Jaguar Cars is writing to all owners of the above vehicles (in timed mailings) to advise them to take their vehicles into their local dealer to have the above modifications made.

This recall will supersede Service Action S483, S675, and S676, no further claims for these Service Actions will be accepted.

A CTION:

Refer to the following charts to determine the appropriate course of action.

M O D E L Y E A R

9 5 M Y R e c a l l p r e v i o u s l y p e r f o r m e d

C O M P O N E N T J S

E G R V a l v e

E G R V a l v e G a s k e t

E G R V a l v e B o l t A s R e q u i r e d

X

X

X


T h r o t t l e S p r i n g R e p l a c e m e n t

N o F u r t h e r

A c t i o n

R e q u i r e d

E P R O M R e p l a c e m e n t X

N o F u r t h e r

A c t i o n

R e q u i r e d


9 5 M Y R e c a l l

M O D E L Y E A R p r e v i o u s l y p e r f o r m e d

C O M P O N E N T

E G R V a l v e


E G R V a l v e B o l t A s R e q u i i i r e d


X J

X

X

X

X

E P R O M R e p l a c e m e n t


E G R V a l v e


E G R V a l v e B o l t A s R e q u i i r e d

X

X

X

X


E P R O M R e p l a c e m e n t

X

X


exhibits a drivability concern that the recall action does not eradicate, normal diagnostic procedures can be followed as necessary to determine the root cause. The completion of any subsequent repairs are subject to normal New Car Warranty or

Select Edition Warranty, or customer pay authorization as appropriate.

Remove the ECM from the vehicle by the following procedure.

1.

Connect the WDS to the vehicle’s data link connector.

2.

Record any diagnostic trouble codes stored in the ECM, then clear them from the system.

3.

Turn the ignition switch to ‘off’, wait 20 seconds before continuing with this procedure.

4.

Note customer settings such as radio stations.

5.

Open the luggage compartment, remove the cover from the battery and disconnect the battery ground cable.

REMOVING ECM

1.

Open the right hand door and remove the carpet from the foot well.

2.

Remove the ECM cover insulation pad.

3.

Remove the securing nuts and remove the cover from the ECM.

4.

Remove the ECM from its mounting, disconnect both harness connectors and remove the ECM from the vehicle.

5.

Mark the VIN on the side of the ECM to prevent confusion when more than one ECM is being modified.

ISSUE 1 - REPLACING PROM

1.

Check that the ‘anti-back out’ plate on the face of each harness connector is still in place after disconnecting the connector.

detached, secure it to the face of the connector, pressing it firmly in place.


workstation (previously supplied) while wearing a grounding wrist-strap (Illustration 1). Additional work mats can be sourced locally, such as Radio Shack cat. no. 910-3780.

AN TI-S T A TIC W A TION

1 – WORK BENCH

2 – WORK MAT

3 – WRIST STRAP CONNECTION

4 – GROUND CONNECTION

5 – FOOT MAT

ILLUSTRATION 1

JSI 2663

2.

Place the ECM on the anti-static work mat, with one flat face to the mat.

Looking towards the two connectors, the red connector should be to the upper right, the black connector to the lower left.

3.

Note the orientation of the top cover with its mounting lugs, relative to the

ECM casing. Mark both the cover and casing, using a felt-tip marker pen, to assist when reassembling.

4.

Remove the four retaining screws of the top ECM cover (i.e. the cover adjacent to the red connector) using a Torx 20 anti-tamper type bit. Remove the cover.


L OCA TION OF PROMS IN ECM

3 – ECM CO VER

4 – PROM CO VERS

5 – CLEARANCE SP A CE

6 – WOOD SUPPOR T

8 - PRIN TED CIRCUIT BO ARD

ILLUSTRATION 2

5.

Remove the seven retaining screws of the printed circuit board (8, Illustration

2). Fold the printed circuit board away from the body of the ECM unit and support it on a block of wood (6, Illustration 2) so that no strain is placed on the ribbon connectors (7, Illustration 2). Allow a clearance space (5,

Illustration 2) so that no damage can occur from contact with the mounting brackets.

6.

The modification kit contains two microchips, one each of the 28-pin (1,

Illustration 2) and 32-pin (2, Illustration 2) design.

7.

Remove the covers (4, Illustration 2) from the microchips on the printed circuit board. Remove each cover by applying a side-to-side rocking action, gripping the cover lightly with combination pliers midway along each long side.

pliers, or mark the surface of the printed circuit board.


EXAMPLE OF CHIP REMO V T OOL

ILLUSTRATION 3

8.

Remove the PROM microchips from the printed circuit board using a suitable proprietary removal/reinstallation tool (Illustrations 3 & 4).

USE OF TYPICAL CHIP REMO V AL T OOL

ILLUSTRATION 4


MICROCHIP ORIEN T A TION

3

1 – O VERHEAD VIEW OF MICROCHIP

2 – O VERHEAD VIEW OF SOCKET ON PRIN TED

CIRCUIT BO ARD

3 – IDEN TIFICA TION OF MICROCHIP

A – ‘HALF MOON’ CUT -OUT ON MICROCHIP

B – ‘HALF MOON’ CUT -OUT ON SOCKET

ILLUSTRATION 5

9.

When inserting the replacement PROM microchips, identify the ‘half moon’ cutouts in both the microchip and the socket on the printed circuit board

(Illustration 5).

both items must be aligned as the microchip is inserted into the socket.

10. The removed microchips should be set on one side, to be returned to Jaguar.

11. Identify and install the replacement 28-pin and 32-pin microchips from the modification kit to the appropriate sockets.


MICROCHIP ALIGNMEN T

ILLUSTRATION 6

12. Use great care to achieve condition ‘1’ in Illustration 6. The microchip must lie parallel to the printed circuit board, with all pins fully engaged into their corresponding locations in the socket.

conditions B or C. Malfunctions will occur with partial engagement, as in condition D.

13. Reinstall the original covers over the replacement PROM microchips.

14. Carefully fold the printed circuit board back to its original location on the casing of the ECM, ensuring that the connector is correctly aligned to its location in the casing. Install and tighten the seven securing screws. Torque setting: 2.25–2.82 Nm (20–25 lb in).

15. Reinstall the ECM cover on the case, aligning the marks made at step 3 of this workshop procedure, prior to removal of the cover. Install and tighten the four securing screws. Torque setting: 2.25–2.82 Nm (20–25 lb in).


ILLUSTRATION 7

16. Apply the PECUS label from the modification kit to the cover of the ECM. The new label must not obscure any existing label on the unit (Illustration 7).

17. Reinstall the ECM in the vehicle, by a reversal of the process used for its removal.

18. Continue with the procedure for replacing the EGR valve.


E GR

ILLUSTRATION 8

ISSUE 2 - REPLACING EGR VALVE

1.

Open the hood and place covers over the fenders.

2.

Disconnect the EGR valve harness connector (Illustration 8).

3.

Remove the EGR valve securing bolts.

4.

Remove the EGR valve and valve gasket.

5.

Clean the valve mating faces.

6.

To reinstall the new EGR valve and gasket, reverse the EGR valve removal process.

bolts. Torque figure: 23–27 Nm (17–20 lb ft).

7.

Continue with the procedure for replacing the throttle spring.

ISSUE 3 - REPLACING THROTTLE RETURN SPRING

1.

Disconnect the inner accelerator cable from the throttle assembly.

2.

Remove the cruise control linkage pin and circlip.

3.

After removing the three Torx head screws that retain the throttle assembly cap to the pedestal, carefully remove the cap sub-assembly. Note the position of the straight extension of the throttle return spring.


4.

Unhook the throttle torsion spring (Illustration 9) from the throttle shaft actuator and then remove the spring and the sleeve from the shaft.

THRO TTLE SPRING

ILLUSTRATION 9

5.

Remove the sleeve from the spring and discard the spring.

6.

Insert the sleeve into the replacement spring. Install the sleeve and spring on the throttle shaft and hook the spring on to the actuator.

by rotating the straight extension one full turn counterclockwise until it can be installed in the same position as the original spring.

7.

Carefully reinstall the cap to the throttle assembly noting the lever location, and install and tighten the screws.

8.

Reconnect the cruise control linkage.

9.

Reconnect the accelerator cable to the throttle assembly.

10. Check the operation of the throttle assembly.

11. Remove fender covers, reconnect the battery, reinstall the battery cover, and close the lid of the luggage compartment. Reset the vehicle clock and customer preferences.

12. Using the WDS, perform the oxygen sensors orientation test. (Select set-up and configuration, engine and transmission, oxygen sensor orientation.)

13. Using the WDS, perform the throttle potentiometer adaptation test.

set-up procedure, the WDS will ask if a new throttle position sensor has been installed. Answer this question with YES even though the existing sensor is being reused. This action will allow the WDS to reset a larger set of parameters.

14. Check for the presence of any erroneous diagnostic trouble codes (DTCs). If

DTCs are present, they should be recorded, and then cleared.


APPLYING MODIFICATION LABEL

MODIFICA TION LABEL (ALL VEHICLES INCLUDING CA. AND MA.)

WRITE IN D A TE

ILLUSTRATION 10

Enter the dealer number and date on the authorized modification label and apply the label (Illustration 10, part no. R 493 STK) next to the left hood hinge.

PROOF OF CORRECTION FORM

California and Massachusetts Dealers (and any other states where required): Fill out and place the salmon colored “Vehicle Emission Recall - Proof of Correction” form (Illustration 11, part no. S CAL RCL) in the vehicle glove compartment.

PROOF OF CORRECTION FORM (CALIFORNIA AND MASSACHUSETTS)


ILLUSTRATION 11


ADDITIONAL INITIATIVES

The following are diagnostic procedures that may be followed should a drivability concern still be apparent after the recall action has been completed. The completion of any subsequent repairs are subject to normal New Car Warranty or

Select Edition Warranty, or customer pay authorization as appropriate.

T S B

1 2 5 4

1 7 1 1

1 8 5 5

D a t e i s s u e o f T i t l e

A m e n d e d

1 2 / 9 8

S p a r k p l u g s

1 2 / 9 8

0 2 / 0 1

S

C y h m a n p g t o e m t o s h o t t e r p l u g

T h r o t t l e s t i c k i n g c l o s e d c o l d e o n n g i n e

T h r o t t l e s t i c k s s h u t w h e n

B l o w o n s p b y a r k s t a i n p l u g s

D i s c o l o r a t i o n o n p o r c e l a i n c o l d

M o d e l

1 9 9 5 9 6

X J S

1 9 9 5 / 9 6

X J S

1 9 9 5 9 6

X J S

A c t i o n

S e r v i c e r e p l a c e m e n t p l u g

M o d i f y c b r e a t h e r r a s y n k c a s e s t e m a n d c l e a n t h r o t t l e

D p o l u n o t g s c h f o r a n g e c o r o n a d i s c h a r g e s t a i n .



The appropriate modification kit for the 1995 MY only (LNC 1411BB) initially will be allocated to each dealer based on size and volume to ensure an even distribution and full coverage. After the initial allocation, parts should be ordered from Jaguar

Parts Operations following normal procedures. All other parts required should be ordered through Jaguar Parts Operations following the normal process.

V E H I C L E

9 5 M Y X J S

9 6 M Y X J S

V I N R A N G E M O D I F I C A T I O N

K I T P A R T

Q T Y K I T U P D A T E S E C M

T O T H I S

N U M B E R

P A R T

1 1 9 4 7 7 5 2 2 2 6 3 1 L N C 1 4 1 1 B B

2 2 2 6 3 2 2 2 6 6 4 5 L N C 1 4 1 1 F A 1

L H E 1 4 1 0 A L

L H E 1 4 1 0 D J

P R O M

I D N O .

9

9

3

3

6

6

2

0

All of the PROM kits include 2 PROMs and a revised ‘PECUS’ label to be applied to the ECM after completing the modification.

P AR T NUMBER

EGR valve - XJS VIN 194775 – 195695 EGR valve LHE 1550BA

EGR valve - XJS VIN 195696 – 226645 LHE 1550AC

EGR valve gasket

EGR valve bolt

Throttle return spring

C2A 1231

FS 108251J

NBB 3131AB

1

1

1

As required

1

To obtain R493 Authorized Modification Labels from the Product Legislation and

Compliance Department, refer to Administration Bulletin 6-94 (USA) or 6-16/02

(Canada) titled “Availability of Service Action and Recall Authorized Modification

Labels/stickers.”

P AR T NUMBER

R 493 STK 1 R493 Modification Label

CA & MA only:

Proof of Correction Form S CAL RCL 1



Warranty claims should be submitted quoting the information found in the table below. This will result in payment of the stated time and, where applicable parts/ miscellaneous expense codes as listed.

Drive in/drive out may only be claimed when the vehicle has been brought in for this action alone to be undertaken.

claim applicable to the repair completed.

R ecall T493 - 1 995 MY XJS 4.0L

REPLACEMENT OF PROMS IN ECM

V ehicle

XJS 4.0 VIN Range:

194775 - 222631

R epair

Replace PROMS within ECM 18.91.18

0.7

EGR VALVE & GASKET REPLACEMENT

XJS 4.0 VIN Range:

194775 - 195695 Replace EGR valve & gasket 17.45.01

0.2

P ar

LNC 1411BB PROM Kit 1

LHE 1550BA

C2A 1231

FS 108251J

EGR valve

Gasket

Set screw

1

1

As Req.

THROTTLE RETURN SPRING REPLACEMENT

XJS 4.0 VIN Range

194775 - 226645 Replace throttle return spring 19.91.46

0.2

NBB 3131AB Throttle return spring 1

DRIVE IN/DRIVE OUT

ALL Drive in/drive out 10.10.10

0.1

R ecall R493 - 1 996 MY XJS 4.0L

REPLACEMENT OF PROMS IN ECM

V ehicle

XJS 4.0 VIN Range:

222632 - 226645

R epair

Replace PROMS within ECM 18.91.18

0.7

EGR VALVE & GASKET REPLACEMENT

XJS 4.0 VIN Range:

195696 - 226645 Replace EGR valve & gasket 17.45.01

0.2

P ar t Number

LNC 1411FA PROM Kit 1

LHE 1550AC

C2A 1231

FS 108251J

EGR valve

Gasket

Set Screw

1

1

As Req.

THROTTLE RETURN SPRING REPLACEMENT

XJS 4.0 VIN Range

194775 - 226645 Replace throttle return spring 19.91.46

0.2

NBB 3131AB Throttle return spring 1

DRIVE IN/DRIVE OUT

ALL Drive in/drive out 10.10.10

0.1


Sedan Range

DATE

10/95 18-04

SERVICE TECHNICAL BULLETIN

Security System – Rear Door False Alarm –

Repair Information

MODEL

1995 MY

Sedan Range

VIN

720001-735432

Sedan Range vehicles within the above VIN range may experience a security system false alarm that is recorded in the last alarm data as a door instrusion. On some vehicles, the side of the actuator connector facing the rear door lock actuator was incorrectly molded. This may increase the possibility of water entering the connector, which may trigger the vehicle security system intermittently.

In case of a customer complaint of a security system false alarm on a Sedan

Range vehicle within the above VIN range, proceed as follows:

1.

Inspect the rear door lock actuator on the affected doors for signs of water entry.

2.

If corrosion is found, clean the connector and seal the connector with Jaguar electrical contact grease, part no. JLM 11472.

3.

If the corrosion is too extensive, the door harness and/or door lock actuator should be replaced as necessary. The replacement parts are the latest design.


Jaguar electrical grease

Right rear door latch/actuator assembly

Left rear door latch/actuator assembly

Right rear door harness

Left rear door harness

P AR T NUMBER Q T Y

JLM 11472

GNA 2550BD

GNA 2551BD

LNA 3190CF

LNA 3190FE

*= Claim no more than 25% of container cost per vehicle.

*

1

1

1

1

Date of issue 10/95 Bulletin Number 18-04 Page 1 of 2


F A U L T

RB BD MB 86.25.47

A L L O W A N C E

Left rear door lock actuator - replace 1.00 hrs.

(with diagnostic time)

RB BD MB 86.25.47.09 Left rear door lock actuator - replace 0.65 hrs.

(without diagnostic time)

RB BF MB 86.25.47

Right rear door lock actuator - replace


1.00 hrs.

RB BF MB 86.25.47.09 Right rear door lock actuator - replace 0.65 hrs.


LJ GK PS 86.70.47

Replace left rear door harness


LJ GK PS 86.70.47.09 Replace left rear door harness


LJ HK PS 86.70.47

Replace right rear door harness


LJ HK PS 86.70.47.09 Replace right rear door harness


1.15 hrs.

0.80 hrs.

1.15 hrs.

0.80 hrs.

Page 2 of 2 Bulletin Number 18-04 Date of issue 10/95

Sedan Range

DATE

10/95 18-05


Security System – Panic Alarm –

Diagnostic Procedure –

Service Action S635

MODEL

1995 MY

Sedan Range

VIN

720001 - 739235

The Panic Alarm may not operate on some 1995 MY Sedan Range vehicle in the above VIN range. The absence of the Panic Alarm may result from either a transmitter problem or an Security Locking Control Module, (SLCM) problem or a combination of both.

All vehicles in the above VIN range should be inspected, regardless whether in dealer stock or in service. Check customer vehicles at the next service opportunity or in response to a customer complaint as described below.

SECURITY SYSTEM PANIC ALARM OPERATION type) must be replaced with the later 101 type. The 101 type can be identified by a pink paint spot on the blue tags supplied with transmitters and all new vehicles. If the blue identification tag is not available, check the oscillator identification mark (101 or 113) on the printed circuit board in the transmitter.

1.

Remove the ignition key from the ignition switch and ensure that the vehicle doors are closed.

2.

Check the operation of the Panic Alarm by pressing either button on the transmitter for at least 3 seconds and then releasing it.

possible, due to the noise level.

3.

Repeat the operation using the other transmitter button.

4.

The Panic Alarm will sound for five times the normal full alarm period.

5.

Insert the ignition key and turn to position I or II and back to 0 to cancel the

Panic Alarm.

with the battery transit relay, the checking procedure described above must be carried out within 30 seconds of the initial removal of the ignition key.

6.

Remove the key and begin checking the second transmitter.


7.

If the second transmitter needs to be checked after the 30 second period has elapsed, the ignition should first be switched on and off as described in step

5.

CHECKING THE REPLACEMENT TRANSMITTER

1.

A maximum of five transmitters can be programmed for one system.

2.

Remove the ignition key from the ignition switch and ensure that the vehicle doors and trunk are closed.

3.

Check the operation of the Panic Alarm by pressing first one and then the other button as described above.

4.

If the Panic Alarm functions, no further action is necessary.

5.

If the Panic Alarm does not function, and the system is equipped with the 101 type remote transmitter, (pink spot), DO NOT attempt to restore the Panic

Alarm, install a new SLCM. (Refer to “Replacing the SLCM”).

6.

When the SLCM has been replaced, check the operation of the Panic Alarm as described above.

REPLACING THE SLCM

JSI-2525

1.

Disconnect the vehicle battery.

2.

Remove the luggage compartment carpet, front liner, seal retainer and the side liner.

3.

Loosen and remove the nuts retaining the SLCM, Illustration 1.

4.

Withdraw the SLCM mounting studs from the mounting holes, (arrows,

Illustration 1) in the body support bracket.

5.

Disconnect the SLCM from the vehicle harness, noting the position of the connectors.


6.

Connect the harness connectors to the new SLCM in the same order as they were on the original module.

7.

Insert the SLCM mounting studs through the holes in the support bracket and install nuts.

8.

Reconnect battery and install trunk trim.

PROGRAMMING THE HAND TRANSMITTER.

Use the PDU to reprogram the security system RF handset transmitters. The following method can be used to manually reprogram handset transmitters: being serviced must be available. If the learning process is carried out without having all the transmitters present, all previous transmitter codes will be overwritten, rendering the missing transmitters inoperable.

1.

Open the trunk lid and driver’s door.

2.

Turn the ignition switch to the ON or II position.

3.

Rock the valet switch located in the center console storage compartment

(Illustration 2) 5 times. A single confirmation chirp and flash of the headlamps indicate that the security system has entered the learning mode.

check that the valet switch is functioning properly.

V ALET SWITCH

Date of issue 10/95

ILLUSTRATION 2

JWX-163

Bulletin Number 18-05 Page 3 of 5

4.

Press the arm/lock (larger) button of the first transmitter. This transmitter will be linked to position 1 of the seat/column/mirror memory. A tone will confirm that the transmitter code was accepted. If no transmitter buttons are pushed, the SLCM will also time out after 15 seconds of inactivity, indicated by two chirps.

5.

Rock the valet switch once. Two short chirps will signal that the system is prepared to accept the second transmitter.

6.

Press the arm/lock button of the second transmitter. This transmitter will be linked to the position 2 of the seat/column/mirror memory. A tone will confirm that the transmitter code was accepted.

7.

Rock the valet switch once. Three short chirps will signal that the system is prepared to accept the third transmitter.

8.

Press the arm/lock button of the third transmitter. A tone will confirm that the transmitter code was accepted. This transmitter and any others will not be linked to a position in the seat/column/mirror memory.

9.

The process of pressing the valet switch and waiting for the number of chirps equivalent to the transmitter number can be repeated for a fourth and fifth transmitter. The valet switch can be pressed to cycle through the unneeded transmitter programming sequences. The SLCM will also time out after 15 seconds of inactivity, indicated by two chirps. This will save the transmitter codes entered up to this point.

10. Turn the ignition switch off, remove the key, and close the doors and trunk lid.

11. Check for proper system operation including the recall of seat, steering wheel and mirror memory positions 1 and 2 from the handset transmitter.


Service Action S635

S U M M A R Y

Sedan Range 1995 MY

VIN 727000 - 739235

Model codes 2310, 2311,

2313, 2314, 2512

HA

Sedan Range 1995 MY

VIN 727000 - 739235


2313, 2314, 2512

HB

A L L O W A N C E

Check, replace and reprogram 0.15 hrs.

new transmitters when performed at PDI or in conjunction with another repair

(no drive in/out time)


new transmitters

- only repair performed

- with drive in/out time


Sedan Range 1995 MY

VIN 727000 - 739235


2313, 2314, 2512

HC

Sedan Range 1995 MY

VIN 727000 - 739235


2313, 2314, 2512

HD


new transmitters and replace

SLCM when performed at PDI or in conjunction with another repair

(no drive in/out time)


new transmitters and replace

SLCM - only repair performed




DCS DEALERS


NON-DCS DEALERS



Sedan Range

DATE

10/95 18-06


Security System – Handset Transmitter –

Manual Programming

MODEL

1995-96 MY

Sedan Range

VIN

720001-ON

The Security System RF handset transmitters can be programmed manually in case a PDU is not immediately available.

Use the following method to manually reprogram security system RF handset transmitters: being serviced must be available. If the learning process is carried out without having all the transmitters present, all previous transmitter codes will be overwritten, rendering the missing transmitters inoperable.

1.

Open the trunk lid and driver’s door.

2.

Turn the ignition switch to the ON or II position.


V ALET SWITCH

JWX-163

ILLUSTRATION 1

3.

Rock the valet switch located in the center console storage compartment

(Illustration 1) 5 times. A single confirmation chirp and flash of the headlamps indicate that the Security Locking Control Module (SLCM) has entered the learning mode.

check that the valet switch is functioning properly by removing it and checking continuity.

4.

Press the arm/lock (larger) button of the first transmitter. This transmitter will be linked to position 1 of the seat/column/mirror memory. A tone will confirm that the transmitter code was accepted. If no transmitter buttons are pushed, the SLCM will also time out after 15 seconds of inactivity, indicated by two chirps.

5.

Rock the valet switch once. Two short chirps will signal that the system is prepared to accept the second transmitter.

6.

Press the arm/lock button of the second transmitter. This transmitter will be linked to the position 2 of the seat/column/mirror memory. A tone will confirm that the transmitter code was accepted.

7.

Rock the valet switch once. Three short chirps will signal that the system is prepared to accept the third transmitter.


8.

Press the arm/lock button of the third transmitter. A tone will confirm that the transmitter code was accepted. This transmitter and any others will not be linked to a position in the seat/column/mirror memory.

9.

The process of pressing the valet switch and waiting for the number of chirps equivalent to the transmitter number can be repeated for a fourth and fifth transmitter. The valet switch can be pressed to cycle through the unneeded transmitter programming sequences. The SLCM will also time out after 15 seconds of inactivity, indicated by two chirps. This will save the transmitter codes entered up to this point.

10. Turn the ignition switch off, remove the key, and close the doors and trunk lid.

11. Check for proper system operation including the recall of seat, steering wheel and mirror memory positions 1 and 2 from the handset transmitter.


Sedan Range

DATE

11/94 18-09


Security System Transmitter –

Battery Replacement

MODEL

1995 MY

Sedan Range

VIN

720001-ON

ISSUE:

Attempting to pry the battery access cover off of the security system transmitter may cause the transmitter to separate and damage electronic components.

ACTION:

To prevent damage when removing the battery access cover of 1995 MY Sedan Range security system transmitters, use the following procedure.

SECURITY SYSTEM TRANSMITTER BATTERY ACCESS COVER REMOVAL

1.

Insert a small (1/16" thick) screwdriver between the access cover and body

(Illustration 1).

SECURITY SYSTEM TRANSMITTER

86-135.1

ILLUSTRATION 1

2.

Push the screwdriver straight in to release the lock as shown in Illustration 2.

CAUTION: Twisting the screwdriver or attempting to pry the cover open will damage the transmitter.


3.

The internal spring will push the access cover open.

RELEASING THE BATTERY ACCESS COVER

INSERT SCREWDRIVER PUSH IN TO RELEASE LOCK TAB

86-135.2

ILLUSTRATION 2

NOTE: Dispose of used batteries according to local laws.

Page 2 of 2 Bulletin Number 18-09

Sedan Range

DATE

10/95 18-10


Security System – Fault Diagnosis Guide

MODEL

1995-96 MY

Sedan Range

VIN

720001-ON

Additional fault tracing information for Sedan Range vehicle security system.

Refer to the possible symptom and cause information grouped by topic on the following pages.

FAULT TRACING CONTENTS PAGE

False Alarms ............................................................... 2

Security System not arming ..................................... 3

Transmitter totally inoperative.................................. 4

Poor transmitter range .............................................. 5

SLCM does not enter Manual Learn mode .............. 5

Checking the “Last Alarm” data using the PDU ..... 6


FALSE ALARMS

The cause of the last 8 vehicle alarms may be checked by using the PDU to interrogate the Security

Locking Control Module (SLCM).

The causes of the alarms are stored in the Last Alarm Data section of the Security Diagnostic PDU software. See flowchart on page 6.

It is possible for False Alarms to be generated along with the following symptoms:

1.

Symptoms:

• Transmitter will intermittently not lock the vehicle and/or the door locks “cycle” and/or the security system emits error tones.

• Vehicle will not start and alarm is inoperative.

• Alarm self-activates.

• When “Drive” is selected, all doors do not lock automatically.

VIN Range affected: 720001 - 735432

Possible cause:

Moisture contamination in one or both right and left door multiplugs RD3. Experience has shown that the multiplug on the right rear door is more prone to this problem and should be checked first. If the connector is corroded, both the door lock module harness and the door harness should be replaced.

2.

Symptom

• Intermittent error tone whenever the transmitter button is pressed and/or the system will not arm.

VIN Range affected: 720001-ON

Possible cause:

Faulty ignition switch in steering lock.

3.

Symptom

• Trunk lock intermittently does not release from either the transmitter or from the internal or external trunk lock release switches and/or error tones occur following security system arming.

VIN Range affected: 720001-723274

Possible cause:

Faulty “Trunk Lid Ajar” switch.

SECURITY SYSTEM NOT ARMING

1.

If arming of the security system is inhibited when using either the key or the transmitter, check that the following inputs to the SLCM are not active:

Function

Ignition key “In”

(UR)

Ignition auxiliary “On”

(WN)

Ignition “On”

Connector Identification

SLCM Connector CA 19-18


SLCM Connector CA 19-17 (WO)

(Wire color codes: U=Blue, R=Red, W=White, N=Brown, O=Orange)

2.

If the security system will not arm from the remote transmitter, with all the doors properly closed, the following inputs to the SLCM should be checked:

Function

Passenger door ajar

Driver’s door ajar

Rear door ajar





(UO)

(PR)

(P)

(Wire color codes: U=Blue, R=Red, W=White, N=Brown, O=Orange)

If any of the circuits are suspect, also check for entry of moisture into the rear door multiplug RD3.

TRANSMITTER TOTALLY INOPERATIVE

If the transmitter is totally inoperative, check whether the

LEDs on the transmitter illuminate when the “Lock” or

“Unlock” button is pressed.

If the LEDs do NOT illuminate, check the transmitter battery voltage levels. Each battery should be approximately 3 volts.

If the LEDs DO illuminate, check that the transmitter and security system have not lost their code synchronization.

The system is designed with a rolling code window of

100 activations of the transmitter. This means that if the transmitter is operated 100 times out of range of the vehicle to which it is coded, it will lose synchronization with the vehicle. If this occurs, repeated operations of the transmitter will not unlock the vehicle.

In this case, the security system may be disarmed by unlocking the doors using the vehicle key.

Once the vehicle is in an unlocked and disarmed state, the RF transmitter(s) will re-synchronize to the vehicle after 3 activations within signal range.

have lost code synchronization, and the transmitter button is pressed while the vehicle is locked and armed, the SLCM may enter the “Anti-scan” mode. This will inhibit any transmitter operation for approximately 2 minutes.

POOR TRANSMITTER RANGE

If the transmitter operates, but the range is poor, first check the range of the second transmitter. If both transmitters have equally poor range, check the following before replacing any items.

1.

Check the voltage of the transmitters’ batteries. Each battery should measure approximately 3 volts.

2.

Check the integrity of the harness for the following inputs to the SLCM:

SLCM DOES NOT ENTER THE

MANUAL LEARN MODE

If the SLCM will not enter the

“Learn mode”, check the following:

• The ignition key must be in the

“Ignition On” position.

• The security system must be disarmed.

• All the vehicle doors must be unlocked.

• The vehicle must not be in the

“Valet” mode. (Open the trunk lid before attempting to enter the “Learn” mode.)

Function

RF Ground

RF Antenna Signal


SLCM Connector CA 20-7 (BRD)

SLCM Connector CA 20-15 (WN)

(WIre color code: W=White, N=Brown, BRD=Shielded cable)

If the points at the left have been checked and the SLCM still will not enter the “Learn” mode, check the integrity of the following inputs to the

SLCM.

Function

Lock Actuator Status (RH)

Lock Actuator Status (LH)

Ignition Auxiliary ON

Trunk Valet mode switch

Ignition ON


SLCM Connector CA 18-12 (YB)

SLCM Connector CA 18-10 (YR)

SLCM Connector CA 18-8 (WN)

SLCM Connector CA 19-6 (YW)

SLCM Connector CA 19-17 (WO)

(Wire color code: Y=Yellow, B=Black, R=Red, W=White, N=Brown,

CHECKING THE “LAST ALARM” DATA USING THE PORTABLE DIAGNOSTIC UNIT

Main Menu

* Diagnostics

* Digitial Multimeter

* Training

* User Self Test

Vehicle Identification

CL

7

4

1 2

0

8

5

773214

9

6

3

Vehicle Features

Steering

Engine

Conditioning

Security

LHD

AJ16

YES

RHD

V12

Transmission MANUAL AUTO

Air

NO

NO System

Driver’s

YES

Memory Seat YES

Passenger’s

NO

Memory Seat YES

Extended

Wheelbase YES

NO

NO

Main Menu

* Diagnostics

* Set up

* TOOLBOX

* OBDII Report

* Vehicle Data Viewer

* Exit

OPERATOR MESSAGE

Ensure the customer fault has been verified before carrying out diagnostics

FAULT DIAGNOSTICS

* ENGINE & TRANSMISSION

* INSTRUMENTATION

* LIGHTING

* CLIMATE CONTROL SYSTEMS

* BODY SYSTEMS

* DOOR SYSTEMS

* BRAKE SYSTEM

* POWER FEEDS

* SERIAL COMM BUS TEST

* EXIT

BODY SYSTEMS

* AUDIBLE WARNINGS

* CIGAR LIGHTERS

* IN CAR ENTERTAINMENT

* RADIO TELEPHONE

* SEATS

* SECURITY SYSTEM

* SUN ROOF

* WASH/WIPE CIRCUITS

* GEARSHIFT & KEY LOCK

* POLYCHROMIC REAR

VIEW MIRROR

* HEATED WASH JETS

* SCREEN HEATERS

* STEERING COLUMN &

MIRROR MOVEMENT

* GARAGE DOOR OPENER

* AIR BAG

* POWER ASSISTED

STEERING

SECURITY SYSTEM

* L A S T A T A

* IGNITION

* KEY IMMOBILISATION

* VISIBLE OUTPUTS

* SENSORS

* PROTECTED ENTRIES

* SOUNDERS AND HORN

* REMOTE RECALL

* REMOTE TRANSMITTER

* REMOTE ALL CLOSE

* BOOR FUSE 4

* PANIC SWITCH

* COMPLETE TEST



Any parts determined necessary as a result of tracing a fault in the Security system should be ordered as necessary from Jaguar Parts.


Warranty claims must be submitted in accordance with the current published

Jaguar Warranty Policy and Procedures Manual, and Amendments.


Sedan Range

DATE

6/97 18-12

SERVICE


Security System – Frequency Change –

Rear Glass Antenna

MODEL

1996 MY

Sedan Range LWB

VIN

754307-758728

Some long wheelbase (LWB) Sedan Range vehicles within the above VIN range were equipped with 315 MHz Security and Locking Control Modules (SLCM) and key fob transmitters in spite of having rear glass antennas intended for 433 MHz systems. However, this condition has not been found to have a significant effect on the performance of the security system.

While the SLCM and rear glass antenna do not need to match, the key fob transmitters and the SLCM must be the same frequency. A key fob transmitter of one frequency will not function with an SLCM of the other frequency.

Long wheelbase vehicles beginning with VIN 758729 are equipped with a complete 433 MHz system. Short wheelbase vehicles were changed to the 433

MHz system starting with VIN 759614. The 433 MHz was introduced to give improved reliability and more consistent performance.

The frequency is incorporated in the last 3 digits of the FCC ID number. This number is located on the back of the key fob transmitter battery cover and on the sticker on the SLCM. The antenna is located near the top center of the rear glass and can be identified by its configuration (Illustration 1).

REAR GLA SS SECURITY S YS AN TENNA

31 5 MHz

Date of issue 6/97

433 MHz AN TENNA

ILLUSTRATION 1

Bulletin Number 18-12 Page 1 of 2

A CTION:

When replacing Security system components on Sedan Range vehicles within the above VIN ranges, observe the following guide lines:

••••• Do not convert a long wheelbase vehicle equipped with a 433 MHz antenna rear glass and a 315 MHz system (SLCM and transmitters) to a 433 MHz system.

••••• If the SLCM or a key fob transmitter needs replacement on a vehicle equipped with a 315 MHz system and a 433 MHz antenna rear glass, continue to use 315

MHz components to avoid replacing the entire system.

••••• If the rear glass needs to be replaced, it is permissible to replace a 433 MHz antenna rear glass with a 315 MHz antenna rear glass if the vehicle has a 315

MHz system.


LWB rear glass with 315 MHz antenna

LWB rear glass with 433 MHz antenna

P AR T NUMBER

GXF 9021BB

GXF 9021BA

1

1

Page 2 of 2 Bulletin Number 18-12 Date of issue 6/97


Check Engine Light On – DTC 12 Flagged –

Install Changeover Relay and Link Lead

MODEL

ALL 1993 MY

DATE

8/93

Remove and destroy Bulletin 18-36, Date 8/93

Replace with this Amended Bulletin.

Revisions are marked with a bar and indicated in Bold Text.

18-36

AMENDED

8/94

ISSUE:

On 1993 MY Sedans up to VIN 678670 and 1993 MY XJS 4.0L vehicles up to VIN 188104, engine management diagnostic trouble code (DTC) 12 can be flagged if the ignition is switched off when the engine speed is above 1,500 RPM.

If this occurs, there will be no effect on vehicle performance.

ACTION:

On all vehicles within the affected range (whether in dealer stock or in for service) with the

CHECK ENGINE light on and DTC 12 stored in the ECM memory, locate the fuel injection main relay and check the relay case color. The relay can be located as follows:

93 MY Sedan up to VIN 678670: The fuel injection main relay is located in the right rear corner of the engine compartment against the bulkhead and has a black base connector. If the relay is blue

(not violet), perform the procedure as noted below:

93 MY XJS 4.0L up to VIN 188104: The fuel injection main relay is located behind the passenger side footwell "A" post trim panel below the EMS ECM and has a red base connector. If the relay is silver or blue (not violet) perform the following procedure:

NOTE: Later vehicles may incorporate a blue fuel injection main relay and a revised EMS ECM to overcome code flagging. DO NOT modify vehicles after the affected VIN range.

Procedure:

1.

Record radio preset stations (including X-mem.). Disconnect the vehicle battery.

2.

Locate the fuel injection main relay and remove the relay from its base.

3.

Remove the anti-backout clips from the relay base.

4.

Extract the following pins from the relay base:

Sedan brown/yellow wire from pin 30 white/brown wire from pin 87

XJS brown wire from pin 30 white/brown wire from pin 87

5.

Reconnect the wires to the relay base as follows (refer to figure below for pin positions):

Sedan white/brown wire to pin 30 brown/yellow wire to pin 87

XJS white/brown wire to pin 30 brown wire to pin 87

Bulletin Number 18-36 AMENDED Page 1 of 2

6.

Extract the black wire from pin 85 of the relay base.

86

30

CHANGEOVER RELAY PIN AND WIRE POSITIONS

87

87a

85

PIN

30

85

86

87 XJ6

XJS

87a

WIRE COLOR white/brown black unchanged brown/yellow brown black/white

7.

Connect the new link lead (LMB 3998AA) to the black harness wire.

8.

Connect the black link lead wire with the white tracer to pin 87A of the relay base.

9.

Connect the remaining link harness wire to pin 85 of the relay base.

10.

Install the anti-backout clips to the relay base.

11.

Use black PVC tape to insulate the black wire connection and tape the link lead to the relay harness.

12.

Install the relay base to the mounting bracket.

13.

Install the changeover relay DAC 7687 (violet case) into the relay base.

14.

Connect the battery and reset the radio stations (including X-mem.).

NOTE: If DTC 12 is flagged and the relay has been changed (violet relay DAC

7687), check that the link harness has been properly installed.

If the fuel injection main relay and wiring installation are correct or if the vehicle is outside the affected VIN range, check for other causes. Refer to the DTC diagnostic flowchart in the XJ6/XJ12 Service Manual, Section 17.

PARTS INFORMATION:

PART NUMBER

LMB 3998AA

DAC 7687

WARRANTY INFORMATION:

DESCRIPTION

Link lead

Changeover relay

SUMMARY

CODE:

BB

REPAIR

CODE:

S405

R.O. NUMBER:

86.91.68

QTY.

1

1

TIME ALLOWANCE:

Sedan - 0.25 hrs.

XJS - 0.40 hrs.



Intermittent Power Loss – Tach Drops to Zero

– Reposition Ignition Amplifier –

Service Action S 439

18-41

MODEL XJS V12 Range 1994 MY

From: VIN 188105

To: VIN 194706

DATE 7/94

ISSUE:

Symptoms of intermittent power loss or engine misfire, with the tachometer needle dropping to zero, may be caused by the under hood liner coming into contact with the “A” bank (right) ignition amplifier connector housing. This may cause damage to the right side primary catalytic converter.

To prevent this contact from occurring, the ignition amplifier was repositioned at VIN 194707.

ACTION:

Modify the ignition amplifier base plate and reposition the right side ignition amplifier on all vehicles within the following VIN range at the next service opportunity.

VIN 188105 to VIN 194706.

1. Disconnect the “A” bank (right) ignition amplifier harness connector and remove the two amplifier base plate nuts (Illustration 1).

IGNITION AMPLIFIER LOCATION

HARNESS CONNECTOR

BASE PLATE NUTS

18-41.1

ILLUSTRATION 1

2. Remove the amplifier assembly and carefully tape its connector housing with masking tape to prevent drill chips from entering.


3. On the amplifier base plate, mark the position of the two new holes. Drill two 15/64"

(6 mm) holes as shown in Illustration 2.

IGNITION AMPLIFIER DRILLING DIMENSIONS

Hole size 15/64"(6.0-6.2 mm)

20 mm

7 mm

100.35 mm

100.85 mm

32 mm

18-41.2

ILLUSTRATION 2

4. Deburr the drilled holes. Use compressed air to clean drill chips from the amplifier and base plate.

5. Remove the masking tape and inspect the inside of the connector housing to be sure it is clean.

6. Reinstall the amplifier assembly using the new mounting holes.


SERVICE ACTION: S 439

Action:

Summary Code:

Reimbursement:

Reposition ignition amplifier

BQ

Labor:

Parts:

0.20 hrs.

None

Action:

Summary Code:

Reimbursment:

Reposition ignition amplifier - Renew right side catalytic convertor

BR

Labor:

Parts:

1.25 hrs.

NHC 67700AA



PDU 1001 Software – Error – Does Not

Recognize V12 6.0L DTC 67

MODEL XJ12 and XJS V12 DATE 7/94

18-42

ISSUE:

If DTC 67 (Air injection operation) is flagged on the Vehicle Condition Monitor, PDU will not recognize or erase the code.

ACTION:

If DTC 67 is indicated on the VCM of XJS V12 or XJ12 vehicles, check for normal operation of the Secondary Air Injection System (AIR).

Secondary Air Injection System Check:

Start engine.

NOTE: At engine start-up with coolant temperature below 117 0 F (47 0 C), the Secondary Air Injection Pump (AIRP) operates continuously until the coolant temperature reaches 117 0 F (47 0 C).

• Coolant temperature above 117 0 F (47 0 C).

At engine start-up with coolant temperature above 117 0 F (47 0 C), the AIRP operates for a programmed period of time depending on coolant temperature. The AIRP then operates a second time for OBD monitoring.

NOTE: If engine speed exceeds 900 RPM during the OBD monitoring phase, the

AIRP switches off. When the engine returns to normal idle speed OBD monitoring will repeat and the AIRP will operate.

If Oxygen Sensor Feedback (HO2 SFB) indicates excess oxygen (lean) in the exhaust while the AIRP is running the second time (OBD monitoring), the OBD test is passed.

If Oxygen Sensor Feedback (HO2 SFB) does not indicate excess oxygen (lean) while the

AIRP is running the second time (OBD monitoring), the CHECK ENGINE light turns on and

DTC 67 is flagged.

Refer to Service Manual section 17.3 for DTC 67 diagnosis information.

To erase the DTC from ECM memory:

• Switch ignition OFF.

• Disconnect and reconnect the fuel injection ECM.



Rough Idle/Engine Misfire – New

Spark Plug Wires and Routing

MODEL XJS Range (V12) and XJ12

DATE 11/94

18-43

ISSUE:

Rough idle and engine misfire conditions that develop after approximately 20,000 miles may be caused by high voltage leaks between the spark plug wires and cylinder head bolts.

New spark plug wire sets with revised routing were introduced in production from the following

VIN numbers.

XJS Range (V12) From VIN 195367 (Engine number 8D 11717)

XJ12 From VIN 702376 (Engine number 8C 13693)

ACTION:

If customers complain of engine misfire or rough idle after approximately 20,000 miles on V12 vehicles produced before the VIN numbers shown above, replace the spark plug wires with the latest version.

Route the new wires as shown in Illustration 1.

IMPORTANT: The clip (P/N KDP 108080/J) must be installed on the spark plug wires for cylinders 1A and 1 B as shown in the illustration.

SPARK PLUG WIRE ROUTING

1A 2A 3A 4A 5A 6A

1B 2B

4B

4A

2B

B

1A A

2A

6B

6A

1B

5A

5B

3A

3B

3B 4B

KDP 108080/J

5B 6B

18-43.1

ILLUSTRATION 1


PARTS INFORMATION:

MODEL DESCRIPTION

XJS V12 Spark plug lead set

XJ12

Clip

Spark plug lead set

Clip

PART NUMBER

LHD 1509AA

KDP 108080/J

LMC 1509AA

KDP 108080/J

QTY

1

1

1

1


FAULT CODE

BD DB JD

R.O NUMBER

18.20.11

DESCRIPTION

Spark plug lead set - Renew

TIME

ALLOWANCE

0.45 hrs.



Heated Oxygen Sensor (HO2S) –

Torque Specification

MODEL 1995-96 MY XJS (4.0) Range

VIN 194775-226645

DATE 2/95

18-45

Amended

6/97



The tightening torque for the heated oxygen sensors (HO2S) fitted to all 4.0L 1995-

1 2.5 ± 1 .5 lb f t (1 7 Nm ± 2 Nm)

A CTION:

When installing an HO2S in all 1995-96 MY (4.0L) XJS vehicles, DO NOT EXCEED

1 4 lb f t (1 9 Nm)

The female thread in an existing exhaust system can be cleaned using a plug tap

12 x 1.25 mm. When reinstalling a used sensor, wipe the thread clean using care not to contact the delicate tip of the sensor. Apply a light coat of an anti-seize compound to the thread of the sensor and start the thread by hand. New sensors come coated with an anti-seize compound. Final tightening requires a 17 mm socket.

NO TE: be reoriented using the PDU.



Fuel Injectors – Identification

MODEL All AJ6 (4.0L) and AJ16 DATE 2/95

18-46

ISSUE:

Original equipment fuel injectors are color coded to aid in assembly during engine production.

Fuel injectors supplied as service parts do not follow the same color coding format, but they can be identified by the supplier’s reference number stamped on the injector.

ACTION:

Refer to this bulletin to identify injector applications by referencing the supplier reference number to the Jaguar part number. The locations of the supplier reference numbers and the color code band is shown in Illustration 1.

FUEL INJECTOR

SUPPLIER

REFERENCE COLOR CODE

BAND

H/15/95.1

FUEL INJECTOR IDENTIFICATION

ENGINE

AJ6 4.0L

AJ16 N/A

AJ16 S/C

PART

NUMBER

EBC 4430

DBC 10423

DBC 11041

PRODUCTION

COLOR

SERVICE

COLOR

Green

White

Red

Green

Green

Green

SUPPLIER

PRODUCTION

REFERENCE

D3155KA

D3156KA

D3165KA

SUPPLIER

SERVICE

REFERENCE

D3155AA

D3156AA

D3165AA



Secondary Air Injection (AIR) –

DTC P0411 – Repair Procedure

MODEL All ( 4.0L) 1995 MY DATE 3/95

Sedan (4.0L) Range VIN 720001 - 734672

XJS (4.0L) Range VIN 194774 - 199153

Remove and destroy Bulletin 18-47, Date 3/95.



18-47

Amended

4/95

ISSUE:

The CHECK ENGINE MIL illuminates with no loss of power on 1995 MY vehicles within the

VIN ranges listed below. Diagnosis with PDU indicates that DTC P0411 is stored in memory.

Sedan (4.0L) Range

XJS (4.0L) Range

VIN 720001- 734672

VIN 194774 - 199153

At the end of the secondary air injection cycle, vacuum may become trapped in the hose from the air pump (AIRP) to the secondary air injection check valve (AIRC). The trapped vacuum will not allow the AIRP solenoid operated stop valve (integral with the AIRP) to open during the next air injection cycle. The ECM monitors no drift in the HO2S swings, which triggers the CHECK EN-

GINE MIL.

A revised air pump hose with a vacuum bleed is fitted to all AJ16 engines in production from VIN

734673 (Sedan [4.0L] Range) and VIN 199154 (XJS [4.0L] Range).

ACTION:

If 1995 MY vehicles within the VIN ranges listed above illuminate the CHECK ENGINE MIL with DTC P0411 stored in the ECM memory, perform the following procedure.

CHECK ENGINE MIL ILLUMINATED WITH DTC P0411 - REPAIR PROCEDURE

1.

Diagnose the AIR system following the instructions in the XJ6 - XJ12 Electrical Diagnostic

Manual 1995 MY Volume 1, Section 5.1, pages 271-272.

2.

Repair any faults found.

3.

If no fault is found, clear DTC P0411.

4.

Replace the existing AIRP to AIRC hose with a new hose (normally aspirated engines part number NBC 4798AA, supercharged engines part number NBD 4798AA).

NOTE: Continue to report all DTCs by completing form S-93 and forwarding to

Jaguar Cars Product Investigations.

Date of issue 4/95 Bulletin Number 18-47 Amended 4/95 Page 1 of 2

PARTS INFORMATION:

DESCRIPTION

Air pump hose - AJ16 normally aspirated

Air pump hose - AJ16 supercharged


FAULT

CODE

BG ZB ZZ

R.O NUMBER

17.91.29

DESCRIPTION

Air injection hose - Renew

PART NUMBER

NBC 4798AA

NBD 4798AA

1

1

QT

Y

TIME

ALLOWANCE

0.10 hrs.

Page 2 of 2 Bulletin Number 18-47 Amended 4/95 Date of issue 4/95


Uneven Cold Idle –

Drivability Enhancements –

ECM Upgrade

MODEL XJS (4.0L) 1995 MY

VIN 194775-197549

DATE 5/95

18-48

Amended

4/98



ECMs are no longer sent to Lucas since EPROMs are now available for upgrading ECMs at the dealer.

1995 MY XJS 4.0L vehicles within the above VIN range may display the following symptoms:

SYMPTOMS

Uneven idle following cold start.

Inconsistency at cruising speeds of 50 - 60 mph (80-100 km/h).

Hesitation at low speed, low throttle application with a warm engine.

These symptoms result from an unfavorable combination of fuel volatility and ignition timing factors. The ECM EPROM has been revised to correct these conditions from VIN 197550.

A CTION:

If customers complain of the symptoms listed above on vehicles within the quoted VIN range and all other engine parameters are within specification, the

ECM will require upgrading.

To upgrade an ECM to the latest specifications, follow the procedure as described below.

IMPOR T AN T::::: Inspect the vehicle to determine if a revised air pump hose with a vacuum bleed has been installed. If the existing air pump hose has no vacuum bleed, replace the hose with the correct revised hose for the vehicle.

Refer to Service Bulletin 18-47 for the appropriate part numbers and warranty information.


PREPARATION

1.

Connect the PDU to the vehicle and check for any DTCs stored in the ECM.

2.

Record any DTCs found on an OBDII report form (S-93), then clear them from the system. Any DTCs found must be diagnosed separately.

3.

Turn the ignition OFF. Wait 20 seconds, then disconnect the vehicle battery.

REMOVING ECM

1.

Remove the carpet from the right side footwell.

2.

Remove the ECM cover insulation pad.

3.

After removing the mounting nuts, remove the cover from the ECM.

4.

Remove the ECM from its mounting, disconnect both harness multi-plugs and remove the ECM from the vehicle.

AN TI-S T A TIC W ORKS T A TION

W ORK BENCH

W ORK MA T

WRIS T S TRAP CONNECTION

ILLUSTRATION 1

REPLACING PROM

ECM tools required:

••••• One Anti-static work mat, Part No. JAG 205/ST010

••••• One PROM removal tool, Part No. JAG 999/ND

••••• One TX 20 Torx Tamper-proof screw bit, JAG 20/TORX

CA UTION!

working at an anti-static workstation (Illustration 1) and wearing a grounding wrist strap.

JSI-2663

1.

Position the ECM on the anti-static work mat so that when facing the multiplugs, the red multi-plug is at the upper right and the black multi-plug to the lower left.


ENGINE CON TROL MODULE PROM L

PRIN TED CIRCUIT BO

PROM CO VERS

W OODEN BL OCK

BLA CK MUL TI-PLUG

CLEARANCE SP A CE

RED MUL TI-PLUG

W OODEN BL OCK

ILLUSTRATION 2

2.

Note the position of the top cover with its mounting tab to the ECM housing.

Mark both the cover and the casing using a felt tip marker to assist reassembly. Remove the four tamper resistant retaining screws of the top cover

(the cover adjacent to the red multi-plug) using a Torx 20 Anti-Tamper screw bit.

3.

Obtain a wooden block approximately 6 x 6 x 1 inches. Remove the seven retaining screws of the printed circuit board (Illustration 2). Lift the printed circuit board and support it on the wooden block so that no strain is applied to the ribbon connectors. Allow a clearance space so that no damage can occur from contact with the mounting brackets.

4.

Remove the appropriate PROM covers by lightly gripping the PROM cover with a pair of pliers and using a side to side rocking action.


REMO VING PROM MICROCHIP

JSI-2667

ILLUSTRATION 3

5.

Use a suitable chip removal tool to carefully remove both PROM chips from the printed circuit board (Illustration 3). The PROM removal tool supplied may differ from that shown in the illustration.

6.

Before installing the new microchip(s), identify the semicircular cutouts in both the chip and the socket on the printed circuit board (Illustration 4). The

NO TE: sourced at a local electronics supply store.

Careful manual alignment and installation methods must be used at this point in the procedure.

MICROCHIP ORIEN T A TION

SEMICIRCULAR CUT OUTS


JSI-2661

ILLUSTRATION 4


7.

Identify and install the replacement 28-pin chip from the kit into the 28-pin socket and the 32-pin chip into the 32-pin socket.

CA UTION!

MUS T board with all the pins engaged into the socket (condition A,

Illustration 5). Permanent damage to the chip is likely in conditions B or C. Malfunctions will occur with partial engagement as in condition D.

MICROCHIP ALIGNMEN T

ILLUSTRATION 5

8.

Install the original cover(s) over the PROM chip(s).

9.

Carefully fold the printed circuit board back into its original location on the housing of the ECM. Make sure the multi-plug is correctly aligned with its location in the housing. Install the seven retaining screws. Torque the screws to 20 - 25 lb. in. (2.25 - 2.82 Nm).

10. Install the ECM cover on the housing aligning the marks made during disassembly. Install the four mounting screws. Torque the screws to 20 - 25 lb. in. (2.25 - 2.82 Nm).


11. Apply the PECUS label from the kit to the cover near the existing labels without covering them (Illustration 6).

12. Install the ECM by reversing the removal procedures.

L OCA TION OF PECUS LABEL

REWORKED TO LNA XXXXXX

XX/97

ILLUSTRATION 6

13. Connect the battery and reset the vehicle clock.

14. Start the vehicle and perform an adequate road test to verify proper engine orientation of the oxygen sensors and to perform the engine setup.



Modification kit for 1995 XJS 4.0L

VIN 194775-197549

P AR T NUMBER

JLM 20373


F A UL T

BX DF ** 18.91.18

Replace ECM EPROM

1

ALL O W ANCE

0.75 hrs.



MIL Illumination – DTC P0300 –


MODEL 4.0L Normally Aspirated 1996 MY

XJS VIN 222632 - 224124

DATE 11/95

18-49

Amended

2/98



Some 1996 MY vehicles within the above VIN range may experience illumination of the Malfunction Indicator Lamp (MIL) caused by DTC P0300 being set. The DTC is set due to close software tolerances in the ECM rather than a mechanical problem with the engine.

This condition can be rectified by replacing one or both of the Programmable

Read Only Memories (PROMs), depending on the VIN, with new PROM(s) from the appropriate modification kit.

A CTION:

R efer to T ec hnical Bulletin 1 8-52, dated 4/97 . The sof tw are revisions for S ervice

Action S659 to solve the abo ve complaint were incorporated in the PROMs designed for S ervice Action S67 6.



MIL Illumination – DTC P0441 –


MODEL XJS (4.0L) 1996 MY

VIN 225350 - 226645

DATE

Remove and destroy Bulletin 18-51, Amended 9/96.


7/96

18-51

Amended

2/98

Some 1996 MY XJS vehicles within the above VIN ranges may experience illumination of the Malfunction Indicator Lamp (MIL) caused by DTC P0441 being falsely registered in the Engine Control Module (ECM).

This condition can be rectified by replacing both of the Programmable Read Only

Memories (PROMs) with new PROMs from the appropriate modification kit.

A CTION:

R efer to T ec hnical Bulletin 1 8-52, dated 4/97 . The sof tw are revisions for S ervice

Action S672 to solve the abo ve complaint were incorporated in the PROMs designed for S ervice Action S67 6.



Momentary Engine Hesitation/

Instability – Service Action S676

MODEL XJS (4.0L) 1996 MY

VIN 222632-226644

DATE 4/97

18-52

Amended

11/01



Some 1996 MY XJS vehicles within the above VIN ranges may experience a momentary engine hesitation/instability while cruising at steady highway speeds.

This condition may be accompanied by a very brief illumination of the “Check

Engine” Malfunction Indicator Lamp (MIL).

This condition can be rectified by replacing both of the Programmable Read Only

Memories (PROMs) with new PROMs from the appropriate modification kit.

In addition, this Service Action supersedes S659 (Bulletin 18-49) and S 672

(Bulletin 18-51)

A CTION:

R efer to T ec hnical Bulletin 1 7 -1 2, amended 1 1/0 1 . The sof tw are revisions for

S ervice Action S67 6 to solve the abo ve complaint were incorporated in the PROMs designed for R ecall R493.



DTCs P1176, P1177, P1178, P1179 –

Adaptive Fuelling System –

Diagnostic Procedure

MODEL 1995-96 XJS (4.0L) Range DATE 11/97

18-53

The adaptive fuelling system operates within predefined adaption limits to maintain an optimum performance level. Both the Fuel Mass Flow Rate (FMFR) and the Air Mass Flow Rate (AMFR) are monitored by the ECM to ensure they stay within the adaption limits. However, if a fuelling system problem occurs and the adaption limits are exceeded, a Diagnostic Trouble Code (DTC) is then stored in the ECM. The engine Malfunction Indicator Lamp (MIL) will illuminate to report the presence of the DTC. The MIL will stay illuminated until the DTC has been cleared using the PDU.

The flow charts which accompany this bulletin are provided to assist in diagnosing the above DTCs. Each DTC is represented by an individual flow chart which is used in conjunction with PDU.

A CTION: will rectify the above DTC problems.

If one or more of the above DTCs are stored in the ECM, then the PDU should be used to identify and clear the DTC(s). After identifying the DTC(s) use the appropriate diagnostic flow chart to diagnose the fault.

After repairing a fault described in the flow chart, complete the next flow chart instruction to ‘Reset and Check AMFR adaption’ or ‘Reset and Check FMFR adaption’ to determine if the fault has or has not been successfully repaired. It is not necessary to check or reset adaptions if no faults are identified. Resetting and checking the AMFR and FMFR adaptions is achieved by following the procedure on page 6.

Product Investigation

Fax Number (201) 818-9763.


P1 1 7 6

Check M AFS has correct

Part Num ber

Load PDU Diagnostics,

confirm fault code,

retrieve freeze frame data

for S-93 Form.

In PDU Diagnostics, perform diagnostic routine for fault code in 'LOGGED FAULTS'

Fault

Found

YES

NO

Check fuel pressure at fuel rail

Fault

Found

YES

NO

Check fuel pipe and fuel rail for leaks

Fault

Found

YES

NO

Check injectors for blockage

Fault

Found

YES

NO

Substitute MAFS and check FMFR adaption

FMFR adaption within limits

NO

YES


Release vehicle to customer

Reset and check

FMFR adaption

Reset and check

FMFR adaption

Reset and check

FMFR adaption

Reset and check

FMFR adaption

Contact Jaguar Technical

Hotline

Bulletin Number 18-53

P1 1 77

Check MAFS has correct

Part Num ber

Load PDU Diagnostics, confirm fault code, retrieve freeze frame data for S-93 Form


Fault

Found

YES

NO

On super charged engines check for air leaks on intake system

Fault

Found

NO

YES

Check fuel pressure at fuel rail.

Is fuel pressure high?

NO

YES

Check for sticking fuel pressure regulator

Check for blocked vacuum pipe

Check fuel injectors for leaks

NO

Fault

Found

YES

Reset and check

FMFR adaption

Reset and check

FMFR adaption

Check for blocked fuel return pipe

Reset and check

FMFR adaption

Fault

Found

YES

NO

Reset and check

FMFR adaption

FMFR adaption within limits

NO

YES


Substitute MAFS and check FMFR adaption

Contact Jaguar

Technical Hotline



P1 1 78


Part Num ber



Fault

Found

YES

NO

Check for air leaks on air induction system including inlet manifold

Fault

Found

YES

NO

Check fuel pressure at idle

Fault

Found

YES

NO

Check for blocked injectors

Fault

Found

YES

NO

Substitute MAFS and check AMFR adaption

AMFR adaption within limits

NO

YES



Reset and check

AMFR adaption

Reset and check

AMFR adaption

Reset and check

AMFR adaption

Reset and check

AMFR adaption


Hotline


P1 1 79


Part Num ber



Fault

Found

Fault

Found

Fault

Found

AMFR adaption within limits


YES

NO

Check for leaks on exhaust system including manifold

YES

NO

Check for high fuel pressure

YES

NO

Substitute MAFS and check AMFR adaption

NO

YES


Reset and check

AMFR adaption

Reset and check

AMFR adaption

Reset and check

AMFR adaption


Hotline


PROCEDURE TO CHECK AND RESET ADAPTIONS

• Run engine at normal operating temperature.

• Load disc PDU 1055 into the PDU at the base station.

(PDU Disc 1055 has the capability of reading the long term fuelling trim adaptions. This facility will confirm whether AMFR and / or FMFR are running at mixture that is too lean or too rich. These values are found in the PDU datalogger facility.)

• Select DIAGNOSTICS from the main menu.

• Enter VEHICLE DETAILS.

• Select TOOLBOX from the DIAGNOSTICS MAIN MENU.

• Select POWERTRAIN from the TOOLBOX MAIN MENU screen. The information screen will request that the PDU is connected to the vehicle.

• Select DATALOGGER from the PDU tools function.

• In DATALOGGER clear the default parameters and then select ‘AMFR’, ‘FMFR’,

‘CLV’ (Calculated engine Load Value), and RPM (Illustration 1).

• Select bar chart form, this will enable viewing of the adaption values, and act as an accurate monitor of the RPM.

• Note and record the AMFR adaption and FMFR adaption displayed values.

• Return to the PDU base station and load RESET ADAPTIVE VALUES from the

TOOLBOX menu screen.

• Connect the PDU to the vehicle and reset the adaptive values.

• Return to the PDU base station and reload DATALOGGER from the

POWERTRAIN option of the toolbox menu screen.

• Continue with the procedure in ‘Drive Cycle’ on the next page.

D A O NEEDED P ARAMETERS


ILLUSTRATION 1


DRIVE CYCLE

To enable the AMFR adaption and/or FMFR adaption to reset, the following preconditions must first be obtained:

• Air intake temperature must be between, 10 deg C and 55 deg C.

• Engine coolant temperature must be between, 80 deg C and 100 deg C.

Illustration 1 shows a view of the PDU screen in bar chart form with the relevant conditions and typical values for an engine in good fuelling order.

show the values as g/hr, for example, 500 g/hr rather than 0.5 Kg/ hr. (Illustration 1).

Air Mass Flow R ate (AMFR) adaption

The AMFR adaption value should be no lower than -4.2 kg/hr and no greater than

+2.8 kg/hr for both normally aspirated and super charged engines.

show the values as g/hr, for example 500 g/hr rather than 0.5 Kg/ hr. (Illustration 1).

Allow the vehicle to idle until the AMFR adaption value changes and then stabilizes; if the adaption is within the above values then the previous flow chart repair has been successful. If the adaption is still outside of the above values then continue to follow the flow chart until the fault is found.

After the completion of each flow chart repair, dump the trace snapshot into the trace buffer; which can then be printed out and be used for Warranty Audit

Purposes.

F uel Mass Flow R ate (FMFR) adaption immediately after AMFR adaption; do not switch engine off, or disconnect the PDU.

The FMFR adaption should be between +700 g/hr and -700 g/hr for normally aspirated engines, and between +1.4 kg/hr and -1.4 kg/hr for super charged engines.

show the values as g/hour, for example 500 g/hr rather than 0.5

Kg/hr. (Illustration 1).


Drive the vehicle at a steady speed, between the RPM and the engine load values for the model year stated below, until the FMFR adaption value changes and then stabilizes. Obtain the correct engine load and RPM balance by driving on a highway with 3rd gear (manual) selected at the stated RPM, while applying slight pressure to the foot-brake to maintain engine load.

W arning must be performed by two persons: Driver, and Passenger - to monitor the PDU and advise the driver of when the engine is being driven between the RPM and engine load values stated below.

1995 MY: engine speed 1500 to 3000 RPM; engine load 27.3% to 40%.

1996 MY: engine speed 2000 to 3000 RPM; engine load 23.4% to 40%.

When performing the FMFR adaption drive cycle, the stated RPM and engine load values must be adhered to, otherwise the adaption will stabilize at the incorrect value.

When the FMFR adaption value has changed and stabilized, and the adaption is within the above stated adaption values, then the previous flow chart repair has been successful. If the adaption is still outside of these values then continue to follow the flow chart until the fault is found.

After the completion of each flow chart repair, dump the trace snapshot into the trace buffer, which can then be printed out and be used for Warranty Audit

Purposes.



Poor Starting and Running –

XJR-S – Twin Coil Modification

MODEL 1993 MY XJR-S (6.0L) DATE 8/00

18-54

A combination of high ambient temperature and traffic conditions can cause underhood temperatures on 1993 XJR-S vehicles with the Zytek EMS, to rise to a level where the consequent electrical overloading of the coil can affect engine starting and running.

The overloading of a coil can be alleviated by the installing of a second coil to reduce loading and so extend coil life.

Once engine starting and running have been affected the coil must be replaced.

A procedure and a kit has been developed to replace the affected coil with twin coils.

A CTION:

1.

Remove the battery cover and disconnect the battery.

2.

Open the hood and install protective wing covers.

3.

Disconnect the high tension lead from the distributor cap.

4.

Disconnect the positive and negative harness connectors from the coil.

5.

Loosen and remove the bolts retaining the coil to the mounting bracket.

6.

Remove the coil from the bracket.

7.

If the high tension lead will be retained, the heat shrink sleeve must be cut away from the lead and the coil.

8.

Install the new heat shrink sleeve over the high tension lead and then install the lead securely on the new coil.

9.

When placing the new, (main), coil in position release the bolt retaining the coil mounting bracket and position the coil so that the terminals, and the leads when attached, do not contact any other equipment.

10. Remove the coil and high tension lead from the bracket while maintaining the position of the high tension lead relative to the coil.

11. On a suitable bench area, heat shrink the sleeve securely to the coil and the high tension lead.

coil is in position on the engine.

12. Install the coil on the bracket, recheck the line of the high tension lead and then tighten the bolt to retain the coil.


13. Install the positive and negative harness connectors on the coil.

14. Install the positive and negative connectors of the new link harness on the appropriate unused terminal ends on the coil.

15. Recheck that the terminals and the leads, at the coil, do not contact any other equipment.

LA Y OUT OF LINK HARNESS

MJS-3597

JSI-3597

ILLUSTRATION 1

16. Lay the link harness to follow the route shown in Illustration 1 and then through the grommet at A in Illustration 1, in the top radiator cross member.

17. Fit the link harness through the 19mm. hole in the auxiliary coil protective boot.

18. Connect the link lead terminals to the appropriate terminals on the auxiliary coil.

19. Recheck the connections and then place the boot in position on the auxiliary coil.


AUXILIAR Y COIL MOUN TING

JSI-3598

MJSI-3598

ILLUSTRATION 2

20. Install the auxiliary coil on the existing mounting points on the lower radiator cross member, as shown in Illustration 2.

21. Install plastic ratchet tie straps to the points indicated at B in Illustrations 1 and 2.

22. Do not over tighten the straps and remove all surplus lengths.

23. Remove the protective wing covers and close the hood.

24. Reconnect the battery, reinstall the battery cover and then close the luggage compartment.

25. Reset the clock.



Ignition Coil - Main

Ignition Coil - Auxiliary

Boot - Auxiliary Coil

Link Harness

Heat Shrink Sleeve

Bolt

Washer

Nut

Ratchet Strap

18.19.21

P AR T NUMBER

DAC 2692

DAC 2693

DAC 2713

DAC 2691

DAC 4197

JLM 9566

WC 106041J

C87371

ADU 9028

Twin coil modification

1

1

1

1

4

2

1

2

10 (max.)

LABOR TIME:

The following information is provided as an aid to the calculation of Workshop costs.

ALL O W ANCE

0.70 hrs.



Spark Plug “Blow-by Stain”/Corona

Stain – Spark Plug Function Not Affected – Replacement Unnecessary

MODEL 1988-94 MY Sedan Range DATE 02/01

XJS

18-55

Some vehicle may have spark plugs that have been affected by ‘Corona discharge’ that leads to Corona stain or what is often referred to as ‘Spark Plug Blow-by.’

BA CKGROUND INFORMA TION:

CAUSE OF CORONA DISCHARGE

While an engine is running, Corona discharge can sometimes be visible as a pale blue light around the high-tension secondary boot and the spark plug’s insulator surface. This discharge is due to ionization that occurs when gas molecules separate into free electrons and positively charged ions. If the air is highly ionized, the insulation ability is reduced and partial discharge occurs, resulting in the pale blue light.

Corona discharge occurs on rainy days or when the insulator surface is dirty. Due to ribbed corrugations at the top portion of the spark plug, corona is prevented from reaching the top of the spark plug which could cause the engine to misfire.

L OCA TION OF CORONA S T AIN

ILLUSTRATION 1

CAUSE OF CORONA STAIN

When Corona discharge has taken place, there can be a discoloration of the lower portion of the insulator surface (Illustration 1). This is what is known as ‘Corona stain’ and is orange/gray in color. Corona stain is caused by oil particles in the air that are attracted to the Corona discharge, charged and then adhere to the insulator surface.

A CTION:

The Corona stain has no effect on the function of the spark plug. The spark plug



Rough Idle/Drivability – Diagnosis to

Follow Prior To Replacing MAF

MODEL 1995-96 XJS (4.0L) Range DATE 02/01

18-56

Some 1995-96 MY XJS (4.0L) Range vehicles may experience concerns of poor idle quality, hesitation and other drivability concerns. The Mass Air Flow Sensor

(MAFS) is sometimes replaced in an attempt to repair this concern. However, the

MAFS have been tested and found to be fault free. As a result, this Technical

Bulletin has been issued to offer alternatives to replacing the MAFS.

GENERAL INFORMATION

The AJ16 engine has been tuned for maximum power with the best possible fuel consumption to meet the stringent emission regulations for the North American market. Due to individual driving patterns, along with the engine design characteristics, the occasional idle dip can occur. This is considered normal.

However, should a customer complain of poor idle quality (and in comparison to other vehicles seems to be worse) or any other drivability concerns, the following information should be followed rather than replacing the MAFS.

replaced due a known build issue by the supplier. This issue was limited to a specific build range of parts and was corrected on all components produced after that date range. Therefore, this is no longer an issue as a potential root cause.

A CTION:

In case of a customer complaint of poor idle quality on a 1995-96 MY XJS (4.0L)

Range vehicle, check the following alternatives to replacing the MAFS:

1.

Using the Portable Diagnostic Unit (PDU) or World Diagnostic System (WDS), check for relevant Diagnostic Trouble codes in the Engine Control Module

(ECM). If DTCs P0101, P0102 and P0103 are stored and diagnosis confirms a

2.

Identify and ensure that the correct fuel injectors are installed:

P rod.

S ervice Supplier

P ar t No.

P roduction S ervice

NA DBC 10423 White Green

R eference

D3156KA

R eference

D3156AA


3.

Check that the spark plugs are the correct type for the vehicle, are clean and have the correct gap set. (See table below for correct spark plug)

Description

Champion

P ar t Number

EBC 8143

Spark Plug Designation Gap Siz e

RC12 YCC

4.

Check the camshaft timing changes (refer to TSB 12-57).

.038" (0.96mm)

5.

Check that the EGR valve is operating correctly (refer to TSB 17-12).

are stored in the ECM memory.

Should any of the above not rectify any case of poor idle quality, the Mechanical

Fault Diagnosis information in section 3 of the AJ16 Service Manual should be followed. On JTIS, select 1995 XJ6/XJ12, under General Information, select 101-02

Diagnosis & Testing, section 3.2 Diagnostic Procedures.

For poor idle quality and other drivability concerns, using the PDU or WDS, check the long-term and short-term fuel trims. If any are found to be high, check for air

(vacuum) leaks and for the general fuel pressure being too high. The PDU or WDS can be used to re-set the ECM adaptions (refer to TSB 18-53) after rectification work has been carried out.

check that the throttle body and butterfly are clean from carbon deposits and that the engine breather modification has been carried out (refer to TSB 17-11).

If the problem persists, contact the Technical Hotline for further information with a list of any rectification work that has already taken place.


This Technical Bulletin is for information only.



MIL Illuminated – HO2S –

DTC 44 and/or 45 – Add Ground

Straps – Service Action S494

MODEL 1994-95 MY V12 XJS DATE 08/01

1994 MY XJ12

18-57

Service Action S494 applies to the following vehicles:

• 1994 to 1995 Model Year XJS V12 Vehicles

VIN Range: 188105-221234

• 1994 Model Year XJ12 Vehicles

VIN Range: 673590-708235

In addition, the following 1994 Model Year pre-production XJ12 vehicles should be modified: 671007, 671040, 671110, 671139, 671177, 671224, 672305 and 672308

(USA) and 671078 for Canada.

Some XJS 6.0L V12 and XJ12 series vehicles within the above VIN ranges may experience customer concerns of the ‘check engine’ malfunction indicator light illuminating with diagnostic trouble codes (DTCs) FF44 and/or FF45 stored. These

DTCs show an inconsistent reading from the Heated Oxygen Sensors (HO2S). The

HO2S are giving a faulty reading due to a slight degradation of the engine to body ground straps.

In order to prevent this issue occurring again, two supplementary ground straps need to be added to all vehicles within the above VIN range.

A CTION:

INS T ALLA TION OF AUXILIAR Y GROUND STRAPS ON XJS VEHICLES ONL Y

1.

Open luggage compartment.

2.

Open hood.

3.

Place fender protection covers over the front fenders.

4.

Disconnect vehicle battery.

available before disconnecting the battery.


PRO TECTIVE BOO T OF GROUND POIN T (SHO WN ON RHD VEHICLE)

ILLUSTRATION 1

5.

Working on right side of engine compartment, move aside innermost ground point protective rubber boot (Illustration 1).

6.

Remove ground point mounting nut.

7.

Move aside ground lead eyelets.

8.

Clean ground eyelets using emery cloth.

9.

Feed supplemental ground lead through ground point protective rubber boot.

10. Reinstall all three ground eyelets on ground stud.

11. Reinstall and tighten ground point mounting nut.

12. Reinstall ground point mounting protective rubber boot.

13. Route supplementary ground lead behind brake pipes and below plenum drain tube.

14. Remove the Torx mounting bolt from the existing ground lead on the rear of the right side intake manifold (Illustration 2).

T ORX BOL T FOR EXIS TING GROUND LEAD (SHO WN ON RHD VEHICLE)


ILLUSTRATION 2


15. Move aside the existing ground lead.

16. Clean the ground eyelet using emery cloth.

17. Replace the existing and new ground eyelets to rear of right side intake manifold.

18. Install and tighten the Torx mounting bolt.

19. Working on left side of the engine compartment, move aside the protective rubber boot of the innermost ground point (Illustration 3).

INNERMOS T GROUND (SHO WN ON RHD VEHICLE)

ILLUSTRATION 3

20. Remove the ground point mounting nut.

21. Move aside the ground lead eyelet.

22. Clean the ground eyelet using emery cloth.

23. Feed the supplemental ground lead through ground point protective rubber boot.

24. Install the existing and the supplemental ground eyelets to ground post.


26. Reinstall ground point mounting protective rubber boot.

27. Remove the Torx bolt from the rear of left side intake manifold (Illustration 4).

T ORX BOL T FOR EXIS TING GROUND LEAD (SHO WN ON RHD VEHICLE)


ILLUSTRATION 4


28. Position new ground eyelet on rear of left side intake manifold.

29. Reinstall and tighten Torx bolt on rear of left side intake manifold.

OUTERMOS T BULKHEAD GROUND (SHO WN ON RHD VEHICLE)

ILLUSTRATION 5

30. Remove outer most ground point protective rubber boot (Illustration 5).

31. Loosen and remove ground point mounting nut.

32. Move aside ground eyelet from ground point mounting post.

33. Clean ground eyelets using emery cloth.

34. Reinstall ground eyelet to ground point mounting post.


36. Reinstall ground point protective rubber boot.

37. Working inside luggage compartment, remove right side forward trim.

38. Remove mounting bolt securing the battery ground cable to the body

(Illustration 6).

BA TTER Y GROUND CABLE L OCA TED IN


ILLUSTRATION 6


39. Remove the battery ground cable.

40. Clean the battery ground lead eyelet and the body ground point using emery cloth.

41. Reinstall the battery ground cable to body.

42. Reinstall and tighten the battery ground cable to body mounting bolt.

43. Using electrical grease, cover the ground point and any exposed bodywork.

44. Loosen and remove the right side forward most ground point mounting bolt

(Illustration 7).

HARNESS GROUND POIN T IN TRUNK

ILLUSTRATION 7

45. Move aside the right side forward ground eyelets.

46. Clean the ground eyelets and the ground point using emery cloth.

47. Reinstall the ground eyelets on the body.

48. Reinstall and tighten the right side forward ground point mounting bolt.

49. Using electrical grease, cover the ground eyelet and any exposed bodywork.

50. Reinstall the right side forward luggage compartment trim.

51. Reconnect the vehicle battery.

52. Load the PDU at the base station with the latest disc.

53. Load datalogger V12 fuelling and check the HO2S reference voltage.

PDU is not available, use a DVOM to monitor the HO2S reference voltage, which should oscillate frequently.

54. Remove the fender protection covers.

55. Close the luggage compartment.

56. Close the hood.


INSTALLATION OF AUXILIARY GROUND STRAPS ON XJ 12 VEHICLES ONLY

1.

Open the luggage compartment.

2.

Open the hood.

3.

Place fender protection covers over the front fenders.

4.

Disconnect the vehicle battery.

disconnecting the battery.

CEN TER BULKHEAD GROUND POIN T (SHO WN ON RHD VEHICLE)

ILLUSTRATION 8

5.

Working in the engine compartment, loosen and remove the center bulkhead ground point mounting nut.

6.

Move aside the ground lead eyelets.

7.

Clean the ground eyelet using emery cloth.

8.

Reinstall all four ground eyelets to the ground post and the two supplementary ground leads.

9.

Reinstall and tighten the ground point mounting nut.


L OCA TION OF T ORX BOL AKE MANIFOLD (SHO WN ON RHD VEHICLE)

ILLUSTRATION 9

10. Loosen and remove the Torx bolt mounting from the rear of the right side intake manifold (Illustration 9).

11. Install one supplementary ground eyelet to the rear of right side intake manifold.

12. Install and tighten the Torx bolt mounting.

13. Loosen and remove the Torx bolt from the rear of the left side intake manifold

(Illustration 10).

L OCA TION OF T ORX BOL T ON LEFT IN AKE MANIFOLD (SHO WN ON RHD VEHICLE)

ILLUSTRATION 10

14. Install the second supplementary ground eyelet on the rear of the left side intake manifold.

15. Reinstall and tighten the Torx bolt to the rear of the left side intake manifold.

16. Working in the luggage compartment, remove spare wheel cover.


17. Loosen and remove the spare wheel mounting.

18. Remove the spare wheel from the vehicle.

19. Loosen and remove the wheel chock securing wing nuts.

20. Remove the wheel chocks from the mounting bracket.

21. Remove the lug wrench and the jack handle from the mounting bracket.

22. Remove the jack from the mounting bracket.

23. Remove the forward most trim from the luggage compartment.

24. Loosen and remove the right side rear lamp cover securing nuts.

25. Remove the right side rear lamp cover.

26. Remove the right side trim assembly from the luggage compartment.

27. Loosen and remove the battery ground lead securing bolt (Illustration 11).

BA TTER OCA TED IN TRUNK

ILLUSTRATION 11

28. Remove the battery ground lead from the vehicle.

29. Clean the battery ground lead eyelet and the body ground point using emery cloth.

30. Reinstall the battery ground cable to the body.

31. Reinstall and tighten the battery ground cable to body mounting bolt.

32. Using electrical grease, cover the ground point and exposed bodywork.


BA TTER OCA TED IN TRUNK

ILLUSTRATION 12

33. Loosen and remove the right side rearward most ground point-mounting bolt

(Illustration 12).

34. Move aside the right side rearward most ground eyelets.

35. Clean the ground eyelets and the ground point using emery cloth.

36. Reinstall the ground eyelets to the body.

37. Reinstall and tighten the right side ground point mounting bolt.

38. Using electrical grease, cover the ground eyelet and the exposed bodywork.

39. Reinstall all the luggage compartment trims.

40. Reinstall the right side rear lamp cover.

41. Reinstall and tighten the right side rear lamp cover securing nuts.

42. Reinstall the jack to mounting bracket.

43. Reinstall the lug wrench and jack handle to the mounting bracket.

44. Reinstall the wheel chocks to the mounting bracket.

45. Reinstall the wheel chock securing nuts.

46. Reinstall the spare wheel to vehicle.

47 Reinstall the spare wheel cover.


49. Reconnect vehicle battery.

50. Load the PDU at the base station with the latest disc.

51. Load datalogger V12 fuelling and check HO2S reference voltage.

PDU is not available, use a DVOM to monitor the HO2S reference voltage, which should oscillate frequently.

52. Remove the fender protection covers.

53. Close the luggage compartment.

54. Close the hood.



Ground strap

P AR T NUMBER

LJA 3744AC 2

WARRAN TY INFORMA TION:

Service Action S494

XJ12 1994 MY

VIN 671007, 671040,

671078, 671110,

671139, 671177,

671224, 672305,

672308

673590-708235

Model code 2111

SUMMAR Y R.O

NUMBER DESCRIPTION

86.92.84

Install auxiliary ground straps -

XJ12 models

XJS V12 models

ALL O W ANCE

0.60 hrs.

0.70 hrs.

XJS V12 1994-95 MY

VIN 188105-221234

Model codes 2100,

2130, 2140

Ground strap

P AR T NO

LJA 3744AC 2

XJ12 1994 MY

VIN 671007, 671040,

671078, 671110,

671139, 671177,

671224, 672305,

672308

673590-708235

Model code 2111

SUMMAR Y R.O

NUMBER DESCRIPTION

86.92.84

Install auxiliary ground straps -

XJ12 models

XJS V12 models

10.10.10

Drive in/drive out

ALL O W ANCE

0.60 hrs.

0.70 hrs.

0.15 hrs.

XJS V12 1994-95 MY

VIN 188105-221234

Model codes 2100,

2130, 2140

Ground strap

P AR

LJA 3744AC 2


NO TE: whether this service action has been performed on this vehicle.

The warranty selection under the vehicle inquiry will give a listing of all claims against the vehicle. If S494 appears in the fault code field, do not perform this service action.



DCS DEALERS


NON-DCS DEALERS

Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the

Repair Code column. Do not use the W-1 warranty claim form.


August 2001

Dear Jaguar Owner:

Re: Jaguar Service Action S494 – Oxygen Sensor Ground Strap

1994, 1995 Model Year Jaguar V12 6.0L Engine Vehicles

Jaguar and the U.S. Environmental Protection Agency have determined that your vehicle may be emitting pollutants in excess of the Federal emission standards or family particulate emission limits. These standards or family particulate emission limits, were established to protect the public health or welfare from the dangers of air pollution.

What is the problem?

The purpose of this letter is to inform you as an owner of a 1994, or 1995 model year Jaguar V12

6.0L vehicle that your vehicle may be fitted with an oxygen sensor that has an inconsistent ground condition in the sensor heater circuit. This condition does not affect drivability of your vehicle but it will cause illumination of the MIL (Check Engine Light), and can cause an increase in exhaust emissions. Failure to have this repair performed, over time, may lead to the degradation of your vehicle's catalytic converter.

What will Jaguar do?

To correct this concern Jaguar Cars, in agreement with the Environmental Protection Agency

(EPA), are initiating a Service Action campaign (S494) that will instruct authorized Jaguar dealers to fit two additional ground straps to all affected vehicles. You should be aware that due to scheduling, your dealer may require your car for one working morning or business day.

What should you do?

You are requested therefore to contact, at your earliest convenience, your nearest authorized

Jaguar dealer to arrange for this modification to be carried out on your vehicle. This work will be performed by the dealer free of charge and will increase your vehicle's emission system performance and enhance it's reliability. Such a non-conformity may cause your vehicle to fail an emission test when such tests are required under state or local law.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle.

Where is the closest Jaguar Dealer?

Should you have any questions regarding this Service Action or need assistance in locating your nearest authorized Jaguar dealer please contact the Jaguar Customer Relationship Center on 1-

800-4-JAGUAR.

Moved or no longer own a Jaguar?

Please fill out the enclosed card and return it to Jaguar by simply putting it in the mail.

Should you have the need to contact Jaguar by mail, please use the following address:

Jaguar Cars

ATTN: Customer Relationship Center

555 MacArthur Boulevard

Mahwah, NJ 07430-2327

If your dealer and the Jaguar Customer Relationship Center are unable to perform the repairs within a reasonable time, you may wish to contact the U.S. Environmental Protection Agency at the following address:

U.S. Environmental Protection Agency

National Vehicle and Fuel Emissions Laboratory

Certification And Compliance Division

2000 Traverwood

Ann Arbor, Michigan 48105

Yours sincerely

Gary Temple

Vice President – Customer Care


Fuel Pump Modules – XJR-S

– Install Modification Kit –


MODEL XJR-S DATE 10/94

From: VIN 187460

19-27

ISSUE:

The Fuel Pump Modules of XJR-S vehicles were changed in production at VIN 187460.

ACTION:

Upgrade XJR-S vehicles with the revised Fuel Pump Modules as necessary.

All XJR-S vehicles must be examined at the next service opportunity to determine if they are part of this action. If the vehicle’s VIN appears on the S385 SERVICE ACTION VIN LIST (page 4) check the underside of the hood panel for an S385 label.

If the vehicle is on the list and there is no S385 label under the hood, perform the following Service

Action

Procedure:

WARNING: LIQUID FUEL AND FUEL VAPOR WILL BE PRESENT DUR-

ING THE FOLLOWING OPERATIONS. BE SURE THAT THE WORK AREA

IS WELL VENTILATED. FOLLOW ALL SAFETY PRECAUTIONS DE-

TAILED IN THE

SERVICE MANUAL FUEL SYSTEM SECTION.

1.

Remove the in line fuel pump fuse (light blue, 15 amp), located at the right rear on the ECM bracket.

2.

Run the engine until it stalls. Crank the engine for several seconds to make sure the fuel system is completely depressurized.

CAUTION: DO NOT remove the fuel pump relay to depressurize the fuel system or DTC 22 will flag and be stored in the ECM. If this occurs call the Jaguar Technical Hotline for instructions.

3.

Record all preset radio stations (including X-mem). Disconnect and remove the battery from the vehicle.

4.

Remove the fuel tank following XJS Service Manual instructions in Service Manual section

19.55.01.


5.

Disconnect the evaporative loss flange hoses. Release the flange retaining ring using Jaguar special tool JD 174.

WARNING: OPERATIONS INSIDE THE FUEL TANK MUST ONLY BE

PERFORMED USING JAGUAR SPECIAL TOOL JD 175

6.

Label, and remove the fuel supply and return hoses from the fuel pump modules.

FUEL PUMP MODULES IN CUTAWAY FUEL TANK

EVAPORATIVE LOSS

FLANGE

LABEL

FUEL HOSES

SU

PP

L

Y

R

E

T

U

R

N

19-27.1

ILLUSTRATION 1

7.

Cut and remove the tie straps on the fuel pump module mounting rubbers.

8.

Separate the fuel pump modules from the mounting rubbers and remove both from the tank.

FUEL PUMP MODULES

CUT TIE STRAPS

Page 2 of 5 Bulletin Number 19-27

ILLUSTRATION 2

19-27.2

9.

Confirm that the bottom edge of the mounting rubbers is formed to clear the elongated fuel pickup filters of the new pump modules. If the mounting rubbers will not clear the new pump modules’ filters, install new mounting rubbers (P/N EBC 10124).

10. Place the mounting rubbers in the fuel tank.

11. Place the new pump modules in the fuel tank.

CAUTION: Do not bend or kink the module fuel pick-up filters.

12. Align the module and mounting rubber location lugs, seat the modules into the mounting rubbers and install new tie straps.

13.

Fit the module/mounting rubber assembly to the fuel tank base and reconnect the fuel feed and return hoses. Tighten the hose clamps with tool JD 175.

14.

Install the new evaporative loss flange and sealing ring.

15.

Remove the original fuel tank part number label and affix the modified fuel tank part number label in its place.

16.

Reinstall the fuel tank using the new fuel line and “O” rings for the new filler neck gaiter.

17.

Remove and discard the vent pipe from the old evaporative flange and replace the trunk floor grommet with the new blanking plug,

18.

Remove the fuel pump link harness from the chassis harness and replace with the new link harness.

FUEL TANK INSTALLED

FUEL PUMP

LINK HARNESS

19-27.3

ILLUSTRATION 3

19.

Install the new 25 amp fuel pump fuse and replace the existing fuse label with the new one.

20.

Reinstall the battery and trunk interior panels. Program the preset radio stations and reset the clock.

21.

Clean the left rear underside corner of the hood panel and affix the S385 label.


PARTS INFORMATION:

MODEL

Coupe

Convertible

DESCRIPTION

Modification Kit

Filler Neck “O” Ring

Filler Filler Hose

Modification Kit

Filler Neck “O” Ring

Fuel Filler Hose

PART NUMBER

SPM 6041

C 46157

C 43958

SPM 6042

CAC 7509

CBC 8703/3


Service Action S385

VEHICLE

XJR-S Convertible Model Code 2104

From VIN 187460

XJR-S Coupe Model Code 4060

From VIN 187460

SUMMARY

CODE

BU

DESCRIPTION

TIME

ALLOWANCE

Install modification kit S385 2.75 hrs.

BV Install modification kit S385 2.75 hrs.


Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the labor time allowance and parts as indicated.

DCS Dealers


Non-DCS Dealers

Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the Repair Code column. Do not use the

W-1 warranty claim form.


S385 SERVICE ACTION VIN LIST

186566

186596

186612

186624

186632

186654

186706

186710

186731

185339

185355

185527

185530

186491

186505

186535

186552

XJR-S COUPE

186735

196753

186765

186799

186820

186828

186850

186862

186870

186879

186902

187334

187412

XJR-S CONVERTIBLE

186713

186717

186746

186772

186796

186959

186981

187315

187459

185475

186589

186601

186619

186629

186637

186667

186679



Fuel Pressure Regulator – Hard Starting/

Long Cranking Time, Hot/Warm Engine –

Repair Procedure

MODEL XJ12, XJS Range (V12) DATE 11/94

Remove and destroy Bulletin 19-28, Date 11/94. Replace with this Bulletin.


19-28

AMENDED

2/95

ISSUE:

Symptoms of hard starting while hot or warm, with cranking times in excess of 5 seconds, on 1994

MY XJ12 Sedans and 1994 MY XJS Range V12 vehicles within the following VIN ranges.

XJ12

XJS Range (V12)

VIN 687219 – 707625

VIN 190528 – 195120

Damage to the “O” ring that seals the fuel pressure regulator to the fuel pressure regulator housing can cause low fuel pressure during cranking, resulting in this hard starting condition.

ACTION:

If customers with vehicles within the VIN range complain of hard starting hot or warm, with prolonged cranking time, perform the following diagnostic operation.

1.

Depressurize the fuel system following the instructions in Service Manual Section 12, operation 19.50.02.

2.

Fit a fuel pressure gauge to the fuel rail.

3.

Run, then stop the engine while watching the fuel gauge.

4.

If the fuel pressure drops LESS than 10 psi one minute after the engine is stopped, the cause of the hard starting is not with the pressure regulator “O” ring

5.

If the fuel pressure drops MORE than 10 psi one minute after the engine is stopped, perform the following repair procedure.

REPAIR PROCEDURE

1.

Ensure that the radio code is available. Record all preset radio stations (including X-mem) and disconnect the negative cable of the battery.

2.

Remove the fuel pressure regulator following the instructions in Service Manual Section 18, operation 19.45.11. Remove the fuel pressure regulator housing (Illustration 1).

FUEL PRESSURE REGULATOR HOUSING

FUEL PRESSURE

REGULATOR

HOUSING

19-28

ILLUSTRATION 1

Bulletin Number 19-28 Amended Page 1 of 2

3.

Examine the fuel pressure regulator “O” ring for damage (Illustration 2).

4.

Examine the ”O” ring seal bore in the fuel pressure regulator housing for sharp edges or burrs (Illustration 2).

5.

If sharp edges or burrs are evident, carefully remove them with a hand tool such as a countersink.

6.

Thoroughly clean the fuel pressure regulator housing.

7.

Lubricate a new pressure regulator housing to fuel rail “O” ring with petroleum jelly. Fit the

“O” ring to the fuel rail and install the fuel pressure regulator housing.

FUEL PRESSURE REGULATOR/HOUSING ASSEMBLY

FUEL PRESSURE REGULA-

TOR “O” RING

HOUSING/FUEL

RAIL “O” RING

WARRANTY INFORMATION:

HOUSING

SEAL BORE

19-28

ILLUSTRATION 2

8.

Install a NEW fuel pressure regulator

9.

Connect the negative cable of the battery.

10.

Run the engine and check for fuel leaks. Stop the engine.

11.

Observe the fuel pressure gauge for one minute. The fuel pressure should drop no more than

10 psi after the engine has been stopped for one minute.

12.

Remove the fuel pressure gauge and check the fuel system for leaks.

13.

Recode the radio and reset all radio stations and the clock.

PARTS INFORMATION:

DESCRIPTION

Fuel pressure regulator

“O” ring seal - housing to fuel rail

FAULT

CODE

R.O. NUMBER

CL KB BL 19.91.39

DESCRIPTION

XJ12

XJS (V12)

PART NUMBER

EBC 10768

EBC 2207

QTY

1

1

TIME

ALLOWANCE

0.40 hrs.

0.60 hrs.

Page 2 of 2 Bulletin Number 19-28 Amended


Fuel Tank – Replacement Procedure

MODEL Sedan Range 1991-1994 MY DATE 12/94

19-29

ISSUE:

The replacement fuel tank for 1991 - 1994 MY Sedan Range vehicles is available only as an assembly (part number NMB 5908DG/1) complete with the fuel pump module and a two-port evaporative flange.

ACTION:

Follow the appropriate procedure when replacing the fuel tank of 1991-1994 MY Sedan Range vehicles.

SEDAN RANGE 1991-1993 MY – VIN 629286 - 667828

The original fuel tank has a three-port evaporative flange.

• One vapor line to the canister

• One breather line to the fuel filler neck

• One fuel tank pressure relief vent line through the trunk floor.

A black 2-way Econoseal III HE electrical connector was used for the fuel pump (Illustration 1)

Fuel Tank Replacement Procedure:

Replace the fuel tank following the instructions in the appropriate Service Manual. In addition, perform the following modifications.

1.

Remove and discard the existing fuel tank pressure relief vent line and grommet from the trunk floor.

2.

Install a new floor grommet (part number BEC 23778) in the trunk floor. Reroute the fuel filler neck breather line through the new grommet.

3.

Replace the existing fuel filler cap with a new cap (part number NMB 5942AB).

4.

Connect the vehicle side harness fuel pump Econoseal III HC connector to the Sumitomo connector (Illustration 1) on the evaporative flange with a new R. F. I. protection lead (part number DBC 12115).

FUEL PUMP CONNECTORS

ECONOSEAL III HC

ILLUSTRATION 1

SUMITOMO

9/1.31


SEDAN RANGE 1993 MY - FROM VIN 667829

The original fuel tank has a two-port evaporative loss flange

• One vapor line to the canister

• The second port is sealed with an internal membrane or a blanking cap and clamp.

Fuel Tank Replacement Procedure:

Replace the fuel tank following the instructions in the appropriate Service Manual.

1.

If the original fuel tank had Econoseal III HC fuel pump connectors, connect the existing vehicle side harness fuel pump Econoseal III HC connector to the new Sumitomo fuel pump connector (Illustration 1) with a new R. F. I. protection lead (part number DBC 12115).

NOTE: The Sumitomo fuel pump connector was introduced as a running change during the 1993 MY.


DESCRIPTION

Fuel tank assembly

Floor grommet

Fuel filler cap

R. F. I. protection lead

PART NUMBER

NMB 5908DG/1

BEC 23778

NMB 5942AB

DBC 12115


Refer to the Warranty Codes and Repair Operation Times manual, Sedan Range: through 1994

Model Year, Section CJ for the appropriate information.



Poor Running in Wet or Hot Weather

Conditions – Replace Air Cleaner Housing

MODEL Sedan (3.6/4.0L) Range through 94 MYDATE 2/95

Up to VIN 708757

19-31

This Bulletin supersedes Technical Bulletin 19-24 Poor Running in Wet Conditions

– Water in Air Cleaner Housing – Add Drain Holes, date of issue, 3/94.

ISSUE:

Engine hesitation, misfire or stalling during wet driving conditions or hot weather on all 3.6L and

4.0L Sedan Range vehicles up to VIN 708757 (end of the 1994 MY).

These symptoms can be the result of conditions outlined in Technical Bulletin 18-38 Momentary

Engine Power Loss or Stalling – Diagnosis and Repair, date of issue 4/94.

The symptoms may also be caused by water entering the air cleaner housing through the air intake duct under the left front wheel arch during wet weather driving. Also, during low speed operation in very hot weather, fuel vapors may vent from the evaporative emission canister and be drawn into the engine air intake. The excess fuel vapor will cause poor idling or stalling at low vehicle speeds.

ACTION:

If customers experience symptoms of hesitation, misfire or stalling on 3.6L or 4.0L Sedan Range vehicles up to VIN 708757, perform the following procedures.

1.

Confirm that all applicable procedures outlined in Technical Bulletin 18-38 Momentary

Engine Power Loss or Stalling – Diagnosis and Repair, date of issue 4/94, have been performed.

2.

Diagnose the EMS with PDU or JDS. Repair any faults found.

3.

Ensure that the engine set up is within specification.

4.

Check the condition of the primary and secondary ignition electrical systems.

5.

If the poor running condition persists, replace the existing air cleaner assembly with a new air cleaner assembly (part number NBB 3500EA)

AIR CLEANER ASSEMBLY REPLACEMENT PROCEDURE

1.

Remove the existing air cleaner assembly

2.

Install 2 mounting grommets (part number NBC 3530AA) in the holes in the left side crush tube. The grommets will support the new air cleaner assembly.

NOTE: The air cleaner mounting pegs must be lubricated with soap in order to fit into the new grommets.


3.

In the left side valance panel, cut and remove the existing grommet for the air intake duct.

4.

Install a new grommet (part number DBC 11336). Carefully cut the new grommet to allow it to pass over the harness. Trim the grommet wall to conform to the harness.

NOTE: The grommet should provide an effective seal against water and fuel vapor between the wheel arch and the engine compartment.

5.

Route the wiring harness behind the left headlight to ensure clearance for the new air intake duct.

6.

Trim the flared end of the air intake duct with a round file to provide clearance for the left headlight assembly as shown in Illustration 1.

AIR CLEANER ASSEMBLY

LEFT SIDE HEADLIGHT

TRIM O.20 IN (5MM)

FROM END -

MAXIMUM

INTAKE AIR DUCT

1/12.1

ILLUSTRATION 1

IMPORTANT: Do not trim more than 0.20 in (5mm) from the end of the air intake tube.

Profile the trimmed area to provide clearance for the headlight connector assembly.

Radius all sharp edges of the trimmed area to avoid intake air “whistles” or noise.

NOTE: Headlight adjustment or bulb replacement will require removal of the air cleaner cover.


PARTS INFORMATION:

DESCRIPTION

Air cleaner assy.

Mounting grommet

Grommet

PART NUMBER

NBB 3500EA

NBC 3530AA

DBC 11336

QTY

1

2

1


FAULT

CODE

R.O. NUMBER

CB DB PS 19.10.05

DESCRIPTION

Air cleaner assy. - Renew

MODEL

Sedan (3.6L) Range

1988 & 1989 MY

Sedan (4.0L) Range

1990 - 1992 MY

Sedan (4.0L) Range

1993 - 1994 MY

TIME

ALLOWANCE

0.25 hrs.

0.20 hrs.

0.20 hrs.



Intermittent High Idle – Replace Throttle

Return Springs

MODEL XJ12 (6.0L) 1994 MY

VIN 673299-708757

DATE 7/95

19-33

ISSUE:

Some 1994 MY XJ12 Sedan Range vehicles may experience an intermittent high idle speed of approximately 900 rpm (normal idle speed, 750 rpm in neutral). This condition occurs when slowly returning the throttle to the idle position.

Revised throttle springs with increased preload were installed on all 6.0L engines beginning with

1995 MY production.

ACTION:

If customers of 1994 MY XJ12 vehicles complain of intermittent high idle speed, replace the existing throttle return springs with two revised springs (part number NAC 3030AB) as follows:

1.

Remove throttle return spring from the throttle body, Illustration 1.

2.

Install the new spring first to the bracket, then to the throttle lever.

3.

Repeat the procedure on the throttle body on the opposite bank.

4.

Check for correct throttle return operation.

THROTTLE RETURN SPRING

THROTTLE RETURN SPRING

(B BANK)


ILLUSTRATION 1


PARTS INFORMATION:

DESCRIPTION

Throttle return spring

PART NUMBER

NAC 3030AB

QTY

2


MODEL

Sedan (6.0L) Range

FAULT CODE

CD KF NS

R.O. NUMBER

10.10.99

DESCRIPTION

TIME

ALLOWANCE

Replace throttle return springs 0.10 hrs.



Fuel Tank Pipe Seals –

Replacement Procedure

MODEL All 1995 MY DATE 8/95

19-34

ISSUE:

Replacement seals for the fuel supply or return pipe connections at the fuel tank are supplied as a kit. The seal kit (part number EBC 9606) includes the required seals and spacers mounted on a disposable “stuffer pin.” The “stuffer pin” is used to insert the seals into the fuel pipe connector bore.

FUEL PIPE SEAL KIT

SEAL

(YELLOW)

SPACER RETAINER

PROTECTOR

SEAL

(BROWN)

SPACER “STUFFER PIN”

3/14.1.1

ILLUSTRATION 1

ACTION:

To replace the seals for the fuel supply or return pipe connections at the fuel tank, follow the procedure described below.

NOTE: It is not required to replace the seals each time the a fuel pipe is disconnected. Change the fuel tank supply or return pipe connection seals in the event of fuel leaks only.

FUEL TANK PIPE SEAL REPLACEMENT PROCEDURE

1.

Depressurize and drain the fuel tank following the instructions in the applicable service manual.

2.

Thoroughly clean the fuel tank pipe, tank connector and the surrounding area.


3.

Place tool JD 203 around the fuel pipe as shown in Illustration 2. With a twisting motion, slide the tool upward along the pipe and into the connector. The tool will release retainer legs from the fuel pipe.

FUEL PIPE AND CONNECTOR BORE

RETAINER LEGS

CONNECTOR LIP

PIPE COLLAR

JD 203

FUEL PIPE

3/14.1.2

ILLUSTRATION 2

4.

Pull the fuel pipe and the tool, together, out of the tank connector.

5.

With needle nose pliers, bend the retainer legs of the tank connector inward to release the retainer from the tank connector bore. Pull the retainer out of the tank.

6.

With a plastic or soft metal hook, pull the two spacers and seals out of the connector bore.

NOTE: Sharp tools may damage the bore and cause leaks.

7.

Clean and inspect the tank connector bore.

8.

Remove the seal kit assembly protector, check the position of the seals and spacers and lubricate them liberally with clean engine oil (Illustration 3).

FUEL PIPE SEAL KIT SEAL

(YELLOW)

SPACER RETAINER

PROTECTOR


SEAL

(BROWN)

ILLUSTRATION 3

SPACER “STUFFER PIN”

3/14.1.1


9.

Insert the assembly fully into the tank connector bore. Check that the retainer legs are seated behind the connector lip. Slide the “stuffer pin” out of the assembly and check the position of the seals and spacers in the bore.

NOTE: The “stuffer pin” should slide out easily; if not, the retainer legs are not seated, or the assembly or connector bore is damaged.

10. Clean the fuel pipe end and lubricate it with clean engine oil.

11.

Push the pipe into the connector until its collar seats behind the retainer legs.

NOTE: If the pipe does not slide in easily, check the seal assembly or bore for damage.

12.

Refill the tank, pressurize the system and check for fuel leaks.

PARTS INFORMATION:

DESCRIPTION

Stuffer pin

PART NO.

EBC 9606

QTY

1

WARRANTY INFORMATION

Use warranty code applicable to fault. Refer to Warranty Codes & Repair Operation Times Manual.


TECHNIC AL BULLETIN

Chec k

P oor Dri vv

T hr ottle Sync hr onization

MODEL XJ12 Sedan 1994 MY

This Bulletin applies to the following vehicles:

All 1994 MY XJ12 Sedan (VIN 673299-708757)

All Series III XJ12 Sedan (up to VIN 487641, 1979-92 MY Canada,

1979 MY USA)

All Jaguar XJS V12

Poor throttle valve synchronization may cause customer complaints of poor drivability and idle quality.

An improved factory procedure for setting the throttle stop screws, using an air flow measuring gauge, was introduced during the 1994 MY production of V12 engines.

An additional revision was made to the method for setting the throttle linkage to improve synchronized opening of both throttle valves starting with:

ENGINE NO.

8D12554

VIN

222252

When diagnosing drivability or idle complaints, check the throttle valve and linkage settings as described in the following procedure before any further diagnosis or repair.

Perform a road test after adjusting the throttle valves and linkage. If the complaint still exists, refer to the diagnostic procedures in the Vehicle Service Manual.


THRO TTLE V AL VES unless a noticeable fault is present.

1.

Check that both throttle valves are centered horizontally and vertically in the throttle bodies.

2.

With the throttle valve closed, use a feeler gauge to check the clearance between the throttle valve and the throttle body (Illustration 1).

Throttle valve checking clearance: 0.001 - 0.003 inch (0.025 - 0.076 mm)

Check the clearance at the bottom as well as at the top of the throttle valve. If a significant difference is found between the top and bottom measurements, the throttle valve may be offset on its shaft. If both measurements are within the above range, do NOT adjust the throttle stop screw (Illustration 1).

3.

If adjustment is necessary, set the throttle stop screw to achieve the following throttle valve clearance range:

Throttle valve setting clearance: 0.001 - 0.0015 inch (0.025 - 0.040 mm).

After completing throttle valve adjustment, seal the locknuts with a dab of paint.

4.

Repeat the checking procedure on the opposite throttle valve.

THRO TTLE V AL VE CLEARANCE


V A L V E

ILLUSTRATION 1

J19-358


been set at the factory using special equipment to obtain simultaneous opening of both throttle valves. Do not change these settings unnecessarily.

Use the following procedure to obtain the required backlash in the throttle linkage to ensure correct synchronization of throttle opening.

1.

Loosen both locknuts on the two linkage rods between the center throttle turntable and the throttle levers.

2.

Disconnect one linkage rod from its ball pin on the linkage rod bracket.

3.

Position a 0.079 inch (2.00 mm) spacer between the linkage rod bracket and its stop (Illustration 2).

L OCA

S P A C E R

JSI-2620

ILLUSTRATION 2

4.

Turn the linkage rod that is still connected to increase its length until the throttle lever clears its stop screw.

5.

Shorten the linkage rod until the throttle lever just touches its stop screw.

Tighten both lock nuts on the linkage rod.

6.

Connect the second linkage rod and repeat steps 4 and 5 to adjust its length.

7.

Remove the spacer inserted between the linkage rod bracket and its stop.

8.

Check the backlash by turning the linkage rod bracket of the throttle turntable slightly clockwise. A gap should appear between the bracket and its stop before either throttle lever leaves its stop screw.

Gap dimension: 0.062 - 0.094 inch (1.57 - 2.39 mm)

9.

Both throttle levers should leave their stops at the same time. Satisfactory synchronization is possible if the second throttle lever moves from its stop after the first throttle lever within a maximum additional increase of 0.030

inch (0.76 mm) in the gap.


10. Release the linkage rod bracket to allow the turntable to return to the closed throttle position. Check that the linkage rod bracket is now in contact with its stop. If any gap is present, repeat steps 1 through 10.

Perform a road test after adjusting the throttle valves and linkage. If the complaint still exists, refer to the diagnostic procedures in the Vehicle Service Manual.


F A U L T

1994 MY XJ12 CD GB GG 19.20.05

XJ12 Series III

XJS (5.3L

& 6.0L)

CD GB GG 19.20.05

XJR-S CD GB GG 19.20.05

1994 MY XJ12 CD KF GG 19.20.11

XJ12 Series III CD KF GG 19.20.11

XJS (6.0L only) CD KF GG 19.20.11

XJR-S

XJS (5.3L)

CD KF GG 19.20.11

1994 MY XJ12 CD GB GG 19.20.40

CD KF GG

XJS (6.0L only) CD GB GG 19.20.40

CD KF GG

Throttle linkage rods check and adjust



A L L O W A N C E

0.25 hrs.

0.25 hrs.

0.25 hrs.

Throttle valves - engine set - 0.40 hrs.

check and adjust


check and adjust


check and adjust

Throttle valves - engine set - 0.95 hrs check and adjust

Throttle valves and linkage 0.60 hrs.

rods - engine set check and adjust

Throttle valves and linkage 0.90 hrs.

rods - engine set check and adjust



Intermittent High Idle – Replace

Return Spring

T hr ottle

MODEL XJS (4.0L) 1995-96 MY

Some 1995-96 MY 4.0L XJS vehicles may occasionally exhibit a higher than target idle speed under certain driving conditions.

This condition may occur under city driving conditions when there is no pressure on the accelerator pedal.

In case of a customer complaint of intermittent high idle on 1995-96 MY 4.0L XJS vehicles within the above VIN range, verify the complaint by checking whether the engine returns to the target idle speed when the throttle is released:

700 rpm* in Park/Neutral; 580 rpm* in Drive or Reverse ranges.

* At coolant temperatures less than 86°F (30°C) idle speed ± 30 rpm; at coolant temperatures greater than 86°F (30°C) idle speed ± 20 rpm.

If a condition of high idle speed is confirmed, check the throttle pedal for obstructions, check that the throttle cable moves freely, and check the throttle cable adjustment. If the condition is still present, replace the throttle spring with a stronger spring as described in the following procedure.

REPLACING THROTTLE SPRING

1.

Disconnect the inner accelerator cable from the throttle body.

2.

Remove the cruise control linkage pin and circlip.

3.

After removing the three torx screws, carefully remove the throttle assembly cap from the pedestal.

throttle return spring is against the post next to the idle speed control valve. The straight extension of the spring must rest against this post only.


IDLE SPEED CON TROL V A L V E

THRO TTLE A SSEMBL

J18-232

ILLUSTRATION 1

4.

Unhook the throttle return spring (Illustration 1), from the throttle shaft actuator and then remove the spring and sleeve from the shaft.

5.

Remove the sleeve from the spring and discard the spring.

6.

Insert the sleeve into the replacement spring, install the sleeve and the spring on the throttle shaft and hook the spring on the actuator.

rotating the straight extension one full turn counterclockwise until it can be installed in the same position against the post next to the idle speed control valve, as the original spring.

6.

Carefully install the cap on the throttle assembly noting the lever location.

7.

Reconnect the cruise control linkage.

8.

Reconnect the accelerator cable to the throttle body assembly.

9.

Check the operation of the throttle body.


Throttle Return Spring

P AR

NBB 3131AA


F A U L T

CD GC GC 19.91.46


Remove and install throttle return spring 4.0L

A L L O W A N C E

0.15 hrs.

1



Special

T

T ool JD 208 – Fuel Pr essur esting – Method of Use ee

MODEL All with AJ6 & AJ16 engines

Special Tool JD 208 (Illustration 1) has been introduced to permit the connection of a fuel pressure gauge on AJ6 and AJ16 engines for diagnostic purposes. The tool is a threaded “T” adaptor with a Schrader valve for connecting a suitable gauge set.

When used with a compatible gauge set (such as Snap-on Tools Part No. MT

337A), JD 208 provides a means to check fuel rail pressure on a running engine under workshop conditions. It is not suitable for use on V12 engines.

W ARNING: in the Vehicle Service Manual, Section 5.1 for 1995 MY-ON Sedan

Range or Section 19.1 for 1988-94 Sedan Range and XJS, while working on the fuel system.

CHECKING FUEL PRESSURE

1.

Remove the oxygen sensor heater relay and run the engine at idle to depressurize the fuel system (19.50.02).

2.

Have absorbent shop towels ready to soak up fuel spillage in the following steps.

3.

Remove the cover over the fuel injectors.

4.

Disconnect the union between the fuel supply pipe and the fuel rail. Wipe up any fuel spillage.

V A L V E


ILLUSTRATION 1

Date of issue 4/96

JSI-2673

Page 1 of 4

5.

Align special tool JD 208 with the fuel rail with the Schrader valve positioned upright. Start and fully tighten the union nut. (Illustration 2).

fuel supply line and the throttle cable and mechanism.

6.

Align the fuel supply line with the special tool, then start and fully tighten the union nut. Ensure that the fuel supply line is positioned so that it has the maximum possible clearance from the throttle quadrant, as indicated in

Illustration 2.

V A L VE IN

U A TE

JSI-2671

ILLUSTRATION 2

7.

Dispose of any shop towels soaked with fuel in a safe manner.

8.

Check that the throttle quadrant can move fully and freely before starting the engine.

9.

Connect a suitable gauge set to the Schrader valve of JD 208. Follow the instructions supplied with the gauge.


10. Place any drain tube into a container approved for the storage of fuel

W ARNING: FIRE HAZARD properly connected to the vehicle and that all connections are tight, before attempting to start the engine.

Should it be necessary to disconnect the gauge set from the

••••• Switch off the engine.

••••• Disconnect strictly in the order given in steps 15-20 to first depressurize the fuel system and gauge set.

while the engine is running. Although the special tool is equipped with a Schrader valve, fuel at high pressure could escape if the valve failed to seat properly.

the installed special tool JD-208. In this condition, fuel at high pressure could escape if the Schrader valve in the special tool failed to seat, or if the plunger of the Schrader valve were inadvertently depressed.

C O N T


ILLUSTRATION 3

Date of issue 4/96

JSI-2672

Page 3 of 4

11. Check that the parking brake is fully applied and that the Neutral or Park position is selected.

13. Carefully open the drain valve adjacent to the gauge head, until fuel free of bubbles is flowing into the storage container. Close the drain valve.

14. The gauge will now register fuel pressure.

W ARNING: under workshop conditions only.

No attempt must be made to drive the vehicle with this equipment connected.

DISCONNECTING SPECIAL TOOL JD 208

15. Switch off engine after completing pressure tests.

16. Have shop towels available to soak up any fuel spilled when disconnecting the tool and gauge set.

17. Open the drain valve to drain fuel into the storage container and depressurize the fuel system.

18. Leave the drain valve open while disconnecting the gauge set from the

Schrader valve. Raise the connector immediately, moving it away from the engine compartment, to assist in draining off all residual fuel from the gauge set and pipes.

19. Clean up any spilled fuel. Seal the container into which the fuel was drained and suitably store or dispose of it, observing the appropriate safety precautions.

20. Disconnect tool JD 208 from the fuel supply line and reconnect the supply line to the fuel rail.

21. Safely dispose of any shop towels that may have become soaked with fuel.

22. Install the cover on the fuel injectors.

23. Check that no spilled fuel remains near the engine.

24. Start the engine and check that no fuel is leaking from any of the connections that were opened when the tool was installed.

25. Stop the engine.

26. Ensure that all residual fuel has drained from the gauge set and adaptors before storing them.



Throttle Deposits/Sticking Closed

AJ16 Engines - Revised Idle Speed

Adjustment Procedure

MODEL 1995-96 MY XJS (4.0L) Range

VIN 194775-226645

DATE 6/97

Remove and destroy Bulletin 19-40, amended 8/97.


This bulletin is superseded by Bulletin 17-11, dated

12/98.

19-40

Amended

2/99

This bulletin is superseded by Bulletin 17-11, dated 12/98.

A CTION:

Insert this sheet to maintain the continuity of the bulletin binder numbering system.


Sedan Range

DATE

9/95 04.1-01

SER VICE TECHNIC AL BULLETIN

Radiator Drain Plug –

Specification Change – Replace –

Service Action S652

MODEL

1995 MY

Sedan (4.0L) Range

VIN

Refer to VIN list

Some 1995 MY Sedan Range vehicles specified on the attached VIN list may have radiators assembled with drain plugs manufactured from a material which does not meet current specifications.

Refer to the attached VIN list to determine which vehicles need to be checked.

Under high ambient temperature conditions, the drain plugs may distort, leading to a loss of coolant.

The affected drain plugs must be replaced by those manufactured from the correct material. When possible, the drains plugs should be replaced during PDI.

New vehicles that have a white label with a green letter ‘C’ on the windshield have had the drain plugs replaced at the factory. DO NOT change the radiator drain plug on these vehicles.

On vehicles already in service, the drain plug must be changed at the first service opportunity.

REPAIR PROCEDURE

1.

With the engine cold, slowly open the radiator cap to depressurize the cooling system, then close the cap.

2.

Raise the vehicle on a lift and place a container under the radiator to catch the coolant. The amount of coolant released should not exceed 0.5 qt (0.5 l).

3.

Install a new O-ring, part no. JLM1499 on a new drain plug of the correct specification (part no. JLM 1340).

4.

Remove the existing drain plug (Illustration 1) and immediately install the new

RADIA T OR DRAIN PLUG L OCA TION


ILLUSTRATION 1

J26-174

Bulletin Number 04.1-01 Page 1 of 5

drain plug. Torque the drain plug to 16 - 20 lb ins (1.8 - 2.2 Nm).

5.

Discard the small quantity of coolant that was released while replacing the drain plug. Top up the cooling system using a 50:50 mixture of Jaguar Antifreeze, coolant, and corrosion inhibitor with plain clear water. Do not overfill.

6.

Thoroughly clean up any spills to avoid causing any needless customer concerns of radiator, cap, or expansion tank leakage.


Radiator drain plug

O-ring


Service Action S652

Sedan Range1995 MY

Refer to VIN list


2313, 2314

Sedan Range 1996 MY

Refer to VIN list


2314, 2353

AA

Sedan Range1995 MY

Refer to VIN list


2313, 2314

Sedan Range 1996 MY

Refer to VIN list


2314, 2353

AB

P AR T NUMBER

JLM 1340

JLM 1499

1

1

Replace radiator drain plug

- without drive in/out time

A L L O W A N C E

0.10 hrs.

Replace radiator drain plug


0.25 hrs.

Page 2 of 5 Bulletin Number 04.1-01 Date of issue 9/95


XJ6

MODEL CODE 2311

751763, 751766, 751771, 751775, 751779,

751783, 751791, 751794, 751796, 751805,

751806, 751813, 751821, 751825, 751833,

751836, 751840, 751847, 751850, 751855,

751863, 751867, 751876, 751882, 751889,

751892, 751897, 751905, 751909, 751920,

751924, 751931, 751934, 751939, 751942,

751950, 751954, 751965, 751969, 751976,

751979, 751984, 751992, 751996, 752011,

752018, 752021, 752026, 752034, 752038,

752049, 752053, 752060, 752063, 752068,

752076, 752080, 752091, 752095, 752102,

752105, 752110, 752118, 752121, 752132,

752136, 752140, 752143, 752146, 752151,

752159, 752163, 752174, 752178, 752185,

752188, 752193, 752201, 752205, 752216,

752220, 752227, 752230, 752235, 752243,

752247, 752257, 752261, 752268, 752271,

752276, 752284, 752288, 752298, 752302,

752309, 752312, 752317, 752401, 752413,

752451, 752843, 753170, 753206, 753818,

753854

Bulletin Number 04.1-01 Page 3 of 5

VANDEN PLAS

MODEL CODE 2313

751760, 751802, 751817, 751844, 751859,

751875, 751886, 751901, 751917, 751928,

751946, 751962, 751973, 751988, 752004,

752015, 752030, 752046, 752057, 752072,

752088, 752114, 752129, 752155, 752171,

752182, 752197, 752213, 752224, 752239,

752254, 752260, 752295, 752306, 752321,

752337, 752344, 752348, 752359, 752363,

752367, 752371, 752379, 752386, 752390,

752405, 752421, 752432, 752654

VANDEN PLAS EXTENDED WHEELBASE

MODEL CODE 2353

753285, 753295, 753305, 753312, 754311,

754315, 754319, 754323, 754339, 754347,

754351, 754355, 754359, 754363, 754375,

754382, 754387, 754391, 754455, 754494,

754537, 754682, 754689, 754693, 754697,

754701, 754709, 754717, 754725, 754729,

754737, 754745, 754765, 754773, 754804,

754844, 754860, 754908, 754912, 754916,

754920, 754976, 754980, 755040, 755044,

Page 4 of 5 Bulletin Number 04.1-01 Date of issue 9/95

XJ12

MODEL CODE 2512

753178

XJ12 EXTENDED WHEELBASE

MODEL CODE 2552

754343, 754379, 754415

XJR

MODEL CODE 2314

751788, 751830, 751872, 751914, 751959,

752001, 752043, 752085, 752126, 752168,

752210, 752334, 752576, 752827

Date of issue 9/95 Bulletin Number 04.1-01 Page 5 of 5


Cooling System – “Bow Spring” Hose

Clamps Introduced

MODEL All 1994 MY On DATE 11/94

26-14

ISSUE:

An improved design radiator hose clamp has been introduced in production from the VINs listed below.

Sedan Range

XJS Range

VIN 706502

VIN 195137

This “bow spring” hose clamp requires special installation and must be tightened to a specified torque.

ACTION:

When fitting “bow spring” hose clamps, the center of the “bow spring” must be at a 5 o’clock (150

° angle) position relative to the center of the screw housing as shown in Illustration 1.

• “Bow spring” hose clamps compensate for the loss of tightening force as the hose ages.

• Routine retightening of the hose clamp is not required.

• Hose clamps of this design must be tightened to a torque of 1.9 - 2.6 lb. ft. (2.5 - 3.5 Nm).

“BOW SPRING” HOSE CLAMP

12 O’CLOCK

150°

5 O’CLOCK

ILLUSTRATION 1

26-14

NOTE: “Bow Spring” hose clamps are not used on the radiator side of Sedan

Range lower hoses.


HOSE CLAMP APPLICATION

Sedan Range - AJ6 and AJ16

LOCATION

Top hose - Radiator side

Top hose - Engine side

Bottom hose - Radiator side

Bottom hose - Engine side

PART NUMBER

JHC 400901

JHC 401001

JHC 201001 (Standard hose clamp)

JHC 401001

XJ12

LOCATION

Right side top hose - Radiator side

Right side top hose - Engine side

Left side top hose - Radiator side

Left side top hose - Engine side



PART NUMBER

JHC 400801

JHC 400801

JHC 400901

JHC 408001

JHC 201101 (Standard hose clamp)

JHC 401101

XJS - AJ6 and AJ16

LOCATION

Top hose - Radiator side

Top hose - Engine side



PART NUMBER

JHC 400901

JHC 401001

JHC 401001

JHC 401001

XJS - V12

LOCATION

Right side top hose - Radiator side

Right side top hose - Engine side

Left side top hose - Radiator side

Left side top hose - Engine side



PART NUMBER

JHC 400701

JHC 400701

JHC 400701

JHC 400701

JHC 401001

JHC 401101



Coolant Expansion Tank – Seam Weld Leaks


MODEL XJ12 Sedan 1994 MY

VIN 673299-708757

DATE 2/95

26-15

ISSUE:

The coolant expansion tanks of some 1994 MY XJ12 Sedans from VIN 673299 - 708757 have developed leaks in the seam weld area. Coolant expansion tanks with improved seam welding were installed in production from VIN 708758.

ACTION:

Replace the coolant expansion tanks of all 1994 MY XJ12 Sedans (VIN 673299 - 708757) with the improved coolant tank at the next service opportunity.

NOTE: Coolant expansion tanks with improved seam welding are fitted with a 1995

MY style pressure cap, which has raised white lettering on the top surface.

COOLANT EXPANSION TANK REPLACEMENT PROCEDURE

Remove and discard the existing coolant expansion tank and replace it with an improved tank (part number MMB 4400AA). Follow the instructions in the XJ6 / XJ12 Sedan Range Service Manual page 26.2-8.

PARTS INFORMATION:

DESCRIPTION

Coolant expansion tank

PART NUMBER

MMB 4400AA

QTY

1


Service Action S451

VEHICLE

XJ12 Sedan 1994 MY VIN

673299-708757

SUMMARY

CODE

GN

GP

DESCRIPTION

TIME

ALLOWANCE

0.35 hrs.

Replace expansion tank - without drive in/out time

Replace expansion tank - with drive in/out time

(only repair performed)

0.50 hrs.




DCS Dealers


Non-DCS Dealers





Coolant Specification Change –

Coolant D542 (Yellow)

MODEL All DATE 2/98

26-17

Amended

4/98



A revised coolant, Jaguar D542, which is yellow, has superseded D985 which was blue-green.

A CTION:

All vehicles can be topped up with D542.

coolant reservoir label (part no. MNA 7698AA) on the coolant reservoir to indicate that the vehicle has been converted. Use only Jaguar D542 coolant when subsequently topping up the coolant level.


D542 coolant (yellow)

P AR T NUMBER

JLM 20404/3

CON T AINER SIZE

5 liter



Automatic Transmission – Shift Quality –

Install Modified TCM

MODEL XJ6 Sedan Range 92-93 MY,

XJS (4.0L) Range 92 MY, as listed:

DATE 9/94

44-21

ISSUE:

Harsh upshift may occur under light throttle at 50 MPH.

A modified TCM (P/N LMA 2400AA) is available for the following vehicles which significantly improves shift quality with the transmission mode switch in the NORMAL position.

• XJ6 Sedan Range From VIN 629286 – 667829

• XJS (4.0L) Range From VIN 179735 – 185820

ACTION:

If customers complain of harsh upshifts, at 50 MPH under light throttle, perform the following procedure.

Procedure:

1.

Use JDS or PDU to interrogate the TCM for DTCs. If DTCs are present, refer to the appropriate Service Manual for repair information.

2.

Ensure that the following are not contributing to the shift quality problem.

• Engine mechanical condition

• Engine management system

• Incorrect transmission oil level

• Incorrect selector cable adjustment

• Incorrect rotary switch adjustment

3.

Verify that the correct transmission and TCM are fitted to the vehicle.

Transmission

TCM

Part Number

Part Number

EBC 4409

DBC 10110

IMPORTANT: DO NOT replace the TCM unless the customer complaint persists after Steps 1, 2 and 3 are performed.

4.

Replace TCM (P/N DBC 10110) with modified TCM (P/N LMA 2400AA).

PARTS INFORMATION:

DESCRIPTION

Transmission control module

PART NUMBER

LMA 2400AA



FAULT

CODE

R.O. NUMBER

FG GC GR 44.15.32

DESCRIPTION

Transmission control module - Renew

TIME

ALLOWANCE

0.75 hrs.



Automatic Transmission Oil Cooler –

Internal Leaks – Remove Tie Strap

MODEL

XJS (4.0L) Range 1994 MY

From: VIN 186000

To: VIN 194774

DATE 9/94

44-22

ISSUE:

Cracks resulting in leaks may occur within the transmission oil cooler causing cross contamination of transmission fluid and engine coolant on 1994 MY XJS (4.0L) Range vehicles from VIN 186000 to VIN 194774.

This failure is caused by the tie strap securing the upper and lower transmission oil cooler pipes

(located behind the right side of the radiator). The tension of the tie strap may amplify normal engine and road vibration causing the pipe stubs in the transmission oil cooler to rupture.

ACTION:

At the next service opportunity, on all 1994 MY XJS (4.0L) Range vehicles from VIN 186000 on, examine the upper and lower transmission oil cooler pipes located directly behind the right side of the radiator). If the transmission cooler pipes are secured together with a tie strap, cut and remove the tie strap.


This action should be performed during normal vehicle servicing. Therefore, no warranty claim should be submitted.

Bulletin Number 44-22 Page 1 of 1


Automatic Transmission –

Engine Stalls When Engaging “R” or “D” –


MODEL

All 4.0L with Auto Trans

DATE

12/94

44-23

ISSUE:

The engine stalls when the transmission is shifted to Reverse or Drive from Park. Stalling is most likely to occur when the engine is cold.

A restricted control unit oil seal in the transmission housing or a sticking torque converter control valve in the valve body may cause partial engagement of the torque converter clutch. Either of these conditions may cause the engine to stall.

ACTION:

If 4.0L vehicles equipped with automatic transmissions stall when shifting into Drive or Reverse from Park, follow the procedure outlined below.

DIAGNOSTIC PROCEDURE

1.

Verify engine setup using JDS/PDU

2.

Verify transmission fluid level and condition

3.

Interrogate the TCM for DTCs

If the engine setup and transmission fluid are within specification and no DTCs are present, perform the procedure appropriate to the mileage of the vehicle.

VEHICLES WITH LESS THAN 1000 MILES – REPAIR PROCEDURE

1.

Remove the transmission valve body following the instructions in the Service Manual, section 44.2 (R.O. number 44.40.01).

2.

Remove the control unit oil seal (part number JLM 863) shown in Illustration 1.

CONTROL UNIT OIL SEAL

OIL SEAL

44-23.1

ILLUSTRATION 1


CAUTION: If the seal is incorrectly fitted or restricted, the lockup clutch may partially engage causing the engine to stall.

3.

Install a new control unit oil seal

4.

Reassemble the transmission following the instructions in the Service Manual.

VEHICLES WITH MORE THAN 1000 MILES – REPAIR PROCEDURE

1.

Remove the transmission valve body following the instructions in the Service Manual, section 44.2 (R.O. number 44.40.01).

2.

Remove the torque converter control valve from the valve body (Illustration 2).

TORQUE CONVERTER CONTROL VALVE

CONTROL VALVE SPRING

TORQUE CONVERTER

CONTROL VALVE

ILLUSTRATION 2

3.

Clean the valve and valve bore. The valve must slide freely in the bore.

4.

Refit the control valve using a new spring (part number JLM 11573).

5.

Install the valve body.

44-23.2

NOTE: Torque the valve body securing screws to 6 lb ft (8 Nm).

6.

Install a new transmission oil filter and reassemble following the instructions in the Service

Manual.


PARTS INFORMATION:

DESCRIPTION

Transmission oil filter (XJS)

Transmission oil filter (Sedan Range)

Control unit oil seal

Spring - Torque converter control valve

PART NUMBER

JLM 664

JLM 2128

JLM 863

JLM 11573


FAULT

CODE

R.O. NUMBER

FG FB CR 44.91.10

DESCRIPTION

Automatic transmission - torque converter clutch - stalling

TIME

ALLOWANCE

1.75 hrs.



Automatic Transmission – Defaults To

“Limp Home” in Wet Weather –


MODEL Sedan Range (4.0L) up to 93 MY DATE 1/95

44-24

ISSUE:

The Transmission Failure malfunction indicator lamp (MIL) illuminates and the transmission defaults to the “Limp Home” mode during rain or after using a car wash.

Water can enter the vehicle through the engine management harness grommet in the vacuum tank under the battery tray. The water can drip onto the Transmission Control Module (TCM) causing it to illuminate the transmission MIL and default to the “Limp Home” mode.

ACTION:

If 4.0L Sedan Range vehicles up to 1993 MY (VIN 667829) illuminate the transmission MIL and default to “Limp Home” mode during rainy weather or after using a car wash, seal the EMS harness grommet as described below.

1.

Record the preset radio stations (including X-mem) and remove the battery from the vehicle.

2.

Remove the battery tray, disconnect the EMS harness from the vacuum tank and remove the vacuum tank

3.

Inject a liberal amount of Bostik Alpha Seal 132 or an equivilant sealant into the areas shown in Illustration 1.

A. - Around the vacuum tank inner recess for the grommet.

B. - Around the EMS harness at the front and back of the grommet

C. - Between the EMS harness grommet and the body panel face

ENGINE MANAGEMENT HARNESS GROMMET LOCATION

A

B

C

B

9/6.1.1

ILLUSTRATION 1

4.

Replace the vacuum tank and press down firmly to squeeze the sealant around all of the


joints

5.

Clip the EMS harness into place.

6.

Reassemble the battery tray before the sealant sets. Torque the mounting bolts to 12 - 16 lb ft (15.5 to 20.5 Nm).

7.

Install the battery, code the radio, and reset the radio stations and clock.

PARTS INFORMATION:

Bostik Alpha Seal 132 or equivilant - source locally

Source sealant locally


FAULT

CODE

FX CB PS

R.O. NUMBER

86.91.58

DESCRIPTION

Seal EMS harness

TIME

ALLOWANCE

0.40 hrs.



ZF Automatic Transmission –

Noise in Reverse After Cold Start in Cold

Weather – Repair Procedure

MODEL All ( 4.0L) DATE 3/95

Sedan (4.0L) RangeUp to VIN 720649

XJS (4.0L) RangeUp to VIN 194774

44-25

ISSUE:

Noise when reverse gear is selected or the vehicle is driven slowly in reverse following a cold start during cold weather.

All 4.0L automatic transmission equipped vehicles up to the VINs listed below may be effected.

The noise is caused by air circulating with the cold transmission fluid. The noise has no detrimental effect on the transmission.

Sedan (4.0L) Range

XJS (4.0L) Range

UP TO VIN 720649

UP TO VIN 194774

Modified transmissions are fitted during production beginning with VINs 720650 (Sedan Range) and 194775 (XJS Range).

ACTION:

If a customer complains of a transmission noise after cold start during cold weather on a vehicle within the VIN range, follow the appropriate procedure described below.

SEDAN (4.0L) RANGE UP TO VIN 720649 - REPAIR PROCEDURE

1.

Drive the vehicle until it is at normal operating temperature (10 to 15 miles minimum).

Immediately check the HOT transmission fluid level with the engine idling and the transmission in PARK.

Set the fluid level to the MAX HOT mark on the dipstick.

2.

Park the vehicle overnight to become thoroughly cold.

3.

Start the vehicle without touching the accelerator. Select reverse and listen for transmission noise. Drive slowly in reverse and listen for transmission noise.

4.

If the transmission is noisy in reverse when cold, remove the transmission valve body (valve block) following the instructions in the Service Manual, Section 44.


5.

Remove the 4 screws shown in Illustration 1. Replace the existing torque converter control valve with a new control valve (part number NHD 5602AA).

TORQUE CONVERTER CONTROL

TORQUE CONVERT-

ER CONTROL VALVE

44/23.2

ILLUSTRATION 1

6.

Reassemble the transmission. Torque the 13 valve body to transmission screws to 6 lb ft (8

Nm).

7.



Set the transmission fluid level to the MAX HOT mark on the dipstick.

8.

Check the transmission for leaks.

XJS (4.0L) RANGE UP TO VIN 194774 - REPAIR PROCEDURE

1.

Install a SERVICE dipstick (part number NHD 4550AA).

2.



Set the transmission fluid level to the MAX HOT mark on the SERVICE DIPSTICK.

3.

Park the vehicle overnight to become thoroughly cold.

4.

Start the vehicle without touching the accelerator. Select reverse and listen for transmission noise. Drive slowly in reverse and listen for transmission noise.

5.

If the transmission is noisy in reverse when cold, remove the transmission valve body (valve block) following the instructions in the Service Manual, Section 44.

6.

Remove the 4 screws shown in Illustration 1 above. Replace the existing torque converter control valve with a new control valve (part number NHD 5602AA).

7.

Reassemble the transmission. Torque the 13 valve body to transmission screws to 6 lb ft (8

Nm).


8.



Set the transmission fluid level to the MAX HOT mark on the SERVICE DIPSTICK.

9.


10. Park the vehicle overnight to become thoroughly cold.

11. Start the vehicle without touching the accelerator. Select reverse and listen for transmission noise. Drive slowly in reverse and listen for transmission noise.

12.

If there is no noise, replace the SERVICE DIPSTICK with the original dipstick.

13.

If the transmission noise is still unacceptable, remove the automatic transmission, starter ring gear/drive plate assembly and crankshaft adapter following the instructions in the Service Manual, Section 44.

14.

Replace the existing components listed below with new components

COMPONENT

Crankshaft adapter

Starter ring gear/drive plate assy.

Spacer

Bolt

Dipstick

Automatic transmission

NEW PART NUMBER

NHE 1425AA

NHE 1428AA

NHE 1431AA

JZB 100046

NHD 4550AB

NHE 4400BA/N

QTY

8

1

1

1

1

1

IMPORTANT: The existing valve body MUST be fitted to the new transmission to maintain shift quality and harness compatibility.

The existing dipstick tube MUST be fitted to the new transmission.

A new dipstick (part number NHD 4550AB) MUST be fitted.

Do not use the existing dipstick or the SERVICE DIPSTICK.

15.



16.

Set the fluid level to the MAX HOT level on the new dipstick.

17.




SEDAN RANGE VEHICLES

DESCRIPTION

Transmission torque converter control valve

XJS RANGE VEHICLES

DESCRIPTION

Transmission torque converter control valve

Service dipstick

Automatic transmission

Crankshaft adapter

Starter ring gear/drive plate assy.

Spacer

Bolt

Dipstick

PART NUMBER

NHD 5602AA

QTY

1

PART NUMBER

NHD 5602AA

NHD 4550AA

NHE 4400BA/N

NHE 1425AA

NHE 1428AA

NHE 1431AA

JZB 100046

NHD 4550AB

QTY

8

1

1

1

1

1

1

1


MODEL

Sedan (4.0L) Range

UP TO VIN 720649

XJS (4.0L) Range

UP TO VIN 194774

XJS (4.0L) Range

UP TO VIN 194774

FAULT CODE

FB BC KS

FG BC KS

FG BC KS

R.O. NUMBER

44.91.10

44.91.10

44.91.11

DESCRIPTION

TIME

ALLOWANCE

1.75 hrs.

Replace transmission torque converter valve

Replace transmission torque converter valve

Replace transmission and drive plate assembly

1.75 hrs.

6.35 hrs.



ZF Automatic Transmission –

Internal Damage Due to High Engine

Speed in Park or Neutral

MODEL All (3.6L and 4.0L) 1988 MY ON DATE 3/95

44-26

ISSUE:

ZF automatic transmissions may be damaged by running the engine at high speed for prolonged periods with the transmission in PARK or NEUTRAL.

ACTION:

If high engine speed operation is required for purposes such as emission testing, charging system testing, injector cleaning or A/C charging, observe the following precautions to avoid transmission damage.

CAUTION: With the transmission in PARK or NEUTRAL,

DO NOT EXCEED 2000 RPM

DO NOT OPERATE THE ENGINE AT HIGH SPEED FOR PROLONGED PE-

RIODS

DO NOT OPERATE THE ENGINE AT HIGH SPEED TO ACHIEVE

For service operations that require that the engine be at normal operating temperature, follow the procedure outlined below.

1.

Drive the vehicle to bring it to operating temperature.

2.

Shift to PARK and switch OFF the ignition.

3.

Wait at least 30 seconds before restarting the engine.

4.

Restart the engine with the transmission in PARK. During the service procedure, do not move the gear selector through the forward or reverse gears with the engine running.

5.

Perform the service procedure. Observe the cautions above.

6.

Following the service procedure, switch OFF the engine.

7.

Wait at least 30 seconds before restarting the engine. Do not increase engine speed above idle before selecting a forward or reverse gear.



ZF 4HP 24 E9 A utomatic T ansmission – oor Shift Quality in R, 3-4

Up to tr ans. serial no. 158813

Some vehicles may exhibit harsh 3-4 upshifts or slip/judder when shifting into reverse. This condition affects automatic transmission vehicles only with transmission unit serial numbers up to 158813.

In case of a customer complaint, advise the customer that this concern can be rectified in the majority of cases by a simple modification to the automatic transmission. Check the manufacturer’s plate on the left side of the transmission for the serial number. On transmissions with a serial no. up to 158813, proceed as follows:

1.

Check the transmission fluid level - engine running - with the transmission at normal operating temperature. If the fluid appears burnt, proceed to step 3 below. If necessary, adjust the fluid level to the correct level.

2.

Verify that the fault is still present. If fault is no longer present, STOP - DO

NOT PROCEED. If fault is still present, continue with step 3.

3.

Drain the transmission fluid and check its condition. If the fluid is burnt, replace the transmission unit. Refer to procedure (R.O. number 44.20.01) in section 44, of the XJ6 or the XJS Service Manual, Volume 3.

4.

If the fluid appears clean, remove the transmission oil pan. Refer to procedure in section 44 of Service Manual (R.O. number 44.24.04).


5.

Remove the retaining bolts from the speed sensor mounting bracket,

Illustration 1, and remove the bracket.

REAR END PLA TE

ILLUSTRATION 1

J44-727

6.

Loosen the bolts holding the rear end plate of the valve body (valve block).

Pull the speed sensor out of the valve body, removing the harness from the securing clip.

7.

Carefully remove the bolts that retain the rear end plate of the valve body.

Remove the end plate, using care to ensure that the two outer springs and the center piston do not pop out.


PRESSURE REDUCING V AL VE SPRING

V A L VE SPRING

J44-726

ILLUSTRATION 2

8.

Remove and discard the pressure reducing valve spring from the right side location (Illustration 2).

9.

Make sure that the pressure reducing valve behind the right side spring moves freely in its bore.

10. Install a new spring, part no. NHD 5601AA, into the bore of the pressure reducing valve.

11. Reinstall the valve body end plate and the clip for the speed sensor harness.

Thread, but do not fully tighten, the retaining bolts.

12. Position and install the speed sensor and bracket on the valve body. Locate the speed sensor harness behind the securing clip.

13. Fully tighten the end plate bolts and torque to 8 lb ft (5 Nm).

14. Align the speed sensor retaining bracket and final tighten the retaining bolts and torque to 6 lb ft (8 Nm).

15. Install the transmission pan as described in section 44 of the Service Manual,

(R.O. number 44.24.04), noting the following torque values:

Dipstick tube nut 15 lb ft (20 Nm)

Drain plug 11 lb ft (15 Nm)

Transmission fluid pan bolts 6 lb ft (8 Nm)

16. Refill the transmission with the recommended fluid, as described in section 44 of the Service Manual (R.O. number 44.24.02). Approximately 4 quarts (4 liters) of fluid will be required.



DESCRIPTION P AR

Spring NHD 5601AA 1


U L

C O D E

T

FG BC PQ 44.91.12

FG CD FG 44.91.12

FG BC NL 44.91.12

Vibration in reverse

Harsh 3 - 4 upshift

Slip in reverse

A L L O W A N C E

1.05 hrs.

1.05 hrs.

1.05 hrs.


TECHNIC AL BULLETIN ansmission Contr ol Module –

All 1995 MY with ZF tr ansmissions

Sedan Range VIN 720028 - 745840

XJS Range VIN 194775 - 222065

Some 1995 MY vehicles equipped with ZF automatic transmissions in the above

VIN ranges may experience the following intermittent conditions:

1) Transmission Malfunction Indicator Lamp (MIL) flashing on and off.

2) Transmission enters limp home mode. Transmission MIL remains on. Code

P1777 is stored in the Engine Control Module and the PDU cannot communicate with the Transmission Control Module.

If a customer complains of either condition on a 1995 MY vehicle equipped with a

ZF automatic transmission, a revised Transmission Control Module is available as installed in production from VIN 745841 (Sedan Range) and 222066 (XJS Range).

1.

If the car exhibits condition 1, install the revised TCM.

2.

If the car exhibits condition 2, read out the OBD II DTC(s) using the PDU. If

DTC P1777 is found in the Engine Control Module, and the PDU cannot communicate with the TCM, install the revised TCM.

3.

Record the DTC(s) on the Diagnostic Trouble Code Report form S-93.

TCM LOCATIONS

Sedan Range - The TCM is located under the passenger side underscuttle. Refer to repair operation 44.15.32 in subsection 8.1.3 of the XJ6 - XJ12 Vehicle Service

Manual .

XJS Coupe - The TCM is located behind the right rear quarter trim panel at the base of the B-pillar. Refer to repair operation 76.13.12 in the XJS Service Manual

Volume 4, to remove the Rear Quarter Lower Trim Pad to gain access to the TCM.

XJS Convertible 2+2 - The TCM is located on the convertible top pump bracket in the trunk.



Transmission Control Module, Sedan Range

Transmission Control Module, XJS Range

P AR

LHE 2400AH 004

LHE 2400AH 001


F A U L T

Sedan Range

Condition 1 FX CH FW

Condition 2 FX CB GH

XJS Coupe



XJS Conv. 2+2



44.15.32

44.15.32

TCM, replace with diagnostic time

TCM, replace with diagnostic time

A L L O W A N C E

0.65 hrs.

0.80 hrs.

44.15.32.80 TCM, replace with diagnostic time 0.55 hrs.

Condition 1 Output to TCM Malfunction Indicator Lamp (MIL), Incorrect output

Condition 2 TCM, Inoperative



Steering – Lower Column – Excessive

Play/Knocking – Repair Procedure –


MODEL Sedan Range 1993 MY DATE 10/94

From: VIN 669506

To: VIN 669989

57-18

ISSUE:

1993 MY Sedan Range vehicles from VIN 669506 to 669989 may have excessive steering wheel play. The excessive play may be accompanied by a knock when the wheel is turned.

These symptoms are caused by a lower steering column with insufficient dampening that was fitted on some vehicles within the VIN range.

ACTION:

Examine all 1993 MY Sedan Range vehicles at the next service opportunity to see if they are part of this action. If the vehicle’s VIN appears on the S398 SERVICE ACTION VIN LIST (page 4), a new lower steering column (P/N BEC 14009) must be installed.

Procedure:

1.

Disarm the SRS (airbag). Refer to Service Manual section 57.60.01.

2.

Center the steering and remove the ignition key.

3.

Remove the pinch bolt and nut clamping the upper steering column universal joint to the lower column (Illustration 1).

4.

Remove the pinch bolt and nut clamping the lower steering column universal joint to the steering rack pinion (Illustration 1).

IMPORTANT: Mark the position of the lower column universal joint on the steering rack pinion.

LOWER STEERING COLUMN ASSEMBLY

UPPER UNIVERSAL

PINCH BOLT

LOWER UNIVERSAL

PINCH BOLT

ILLUSTRATION 1

57-18.1


5.

Remove the lower column. Remove the bulkhead grommet, and inside the vehicle, recover the spring and steering column collar.

STEERING COLUMN AT BULKHEAD

BULKHEAD GROMMET

(OUTSIDE)

57-18.2

ILLUSTRATION 2

6.

Fit the bulkhead grommet to the new lower column. Slide the new column through the bulkhead.

7.

Install the lower steering column universal joint on the steering rack pinion and torque the pinch bolt and nut to 14 – 17 lb ft (19 – 24 Nm).

IMPORTANT: The lower universal joint must align to the bolt hole in the steering rack pinion.

8.

Wedge the universal joint to keep it from closing.

9.

Inside the vehicle, fit the spring and steering column collar to the lower column.

10.

Remove the upper steering column bearing bolts.

UPPER STEERING COLUMN

UPPER STEERING COLUMN

BEARING BOLTS

ILLUSTRATION 3

57-18.3

11.

Connect and fully seat the upper steering column universal joint. Refit but do not fully tighten the pinch bolt and nut.

12. Reposition the upper steering column bearing and fully tighten the bolts.


13. Check the position of the lower column and upper universal joint. Torque the upper universal joint pinch bolt and nut to 14 – 21 lb ft (24 – 30 Nm).

14. Slide the upper universal joint cover down into position.

15. Install the bulkhead grommet.

WARNING: Remove the wedge fitted to the lower column universal joint.

16. Arm the SRS (airbag).

PARTS INFORMATION:

PART NUMBER

BEC 14009


Service Action S398

DESCRIPTION

Lower steering column

VEHICLE

Sedan Range 1993 MY

Model Codes 4064 and 4082

From VIN 669506 to VIN 669989

SUMMARY

CODE

DESCRIPTION

DT Lower steering column - Renew

TIME

ALLOWANC

E

0.30 hrs.


A warranty summary code has been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the labor time allowance and parts as indicated.

DCS Dealers


Non-DCS Dealers




669739

669765

669786

669879

669903

669918

669932

669947

669506

669541

669566

669601

669641

669668

669689

669703

669960

669974

669988

S398 SERVICE ACTION VIN LIST

669748

669770

669787

669891

669913

669919

669933

669955

669514

669542

669572

669603

669645

669670

669691

669719

669961

669983

669989

669755

669772

669822

669893

669914

669927

669942

669956

669969

669984

669527

669551

669575

669606

669647

669674

669692

669722

669760

669775

669864

669899

669915

669930

669944

669957

669972

669985

669532

669559

669583

669616

669658

669684

669699

669734

669761

669779

669868

669902

669916

669931

669945

669959

669973

669986

669538

669563

669598

669632

669663

669686

669702

669735



Steering Rack – Surface Cracks –


MODEL XJS (4.0L) Range 1995 MY

VIN 196998-197112

DATE 8/95

57-20

Amended

8/95




ISSUE:

A limited number of 4.0L XJS Range vehicles may exhibit surface cracks on the aluminum casting of the steering rack. These cracks may result in fluid seepage but will not affect the function of the steering. The specific VINs are listed on page 3.

ACTION:

The steering racks of vehicles in the above VIN range should be inspected for surface cracks. Locate the part number on the plate located on the underside of the steering rack. If the vehicle is equipped with part number MHD 3891CA, replace it with part number MHB 3891AA/NK. If the vehicle is already in service, make arrangements to have it inspected and, if necessary, to have the steering rack replaced at the earliest opportunity.

STEERING RACK REPLACEMENT PROCEDURE

1.

Disconnect the battery negative cable.

2.

Disconnect the supply and return hoses from the rack and allow them to drain into a drain pan.

3.

After the oil has drained into the tray, install plugs into the rack and hoses to prevent dripping.

4.

Remove the clamping bolt and nut that attach the steering shaft to the pinion, Illustration 1.

5.

Turn the ignition key to position 1 and turn the steering wheel to the straight-ahead position.

Turn the key to the OFF position and remove.

6.

Use tool JD 100 to disconnect the tie rod end ball joints from the steering arms.

7.

Loosen the steering rack upper and lower mounting bolts and remove the heat shield bracket.

8.

Remove the steering rack, stiffener, and shims from the crossmember.

9.

Remove the mounting bushes from the rack assembly.

10.

Place the new steering rack in position with the mounting bushes, stiffener, and the heat shield, then connect the steering shaft to the pinion.

11. Insert bolts in position in the double lug and insert the bolt in the single lug with the thrust washers.

Date of issue 8/95 Bulletin Number 57-20 Amended Page 1 of 4

12.

Center the single lug in the mounting bracket using the shims.

NOTE: Check that a gap of 0.10 to 0.12 inch (2.5 to 3.0 mm) exists between the thrust washer and the lug.

13.

Install the nuts on the mounting bolts and tighten them sufficiently to hold the rack while aligning it to the crossmember using the elongated bolt holes. Once the rack is aligned, tighten the mounting bolts to 13.276 - 17.702 lb ft (18 - 24 Nm).

STEERING RACK (SHOWN ON RHD VEHICLE)

CLAMPING BOLT

CENTERING BOLT TO

BE REPLACED BY

SEALING BOLT

J57-286

ILLUSTRATION 1

14.

Insert the clamping bolt and nut (Illustration 1) and tighten to 17.702 - 22.127 lb ft (24 - 30

Nm).

15.

Connect the supply and return hoses.

16.

Connect the tie rod ends to the steering arms and tighten to 44.991 - 50.892 lb ft (61 - 69

Nm).

17.

Remove the centering bolt and replace it with the sealing bolt (JZS 100046) and washer

(JZW 100019), Illustration 1. Tighten the bolt to 4 - 5.25 lb ft (5.5 - 8.5 Nm).

18.

Refill the steering system, reconnect the battery, run the engine and turn the steering wheel from lock to lock to purge the air from the system. Check the fluid level.

19.

Check/adjust the front wheel alignment.

20.

Reset the clock.

Page 2 of 4 Bulletin Number 57-20 Amended Date of issue 8/95

S450 SERVICE ACTION MODEL CODE AND VIN LIST

Model, VIN Model, VIN Model, VIN

U.S.

2030, 196998

2030, 197012

2030, 197029

2030, 197040

2030, 197048

2030, 197062

2030, 197104

2030, 196999

2030, 197014

2030, 197035

2030, 197042

2030, 197053

2030, 197064

2030, 197112

2030, 197002

2030, 197015

2030, 197032

2030, 197044

2030, 197055

2030, 197067

Model, VIN

2030, 197005

2030, 197017

2030, 197034

2030, 197045

2030, 197058

2030, 197083

Model, VIN

2030, 197007

2030, 197020

2030, 197037

4234, 197046

2030, 197059

2030, 197092

CANADA

2030, 197009

PARTS INFORMATION:

2030, 197098

DESCRIPTION PART NUMBER

Bolt

Washer

JZS 100046

JZW 100019

QTY

1

1

1



Service Action S450

VEHICLE

XJS (4.0L) 1995 MY VIN

196998-197112

Model codes 2030, 4234

XJS (4.0L) 1995 MY VIN

196998-197112

Model codes 2030, 4234

SUMMARY

CODE

FX

FY

DESCRIPTION

Inspect steering rack, with no defect found - with drive in/out time

TIME

ALLOWANCE

0.25 hrs.

Replace steering rack, check/adjust wheel

alignment - with drive in/out time

2.05 hrs.



DCS Dealers


Non-DCS Dealers





Power Assisted Steering – Diagnosis

MODEL 1992-96 XJS Range DATE 12/98

57-22

This Technical Bulletin will provide a Diagnostic Procedure to aid in the investigation of power assisted steering (PAS) related problems, and must be used in conjunction with the PAS Rack and Pinion Evaluation Form, W-29.

A CTION:

When diagnosing PAS related problems, the following procedure is recommended:

1.

Enter the Customer’s comments in the appropriate section of the Evaluation

Form.

2.

Inspect the steering assembly and enter the observations in the appropriate section of the Evaluation Form.

3.

Consult the PAS Diagnosis Chart.

4.

Determine the cause of the fault.

5.

Rectify any fault found.

6.

Test to confirm the elimination of the fault.

7.

Record the idle and maximum pump pressures on the completed W-29 form and submit the form.

NO TE: reimbursement.


R epor ted Condition

Very light when driving stationary maneuver good

Heavy during stationary maneuver

Heavy during rapid maneuver

Heavy turning to one side

Heavy turning to both sides

Very heavy when driving stationary maneuver good

Unequal load - center to left or right

Load at steering wheel varies from light to heavy

2 times per revolution

P A S DIA GNOSIS CHAR T

P ossible Causes

Rack reaction limitation valve

- open / incorrect setting

Low pressure pipe restricted

Reservoir filter restricted

Tire pressures too high

Delivery pressure or flow too low

Internal rack leakage

Tire pressures too low

Engine idle speed too slow

Pump drive loose (6 cyl)

Pump drive belt slack (V12)

Air in system

Fluid loss at pump shaft seal

Delivery pressure/flow too low

Faulty rotary valve/seal

Low fluid level



Air in system


Delivery pressure/flow too low

Filter blocked restricting flow

Check valves blocked

Rack damper too tight

Lower column setting

Upper column too tight

Rack reaction limitation valve

- closed / incorrect setting

Leaking rack check valve

Rotary valve blockage



R emedy

Replace rack

Replace pipe

Replace reservoir/filter

Reset tire pressures

Replace pump

Replace rack

Reset tire pressures

Reset idle speed

Replace coupling & pump

Check/replace & tension belt

Stop air leak, refill & bleed

Replace pump

Replace pump

Replace rack

Rectify fluid leak & refill




Replace pump

Replace pump

Replace reservoir

Replace rack

Replace rack

Reset lower column

Replace upper column

Replace rack

Replace rack

Replace rack

Reset lower column

Reset lower column


R epor ted Condition

Load at steering wheel varies from light to heavy many times per revolution

Load at steering wheel very light at center

P

P A S DIA GNOSIS CHAR T ossible Causes


Knocking/vibration at steering wheel

Free play at steering wheel

Noise during rack movement

Continuous noise

Low system pressure

Leakage

Low fluid level

Tire pressures too high

Air in system

Seized steering joint


Steering geometry

Lower column over extended

Low fluid level

Air in system


Rack damper loose

Pinion bearing faulty

Rack or column fixings loose

Rack mounting bracket loose

Rack mounting bush loose

Free play in column assembly

Rack damper loose

Pinion bearing loose

Worn intermediate shaft joint

Worn suspension joint

Loose lower u-joint pinch bolt

Low fluid level

Air in system

Water contamination

Cavitation due to restricted feed hose

Low fluid level



Pump drive pulley loose

Pump mounting loose

Hose/pipe in contact with body

Hose restricted/twisted

Filter blocked restricting flow

Pump worn

High pressure hose restricted/ twisted

Leakage at hose to rack connection

Leakage at ‘O’ rings

Leakage from transfer pipes

Leakage from rack body

Leakage from boots

R emedy

Replace rack


Set to specified pressure


Replace steering joint

Replace rack

Check & rectify

Reset lower column



Replace pump

Replace rack

Replace rack

Retighten to specification

Replace rack

Replace rack

Check & rectify

Replace rack

Replace rack

Replace joint

Replace joint

Inspect & tighten to specification



Replace cooler, flush system at least 2 times & check for damage to transmission

Reposition or replace hose






Reposition or replace hose/pipe


Replace reservoir & filter

Replace pump


Tighten to specification/replace hose

Replace ‘O’ rings

Tighten to specification/replace pipes

Replace rack

Replace rack


Raise the vehicle on a suitable hoist to provide access to the steering rack.

N O TE : reservoir and pump must be thoroughly cleaned of all dirt, grease and fluid, using a suitable degreasing agent, and then thoroughly dried, before testing for leaks.

After cleaning, check the whole PAS system for any outward sign of physical damage or misalignment.

Start the engine and turn the steering steadily from lock to lock observing all the connections and joints for signs of a fluid leak.

W ARNING: when looking for suspected leaks.

running.

PRESSURE MEA SUREMEN T PROCEDURE

Measure the maximum system pressure, (which is governed by the pressure relief valve), by connecting a pressure tester (J25323-D) with suitable adapters (J28579 or JD10-4A), in series into the fluid circuit of the PAS system. When using gauge g auge tester through the thicker high pressure hose.

1.

On all engines except XJS V12 engines, thread the dog leg adapter pipe

J28579 into the high pressure fitting of the PAS pump. On XJS V12 engines, thread the curved adapter pipe from 211-011-03 (JD10-4A) into the high pressure fitting of the PAS pump.

This requires arranging the fittings on the hoses so that the male quick connect is on the thicker high pressure hose on the tester.

2.

Connect the other tester hose to the PAS high pressure hose previously disconnected from the PAS pump.

3.

Run the engine at idle speed, and check that the pressure at idle is 100-150 psi

(6.9-10.3 bar).

4.

Hold the steering wheel at full lock and read the maximum pressure recorded on the gauge which should be 1100-1200 psi (75.8-82.7 bar). If the pressure is within specification, continue to step 6. If the pressure reading is below the minimum, continue with step 5.

5.

Center the steering wheel and close the pressure tester valve for no more than 5 seconds. Read the maximum pump pressure with the valve closed.


RA CK excessive internal leakage causing a high flow rate.

valve seized in the open position allowing excessive flow, or it may be worn and inefficient.

6.

Record the idle and maximum pump pressures on the W29 form.


F A UL T

GC CB 63 57.20

PAS pressure test

ALL O W ANCE shop time



Suspension – Alignment Specifications

MODEL All except XJ6 Series III DATE 5/95




60-5

Amended

1/96

ISSUE:

Current alignment specifications for 1988 MY ON Sedan Range vehicles and all

XJS Range vehicles.

ACTION:

Use the following specifications when performing 4-wheel alignment.

• Sedan Range - 1988-1994 MY Alignment Specifications Page 2

• Sedan Range - 1995-1996 MY Alignment Specifications

• XJS Range Alignment Specifications

Page 3

Page 4

IMPORTANT:

• Adjust the tire pressures to the “Comfort Settings” found on the vehicle data plate.

• Ensure that the vehicle setting height is within specification.

• Install the correct mid-laden tools (except on XJR-S and sportspack Coupe vehicles). Adjust to setting height as necessary (Sedan Range, front).

• When measuring caster, use the vehicle steering wheel to turn the road wheels to the left and right. DO NOT START THE ENGINE unless the ride leveling system has been disabled.

• Center and lock the steering rack with the correct centering pin to measure and adjust toe.

• Record the “before” and “after” tire pressures and alignment data on the repair order.


SEDAN RANGE – ALIGNMENT SPECIFICATIONS 1988 – 1994 MY

NOTE: Install the correct mid-laden tools. Adjust the front suspension tools to the correct setting height.

Vehicle Setting Height - Sedan (3.6L and 4.0L) Range VIN 506664 – 708757

FRONT

REAR

DIMENSION

6.00 in ± 0.2 in

6.30 in ± 0.2 in

MEASUREMENT POSITION bottom of the front sub frame to the alignment equipment wheel plates rear edge of the wishbone to the alignment equipment wheel plates

Vehicle Setting Height - XJ12 Sedan VIN 671007 - 708757

FRONT

REAR

DIMENSION

5.63 in ± 0.2 in

6.30 in ± 0.2 in


Vehicle alignment specifications - Sedan Range VIN 506664 – 708757

SEDAN RANGE 1988 - 1994 MY

FROM VIN 506664 - 708757

CASTER ANGLE (degrees)

CAMBER (degrees)

TOTAL TOE (degrees)

TOTAL TOE (inches) with 15 in wheels


FRONT

ALL

+2.0º to +7.0º

+0.4º to -1.0º

+0.25º to -0.08º

NON-ADJ. TOE

Not applicable

-1.15º to -0.35º

0º ± 0.8º

+0.065 in to -0.022 in 0.0 in ± 0.023 in

+0.070 in to -0.023 in 0.0 in ± 0.023 in

REAR

ADJUSTABLE TOE

Not applicable

-1.15º to -0.35º

+0.58º to -0.08º

+0.153 in to

-0.022 in

+0.163 in to

-0.023 in

NOTE: Rear toe is not adjustable before VIN 687219.


SEDAN RANGE – ALIGNMENT SPECIFICATIONS 1995 - 1996 MY

NOTE: Install the correct mid-laden tools. Adjust the front suspension tools to the correct setting height.

Vehicle Setting Height - Sedan (4.0L) Range From VIN 720001

FRONT

REAR

DIMENSION

6.00 in ± 0.2 in

6.30 in ± 0.2 in


Vehicle Setting Height - XJ12 Sedan From VIN 720001

FRONT

REAR

DIMENSION

5.63 in ± 0.2 in

6.30 in ± 0.2 in


Vehicle alignment specifications - Sedan Range From VIN 720001

SEDAN RANGE 1995 - 1996 MY

FROM VIN 720001


CAMBER (degrees)

TOTAL TOE (degrees)



FRONT REAR

ALL

+2.0º to +7.0º

+0.4º to -1.0º

+0.25º to -0.08º

ALL EXCEPT XJR

Not applicable

-1.15º

+0.58º to -0.35º to -0.08º

XJR ONLY

Not applicable

-2.0º to -1.2º

+0.58º to -0.08º

+0.070 in to -0.023 in +0.163 in to -0.023 in +0.163 in to -0.023 in

+0.074 in to -0.024 in +0.172 in to -0.024 in +0.172 in to -0.024 in


XJS RANGE – ALIGNMENT SPECIFICATIONS

NOTE: Install the correct mid-laden tools. All setting height dimensions are for reference only. XJR-S and sportspack Coupe vehicles whose normal ride height prevents the use of mid-laden tools, should be checked/set at their normal ride height.

Vehicle Setting Height - XJS Range - All

FRONT

REAR

DIMENSION

6.00 in ± 0.2 in

6.38 in ± 0.2 in


Vehicle alignment specifications - XJS Range - Except XJR-S

XJS RANGE


CAMBER (degrees)

TOTAL TOE (degrees)



FRONT

+2.0º to +6.0º

-0.1º to -0.9º

+0.5º to +0.17º

+0.131 in to +0.044 in

+0.140 in to +0.047 in

REAR

Not applicable

-1.0º to -0.5º

0º ± 0.33º

+0.087 in to -0.087 in

+0.093 in to -0.093 in

Vehicle alignment specifications - XJR-S - All

XJS RANGE


CAMBER (degrees)

TOTAL TOE (degrees)

FRONT

+3.5º ± 0.25º

-0.75º ± 0.25º

+0.33º

REAR

Not applicable

-1.3º parallel

WARRANTY POLICY:

Wheel alignment is covered under the Jaguar New Car Warranty for a period of 12 months or

12,500 miles, whichever comes first, from first retail sale.

Wheel alignments may not be performed under warranty without a customer complaint.

“Before” and “after” settings must be recorded and kept with the repair order in the vehicle file.



Front Suspension – Vehicle Pulls to One

Side – Check Pull Index

MODEL ALL except XJ6 Series III DATE 10/95

60-6

Amended

5/96




ISSUE:

Sedan Range (from 1988 MY) or XJS Range pulls to one side although alignment values are within specification as listed in Service Bulletin 60-5.

This condition can result from a combination of in-specification alignment value tolerances affecting the vehicle Pull Index. The vehicle Pull Index is a numerical indication of the differences between the left and right camber values (camber balance) combined with the differences between left and right caster values (caster balance).

ACTION:

If a Sedan Range (from VIN 506664) or XJS Range vehicle pulls to one side, check that the vehicle alignment and the Pull Index are within specification for the vehicle model.

CALCULATING PULL INDEX

1.

If the vehicle is properly aligned within specification and still pulls to one side, calculate the

Pull Index based on the vehicle’s current alignment values.

NOTE: The calculated Pull Index will indicate the vehicle’s tendency to pull to one side. Values more positive than the desired Pull Index indicate a tendency to pull to the right, while values more negative than the desired Pull Index indicate a tendency to pull toward the left.

Example:

+5 = pull toward right

0 = neutral

-5 = pull toward left

Sedan Range Pull Index limit:

XJS Range Pull Index limit:

–6

–9

2.

Calculate the Pull Index as follows:

(Camber imbalance – Caster imbalance) x 10 = Pull Index

Right side Camber – Left side Camber = Camber imbalance

Right side Caster – Left side caster = Caster imbalance

NOTE: A calculator will perform the subtraction and multiplication of positive and negative values easily.


EXAMPLE 1 - CAMBER IMBALANCE

Subtract the Left Side Camber from the Right Side Camber to give the Camber Imbalance.

Right Side Camber – Left Side Camber = Camber Imbalance

Right side camber value –0.9º Left side camber value –0.6º

–0.9º – (–0.6º) = –0.3º

NOTE: Always subtract the Left Side Camber value from the Right Side Camber value.

To use a calculator for the example above:

Enter the Right Side Camber value, 0.9. Change the value to a negative (–) number by pressing the [+/–] key).

Press the subtract key [–].

Enter the Left Side Camber value 0.6. Change the value to a negative (–) number by pressing the [+/–] key.

Complete the calculation by pressing the equal key [=].

Record the Camber Imbalance value –0.3 (include the sign, positive [+] or negative [–].

EXAMPLE 2 - CASTER IMBALANCE

Subtract the Left Side Caster from the Right Side Caster to give the Caster Imbalance.

Right Side Caster – Left Side Caster = Caster Imbalance

Right Side Caster value +3.9º Left Side Caster value +3.3º

+3.9º – +3.3º = +0.6º

NOTE: Always subtract the Left Side Caster value from the Right Side Caster value


Enter the Right Side Caster value 3.9. The value is a positive number.


Enter the Left Side Caster value 3.3. The value is a positive number.

Complete the calculation by pressing the equal key [=].

Record the Caster Imbalance value +0.6 (include the sign, positive [+] or negative [–]).


EXAMPLE 3 - PULL INDEX

Subtract the Caster Imbalance from the Camber Imbalance. Multiply the result by 10 to give the Pull Index.

(Camber Imbalance – Caster Imbalance) x 10 = Pull Index

Camber Imbalance –0.3º Caster Imbalance +0.6º

(-0.3 - +0.6) x 10 = -9

NOTE: Always subtract the Caster Imbalance value from the Camber Imbalance value first, then multiply the answer by 10.


Enter the Camber Imbalance value 0.3. Change the value to a negative (–) number by pressing the [+/–] key.


Enter the Caster Imbalance value 0.6 The value is a positive number.

Multiply by 10 (press the [X] key), enter 10.

Complete the calculation by pressing the [=] key. Record the Pull Index.

ADJUSTMENT GUIDELINES

• If the vehicle pulls to the right, change the caster setting(s) to make the pull index more negative. Do not exceed the limit given on page 1.

• If the vehicle pulls to the left, change the caster setting(s) to make the pull index more positive. Do not exceed the limit given on page 1.

WARRANTY POLICY:

Wheel alignment is covered under the Jaguar New Car Warranty for a period of 12 months or

12,500 miles, whichever comes first, from first retail sale.

Wheel alignments may not be performed under warranty without a customer complaint.

“Before” and “after” settings must be recorded and kept with the repair order in the vehicle file.


FAULT

CODE

GB HB **

1)

R.O. NUMBER

57.65.01

DESCRIPTION

TIME

ALLOWANCE

1)

Refer to the warranty codes and repair times manual for the applicable model.



Steering Pull – Corr ection Pr ocedur ee

MODEL Sedan Range 1988 - 94 MY

Steering pull on Sedan Range vehicles may be caused by a camber imbalance between the right and left side front suspension. A method of shimming a Vmount on one side has been developed to reduce this camber imbalance. In extreme cases, caster may have to be biased to reduce the steering pull.

In cases of customer complaints of steering pull, proceed as follows:

1.

Inspect all front suspension components for wear or damage. Verify that the tires are the correct size, brand and type, and are properly inflated. If all four tires are not identical, advise the customer that it may not be possible to eliminate the steering pull.

2.

Install the suspension mid-laden tools. Adjust the front mid-laden tools

(JD133) to the correct setting height. Check the wheel alignment. For current specifications, refer to Bulletin 60-5.

3.

Attempt to correct the camber imbalance using up to three 1mm shims. If this does not eliminate the steering pull, bias the caster.


COMP ARED T O L O WER PIV O T

COMP ARED T O UPPER PIV O T

ILLUSTRATION 1

CAMBER IMBALANCE ADJUSTMENT

••••• After ensuring that the alignment is within specifications (+4º to -1.0º camber) and that no suspension components are bent, ADD shims to the side of the vehicle with the MORE NEGATIVE (LESS POSITIVE) measurement.

••••• Shimming one “V” mount causes the camber on that side to change toward a more positive (less negative) measurement (Illustration 1). At the same time, camber on the side opposite the shim moves toward more negative (less positive). This change has an equalizing effect that reduces the camber imbalance.

••••• Each 1 mm shim corrects 0.1º of camber imbalance. The shims must not exceed a total thickness of 3 mm.

••••• Two examples are given on page 3.


EXAMPLE 1

Left side camber

EXAMPLE 2

Right side camber

Right side camber

Left side camber

EXAMPLE 1

Left side camber = +0.3º

Right side camber = -0.4º

Camber imbalance = 0.3 - (-0.4)º

= 0.7º

Insert 3 shims on right side “V” mount to reduce imbalance to 0.4º.

EXAMPLE 2

Left side camber = -1.0º

Right side camber = -0.2º

Camber imbalance =

=

Insert 3 shims on left

-1.0 - (-0.2)º

-0.8º side “V” mount to reduce imbalance to -0.5º.


V -MOUN

NEW W A SHERS

L ONGER V -MOUN T BOL T S

V -MOUN T

JSI-2288

ILLUSTRATION 2

••••• The camber adjustment shims are installed between the side member and the

V-mount (Illustration 2).

replaced by longer bolts, part no. JZB 100057, along with 2 washers, part no. C 21069 between the head of each bolt and the upper surface of the side member.

••••• Road test the vehicle.

••••• In cases where installing the maximum of 3 shims does not solve the customer complaint, it is possible to bias the self-centering effect of the caster angle.


CASTER ADJUSTMENT

••••• Caster is adjusted by transferring shims from one side of the upper ball joint to the other (Illustration 3). Do not change the total amount of shims by adding or subtracting shims.

specifications of +2º to +7º.

For example, to reduce a pull to the right:

INCREASE the Caster angle on the RIGHT side to become MORE positive, or

DECREASE the caster angle on the LEFT side to become LESS positive, to bias the steering to the LEFT.


SH5073A

ILLUSTRATION 3



Camber adjustment shim 1 mm

Bolt

Washer

P AR T NUMBER

MMD 2258AA/1

JZB 100057

C 21069

3 max.

2

2

W ARRAN TY POLICY

Wheel alignment is covered under the Jaguar New Car Waranty for a period of 12 months or 12,500 miles, whichever comes first, from first retail sale.

Wheel alignments may not be performed under warranty without a customer complaint. “Before” and “after” settings must be recorded and kept with the repair order in the vehicle file.


F A U L

GB HB GG

GH HC MQ

57.65.01

57.91.08

A L L O W A N C E

Front wheel alignment 0.75 hrs.

check and adjust

Camber setting incorrect, adjustment

2.35 hrs.



Rear Suspension – Special Tools JD199 &

JD199-1 – Repair Procedure

64-15

MODEL Sedan Range 1994 MY

From: VIN 696459

DATE 8/94

ISSUE:

New rear suspension design introduced on all Sedan Range vehicles from VIN 696459. The rear road springs are now mounted directly between the body and rear wishbone.

ACTION:

Rear suspension service requires new special tools.

Spring Compressor JD199 2 per set

Shock Absorber Retaining Strap JD199-1

This design change affects the following primary repair operations.

64.20.01

Rear road spring - Renew

2 per set

64.30.02

Rear shock absorber - Renew

NOTE: If repair requires removal of the rear road springs or shock absorbers, use the following information along with existing operations in the Service

Manual.

Removing The Spring/Shock Absorber Assembly From The Vehicle:

1.

Raise the vehicle until the wheels just clear the floor.

2.

Remove the brake caliper and support from the A frame mounting bracket.

3.

With a scribe, mark the position of the hub fulcrum bolt head on the wishbone

(Illustration 1).

NOTE: If no major suspension components are changed, this should allow reassembly without readjusting rear wheel toe.

4.

Remove the hub fulcrum bolt nut and drive out the bolt.

FULCRUM BOLT - TOE ADJUSTMENT

MARK POSITION

HUB FULCRUM BOLT

ILLUSTRATION 1

64-15.1


5.

Move the hub to the rear of the vehicle and support the hub on an axle stand.

NOTE: As the hub separates from the wishbone, recover the bearing adjustment shims.

6.

Install the first spring compressor JD 199, as shown in Illustration 2, in front of the wishbone, close to the hub fulcrum, and outboard of the spring.

7.

The spring compressor jaws should be placed so that one free coil is between the jaws.

INSTALLING SPRING COMPRESSORS JD 199

ONE FREE COIL

AXLE STAND

JD 199

FRONT

64-15.2

ILLUSTRATION 2

8.

Tighten the spring compressor center bolt until there is slight tension on the spring.

9.

Place the second spring compressor JD 199 against the front side of the wishbone, inboard of the spring.

10.

Place the upper upper jaw of the second spring compressorfirst on the same coil as the upper jaw of the first compressor. The lower jaw of the second compressor should be placed so that there are two free coils between the jaws. Tighten the spring compressor center bolt until there is slight tension on the spring.

11.

Compress the spring evenly by tightening each compressor two or three turns at a time, until the spring just separates from its seat on the wishbone. Then, compress the spring

1 inch (25 mm) more.

NOTE: The shock absorber and spring are removed as an assembly. Because gas pressure will force the shock absorber to extend, it must be partially compressed and retained before removal.

12.

Remove the lower shock absorber nut. Remove the three shock absorber upper mounting plate nuts. Pull the plate upper mounting plate down until it is clears the studs.


13. Thread each of the two shock absorber retaining strap JD 199-1 through an upper retaining plate hole and around an upper spring coil as shown in Illustration 3. Tighten and secure each strap.

INSTALLING SHOCK ABSORBER RETAINING STRAPS JD199-1

JD 199-1

JD 199-1

64-15.3

ILLUSTRATION 3

14.

Using a hydraulic jack under the lower shock absorber eye, compress the shock absorber until a bar can be run through the shock absorber eye and spring.

NOTE: A spacer may be necessary to reach the lower eye of the shock absorber.

Cut a “V” notch in the spacer to locate it on the shock absorber eye.

REMOVING SHOCK ABSORBER/SPRING ASSEMBLY

BAR

SPACER

JACK

64-15.4

ILLUSTRATION 4

15.

Slowly lower the jack until the shock absorber is securely held in the spring assembly at the top by the retaining straps and at the bottom by the bar.

WARNING: Be sure shock absorber and spring are firmly held by the compressors, straps and bar. The spring and shock absorber are under compression. If suddenly released they could cause injury or damage. Carefully remove the shock absorber spring assembly from the vehicle to avoid dislodging the spring compressors.


16.

Carefully remove the spring, shock absorber and spring compressor assembly from the vehicle.

17.

Have an assistant hold the complete assembly on a bench with the upper end of the shock absorber against the base of a vise.

COMPLETE SHOCK ABSORBER /SPRING ASSEMBLY

REMOVED

JD 199-1

JD 199

JD 199-1

64-15.5

ILLUSTRATION 5

18.

Push firmly against the lower end of the shock absorber. Remove the bar and allow the shock absorber to slowly extend.

19.

Remove the two JD 199-1 retaining straps. Remove the compressed spring, with the two JD

199 spring compressors still attached, from the shock absorber assembly.

Replacing The Shock Absorber:

1.

Remove the shock absorber from the upper retaining plate. Note the position of the washers below the retaining plate.

2.

Reassemble with the washers in their original positions.

Replacing The Road Spring.

1.

Tape the spring coils to mark the spring compressor jaw positions. Loosen each

JD 199 spring compressor evenly, two or three turns at a time until the spring is free.

MARKING SPRING COMPRESSOR POSITION

MARK WITH TAPE

MARK WITH TAPE

64-15.6

ILLUSTRATION 6

2.

Lay the new spring beside the old, tape marked spring. Install the spring compressor jaws in the same positions on the new spring as they were on the old spring.


3.

Carefully and evenly compress the new spring by tightening each compressor two or three turns at a time.

4.

Place the compressed spring on the upper retaining plate/shock absorber assembly. Secure the upper retaining plate to the spring with two shock absorber retaining straps JD199-1, as explained in step 13 of “Removing The Spring/Shock Absorber Assembly From The Vehicle.”

5.

Compress the shock absorber by hand and slide a bar between the spring coils and through the shock absorber lower eye to retain the shock absorber.

Installing The Spring/Shock Absorber Assembly:

1.

Reverse the removal steps.

2.

Before releasing the spring compressors be sure that the upper and lower mountings are aligned and all spacers are centered.

3.

Carefully and evenly loosen the spring compressors making sure that all components remain aligned.


FAULT

CODE

5KF

5KF

5KA

R.O. NUMBER

64.20.01

64.20.02

64.30.01

5KA 64.30.02

DESCRIPTION

Rear road spring-Renew

Rear road spring-Vehicle set-Renew

Rear Shock absorber absorber-Vehicle set-

Renew

Rear Shock absorber absorber-Renew

TIME

ALLOWANCE

1.25 hrs.

2.35 hrs.

2.35 hrs.

1.25 hrs.



Rear

V

Axle Shaft V ibr ation – Full y Laden ehicle – Install Longer Rear Springs


VIN as listed belo w

Some Sedan Range vehicles within the VIN ranges listed below may experience rear axle shaft vibration when the vehicle is fully laden or if the rear of the vehicle sits low.

MODEL

Sedan Range 1994 MY

VIN RANGE

VIN 696459 - 708757

Sedan (4.0L) Range 1995 MY VIN 720001 - 748670

Sedan (6.0L) Range 1995 MY VIN 720001 - 749481

Bulletin.

Longer rear suspension springs have entered production during the 1995 MY to overcome rear axle shaft vibration. Spring kits are available to correct this condition on earlier production vehicles in case of a customer complaint.

In case of a customer complaint of vibration on Sedan Range vehicles within the above VIN range when in a fully laden condition, perform the following procedure:

1.

Confirm the customer complaint by test driving the vehicle.

2.

Confirm that the condition is worse when a weight of approximately 440 lbs

(220 Kg) is carried in the luggage compartment.

3.

If the complaint is confirmed in steps 1 and 2, replace the rear suspension springs with longer springs. For replacement procedure, refer to Bulletin 64-

15 Date 8/94.



Rear spring kit

P AR

JLM 12257


F A U L T

1994 MY

1995 MY

GR BB FR

GR BB FR

64.20.02

64.20.02

Rear spring - vehicle set replace

Rear spring - vehicle set replace

1

A L L O W A N C E

2.35 hrs.

2.30 hrs.



Knocking Noise – Rear Subframe

Bushing – Modification Procedure

MODEL 1988-94 MY Sedan DATE 4/98

64-17

If a knocking noise is reported as coming from the rear suspension, it is possible that the bushing has moved out of location in the rear suspension subframe.

A CTION:

This bulletin provides a procedure for bonding in replacement subframe bushings in case of a customer complaint of a knocking noise from the rear suspension.

REPLACING/BONDING SUBFRAME BUSHINGS

1.

Remove the subframe from the vehicle.

2.

Press out the old bushings from the subframe and thoroughly clean the bores and the surrounding areas.

3.

Place the subframe on a bench and stretch a line or measuring tape through the centers of the two bores, as indicated in Illustration 1, to indicate the centerline.

CEN TERLINE OF REAR SUBFRAME BUSHING


JSI-3345

ILLUSTRATION 1


4.

Place small squares of masking tape on the top face of each bore, under the line or tape. Mark the centerline, with pen or pencil, on the masking tape.

through the center of the two voids in the bushing, as shown in

Illustration 1.

5.

Use a coarse grade of emery cloth to roughen the bore surface of the subframe and the corresponding outer surface of the replacement bushing. If the surface of the bushing is not roughened sufficiently this may affect the integrity of the adhesive bond.

At this point practice the procedure of installing the bushing to determine the relative positions of the subframe , bushing, support and press ram to ensure that when the installation process is begun, it is completed as quickly as possible.

6.

Place Service Tool JD 143A on the press bed to act as a support for the subframe during the operation to press in the bushing.

7.

In order to determine the starting position of the press ram, locate the subframe on JD 143A, place a spacer on the bushing to contact the outer flange. Position the bushing over the bore in the subframe. Lower the press ram until it is just possible to position the bushing between the ram and the subframe without the bushing entering the subframe. Once the press, tools and components are in position continue with the next step.

8.

Spray the subframe bore with the cleaning solvent, i.e. DuPont Prepsol, wipe clean with a suitable clean cloth and then spray the area again with the solvent and allow it to dry.

9.

Spray the face of the replacement bushing with solvent, wipe clean with a suitable clean cloth and then spray the area again with the solvent and allow it to dry.

TW O-P AR T EPO XY ADHESIVE

JSI-3278

ILLUSTRATION 2

10. Use a suitable 2 part epoxy such as Permatex Quick Set Auto Epoxy, part no

QM50A.


11. Apply approximately one half of the adhesive, i.e. half plunger travel, to a disposable surface and then cap the nozzles.

12. Use a suitable disposable spatula to thoroughly mix the two materials.

Higher air temperature will accelerate the curing and reduce the time available for the installation process.

13. Apply the adhesive over the area of the bushing, shown shaded in Illustration

3, and the bore in the subframe.

AREA T O APPL Y ADHESIVE

ILLUSTRATION 3

JSI-3184

14. Take the bushing to the press and, with the spacer in position on the bushing flange, place the bushing and spacer under the press ram and then align the bushing with the centerline mark.....

15. When the bushing is in position, quickly press the bushing in.

16. Wipe off all excess adhesive from the subframe and the bushing. Remove the masking tape.


GAP MUS T NO T EXCEED 1 .5 MM

JSI-3188

ILLUSTRATION 4

17. After the bushing has been inserted in the subframe, check for any clearance between the bushing flange and the subframe, (Illustration 4). If a gap is it must not exceed 1 .5 mm.

18. Repeat the operation for the other bushing.

4 hour s

P AR TS INFORMA TION

Subframe bushing, ‘Comfort’ specification

P AR T NUMBER

CCC 6875

Permatex Quick Set Auto Epoxy part no. QM50A obtain locally

Dupont Prepsol obtain locally


F A UL T

GM BK GC 64.91.06

Rear suspension subframe bushings - modify

ALL O W ANCE

2.40 hrs.



Ride Leveling Struts Stay at Maximum Height and/ or Pressure Relief Valve Cycles – Charge Valve

Blocked – Clean Hydraulic System/Install Filters

MODEL

Sedan Range 1988 - 1993 MY

DATE

1/94




66-22

AMENDED

9/94

ISSUE:

On 3.6 and 4.0 liter Sedan vehicles with ride leveling, the following conditions can occur:

• The rear struts rise to maximum height when the engine is started and remain fully extended until the engine is switched off.

• The power hydraulic pressure relief valve cycles continuously.

Either or both of these conditions can be caused by debris in the ride level system blocking the charge valve filter screen.

ACTION:

If either of the above conditions occur, confirm that the charge valve is the cause by disconnecting the solenoid valve electrical plug and starting the engine.

If the condition does not occur after the solenoid valves are disconnected, an electrical problem exists and this bulletin does not apply. For further diagnosis, refer to the Power Hydraulic System

Focus Book (S 73).

If the condition still occurs after the solenoid valves are disconnected, disassemble the solenoid valve block and replace the charge valve. Thoroughly clean the valve block and remaining valves(s) before reassembly. For valve block service information, refer to the Power Hydraulic

System Focus Book.

At the same time, perform the following procedure to install rear strut filters and clean and power hydraulic system.

There are procedures for three vehicle groups:

1.

1988/89 MY 3.6L Sedans.

2.

1990 to 1992 MY 4.0L Sedans (with combined reservoir for ride leveling and power steering systems).

3.

1993 MY 4.0L Sedans (with separate reservoir for ride leveling system).

Procedures:

NOTE: Use only approved Hydraulic System Mineral Oil when filling the power hydraulic/ride leveling reservoir.

1.

1988/89 MY 3.6L Sedans

• Install rear strut filters using the following procedure:

A. Remove both rear struts from the vehicle. Refer to XJ6 Service Manual section 66.20.01.


B. Perform the following work on each strut:

• Remove the coiled feed pipe and union nut from the top of the strut shaft.

• Remove the brass restrictor from the shaft.

• Insert a ride leveling strut filter (MMB 3435CA) to the shaft.

• Check that the hole in the brass restrictor is clear and the sealing surfaces are clean.

• Fit the restrictor into the shaft, against the filter.

• Install the coiled feed pipe and torque the union nut to 14.5 ft. lbs. (±2 ft. lbs.).

C. Fit the rear struts to the vehicle.

D. Bleed the ride leveling system using the procedure given at the end of this bulletin.

2.

1990-1992 MY 4.0L Sedans - with combined reservoir for ride leveling and power steering systems

• Install rear strut filters. Perform procedure 1, steps A through C.

• Drain the power hydraulic reservoir using the following procedure:

A. Remove the cap from the power hydraulic reservoir.

Disconnect the feed hose to the power steering pump inlet and drain the reservoir into a 2 quart waste container. Remove the reservoir from its mounts and tip it to fully drain the fluid. Discard the fluid.

B. Fit the reservoir cap. Cap off the power steering pump inlet stub pipe and feed hose to prevent dirt ingress.

• Install a new power hydraulic in-line filter using the following procedure:

A. Disconnect the ignition coil HT lead. Remove the bolts from the coil mounting strip and release the hydraulic feed hose "P" clip. Move the ignition coil rearward to provide access to the power hydraulic pump feed hose.

B. Disconnect the feed hose from the power hydraulic pump and drain the remaining fluid into the waste container. Discard the fluid.

C. Cap off the power hydraulic pump inlet stub pipe and feed hose to prevent dirt ingress.

D. Move the power hydraulic pump feed hose up to gain access to the in-line filter. Carefully remove the original filter. Do not damage the low pressure hose. Install a new filter, part number CBC 9538.

NOTE: The arrow on the new filter must point toward the hydraulic pump inlet.

E. Refit the power hydraulic reservoir to its mounts and position the feed hoses to their original locations.

F. Remove the protection caps and reconnect the feed hoses to the power steering pump and the power hydraulic pump.

G. Install the ignition coil mounting strap bolts with the hydraulic hose "P" clip on the inboard bolt and the ground wire eyelet on the outboard bolt. Connect the HT wire.

• Fill the reservoir with new fluid and install the cap.

• Start the engine and turn the steering wheel lock to lock twice to blend the power steering system.

• Bleed the ride leveling system using the procedure given at the end of this bulletin.

Page 2 of 4 Bulletin Number 66-22 AMENDED

3.

1993 MY 4.0L Sedans - with separate reservoir for ride leveling system

• Install rear strut filters. Perform procedure 1, steps A through C.

NOTE: Strut filters were introduced in production from approximate VIN 676400.

If charge valve blockage occurs on vehicles after VIN 676400, discard the existing strut filters and install new filters.

• Drain the ride leveling fluid reservoir using the following procedure:

A. Remove the ride levelling fluid reservoir from its mounts. Remove the cap from the reservoir. Disconnect the feed hose from the reservoir and drain the reservoir into a 2 quart waste container. Tip the reservoir to fully drain the fluid. Discard all fluid.

B. Reconnect the feed hose. Refit the reservoir to its mounts.

• Fill the reservoir with new hydraulic fluid and install the reservoir cap.

• Bleed the ride levelling system using the procedure given at the end of this bulletin.

ALL MODELS - Ride Leveling System Bleeding Procedure

• Drive the vehicle on a ramp (wheels must support the weight of the vehicle).

• Apply the parking brake and place the gear selector in P (park).

• Top-up the power hydraulic fluid reservoir.

• Start the engine and raise the ramp.

• Disconnect the ride height sensor link rod at the rear suspension right side lower wishbone.

• Raise the sensor link rod approximately 1 inch. The rear of the vehicle will rise after approximately 20 seconds.

• Switch off the engine when the "pulsing" is felt in the strut feed pipe.

• Remove the bleeder valve cover at the top of the left strut. Connect one end of the hose to the valve and place the other end in a waste container.

• Open the bleeder valve and allow fluid flow until the suspension lowers fully.

• Tighten the bleeder valve.

• Top-up the fluid reservoir.

• Start the engine and repeat the bleeding operation.

• Remove the bleed hose and refit the bleeder valve dust cover.

• Top-up the fluid reservoir.

• Start the engine

• Raise the rear suspension by moving the sensor link rod.

• When "pulsing" is felt in the strut feed pipe, reconnect the sensor link rod to the suspension wishbone. The vehicle will return to normal ride height after approximately 20 seconds.

• Lower the ramp and top-up the reservoir.


REPAIR POLICY:

On 1990-92 models with a low pressure hose filter, the filter must be removed carefully to prevent damage to the hose. The low pressure hose must not be changed unless it is leaking from the "Y" joint.

PARTS INFORMATION:

PART NUMBER

CBC 9701

MMB 3435CA

CBC 9538 (Req'd for 90 - 92 MY vehicles only)

JLM 9886

DESCRIPTION

Charge Valve

Strut Filters

In-Line Filter

HSMO - Bottles

QTY.

1

2

1

4


Charge valve blocked - Replace charge valve

Fault Code:

Repair Operation Number:

Time Allowance:

GT GP CB

66.30.18/09

0.70 hrs.

Install strut filters/clean hydraulic system

Repair Operation Number: 66.91.24

VIN RANGE

500001 to 594575

594576 to 667828

667829 - onwards

(88/89 MY)

(90 thru 92 MY)

(93 MY)

TIME ALLOWANCE

1.90 hrs.

2.55 hrs.

2.05 hrs.

WARRANTY POLICY:

Low pressure hoses that are changed for leaking must be returned to Jaguar Cars for inspection.

Hoses that are not leaking will be debited from the warranty claim.

Page 4 of 4 Bulletin Number 66-22 AMENDED


Ne w Br ake Fluid Specification –

Super DO T 4

MODEL Sedan Range VIN 754304 - ON

XJS Range VIN 223045 - ON

All vehicles beginning with the above VINs use Super DOT 4 brake fluid. This brake fluid has been specially formulated to eliminate possible discoloration that may occur between normal service intervals. The supplier was aware that the brake fluid could change color in service and developed this brake fluid to avoid unnecessary customer concern.

above VIN numbers. Regular DOT 4 should not be used since discoloration may occur. Any other brake fluids (DOT 3 or DOT 5)

Super DOT 4 may be used in any previous Jaguar vehicle.


Super DOT 4 Brake Fluid

P AR

MNA 7829AC 1 liter


TECHNIC AL BULLETIN ont Br ake Rattle – Disc Shield –

Install Ne w Retaining Scr ee ws


Some 1994 - 95 MY Sedan Range vehicles within the above VIN range may experience a noise from the front brake area.

The noise is caused by loosening of the Torx screws that secure the brake disc shield and the water shield to the stub axle, allowing the shields to vibrate.

New screws are now available to solve this complaint.

In case of a customer complaint remove the hub assembly as described in Section

70.10.18 of the XJ6 - XJ12 Saloon Range Service Manual. Remove and discard the old screws. Install the new screws listed in the Parts Information and torque to 7.4 - 8.8 lb. ft. (10 -12 Nm.) with a new one using Special Tool JD 179.

The seal face that contacts the hub must be coated with a special lubricant (Shell Retinex LC). Thoroughly clean all traces of the previous lubricant from the hub.


ILLUSTRATION 1

Date of issue 12/95

JSI-2638

Page 1 of 2


Torx screw

Hub seal

P AR

JXB 10610F/P

CBC 2858


F A U L T

GH FC HR 60.91.10

10.10.10

Install replacement screws

Drive in/out

A L L O W A N C E

1.70 hrs.

0.15 hrs.

6

2



A.B.S. Valve Block Assembly –

Replace Separately

MODEL 1990-94 MY Sedan Range

XJS up to VIN 198334

DATE 1/98

70-27

An A.B.S. Valve Block repair kit is available to avoid the need to replace the complete brake actuator unit.

A CTION:

If diagnosis on the above vehicles indicates problems within the A.B.S. Valve

Block, install a valve block repair kit as follows, instead of replacing the complete brake actuator unit:

1.

Remove the Brake Actuator assembly, as detailed in the appropriate Workshop

Manual, Section 70, SRO 70-60-06.

2.

Insert plugs in any disconnected pipes and ports.

CA UTION: following operations.

3.

Empty and discard any remaining brake fluid from the actuator unit.

V AL VE BL OCK RET

JSI-3338

JSI-3338

ILLUSTRATION 1

4.

Remove the 3 nuts (arrowed in Illustration 1) that retain the valve block to the


O-RING L OCA TIONS

JSI-3339

JSI-3339

ILLUSTRATION 2 actuator body to remove the valve block. Discard the 4 O-ring seals arrowed in Illustration 2.

5.

Using a lint-free cloth, clean the faces of the actuator unit and the replacement valve block.

6.

Lubricate the four (4) O-ring seals provided in the kit with brake fluid, and locate them in the four (4) recesses arrowed in Illustration 2.

7.

Hold the actuator and valve block as illustrated, to keep the four (4) O-rings from shifting, and position the replacement valve block on the studs and push it into firm contact with the actuator unit.

af ter verifying that the O-rings are cor rectly located.

8.

Reinstall the remaining 2 nuts, and fully tighten all three to 25 Nm (18 lb.ft).

9.

Reinstall the complete actuator assembly to the vehicle, as detailed in the appropriate Workshop Manual , Section 70, SRO 70-60-06, including refilling and bleeding the brake system.

NO TE: the future, clamp the brake line and open the bleeder valve when pushing the piston back during pad replacement.



Valve block repair kit, Sedan 1990-94

Valve block repair kit, XJS

P AR T NUMBER

JLM 11336

JLM 11337


F A UL T

HD DB ** 70.60.27.09

A.B.S. Valve block -replace

Sedan VIN 593884-667828


Sedan VIN 667829-708757


XJS VIN up to 198334

1

1

ALL O W ANCE

1.50 hrs.

1.60 hrs.

1.35 hrs.



Brake Pedal Switch –

Parts Inventory Simplified

MODEL 1993-94 MY Sedan

1995-96 MY XJS

DATE 4/98



70-28

Amended

11/98

The brake pedal switch assembly used on 1998 MY vehicles is now the only switch available for the above vehicles (Illustration 1).

A CTION:

The current brake pedal switch assembly, as listed on the next page, must be installed if replacement of the switch is necessary. An adapter harness, also listed on the next page, is required to connect the switch to the harness of the above

Sedan vehicles. Any excess harness length should be coiled and taped securely in place.

BRAKE PED AL SWITCHES

SEDAN XJS


ILLUSTRATION 1



Brake pedal switch 1995-96 MY XJS

VIN 198335-226645

Brak e pedal switc h 1 993-94 MY S edan

Link harness assembly 1993-94 MY Sedan

P AR T NUMBER

LJB 6420BA

LNB 3022AA


F A UL T

QN FB 28 86.65.51

86.99.97

Replace brake light switch

Connect PDU/download capture/printout

1

1

ALL O W ANCE

0.25 hrs.

0.15 hrs

0.30 hr s.



Front Seat Belt Height Adjuster – Rattles –


MODEL

Sedan Range with Active Seat Belts

DATE 7/94

To: VIN 683548

76-92

ISSUE:

Front Seat Belt Height Adjusters may rattle on Sedan Range vehicles with active (not passive) seat belts up to VIN 683548.

A change in production at VIN 683548 eliminated this problem.

ACTION:

If customers complain of rattles from the front seat belt height adjusters, perform the following operation.

1. Adjust the front seat for maximum clearance to the seat belt height adjuster.

1. Record all customer preset radio stations (including X-mem) and disconnect the negative cable of the battery.

2. Remove the upper seat belt anchor retaining nut cover, retaining nut, and anchor plate. Discard the wavy washer.

3. Remove the seat belt opening bezel. Pull out the door opening edge trim at the bottom of the

“B-C” post upper trim pad just enough to clear the upper trim pad clip.

4. Pull the upper trim pad down to release the clips. Then, carefully place it on the seat.

5. Remove the height adjuster trim. It is held in place with an adhesive pad.

6. Remove the paper backing from a new foam washer (P/N KZS 100002) and press the washer over the seat belt anchor stud (Illustration 1).

FRONT SEAT BELT HEIGHT ADJUSTER

SEAT BELT ANCHOR

RETAINING NUT AND COVER

SEAT BELT

ANCHOR STUD

UPPER TRIM PAD

FOAM WASHER

SEAT BELT OPENING

BEZEL

76-92.1

ILLUSTRATION 1


7. Remove the height adjuster adhesive pad (Illustration 2) and replace with a new one (P/N

BEC 21458).

8. Reinstall the height adjuster trim after removing the backing paper from the adhesive pad.

9. Install two pieces of anti-squeak tape (P/N JLM 11558) as shown in Illustration 3.

HEIGHT ADJUSTER TRIM

(BACK)

UPPER TRIM PAD

(BACK)

ADHESIVE PAD

ANTI-SQUEAK TAPE

ILLUSTRATION 2

76-92.2

76-92.3

10. Slide the upper trim pad up under its retaining clips, fit and smooth out the door opening edge trim.

11. Fit the upper seat belt anchor plate and install the original retaining nut. Make sure the seat belt anchor plate is free to rotate.

12. Snap on the retaining nut cover and seat belt bezel.

13. Repeat procedure for the other front seat belt.

14. Connect the ground cable of the battery, program preset radio stations, and reset the clock.


NOTE: Repairs may be made only on a customer complaint basis.

FAULT

CODE

8WD

8WC

R.O. NUMBER

76.92.35

76.92.36

DESCRIPTION

Adjustable anchorage, “B/C” post Left

Adjustable anchorage, “B/C” post Right

TIME

ALLOWANCE

0.15 hrs.

0.15 hrs.

PARTS INFORMATION:

DESCRIPTION

Foam washer

Anti-squeak tape

Adhesive pad

PART NUMBER

KZS 100002

JLM 11558

BEC 21485

QTY/VEHICLE

2

4

2


ILLUSTRATION 3


Convertible Top – Outer Cloth Cover/

Interior Headliner – Replacement

MODEL

XJS Convertible

DATE

8/94

76-93

ISSUE:

The convertible top Outer Cloth Cover and Interior Headliner are available as separate assemblies.

Do not replace the complete convertible top assembly if the fault is with either the Outer Cloth

Cover or the Interior Headliner.

NOTE: The Outer Cloth Cover should be used when the fault is the outer cover. The Interior Headliner should be used when the fault is the headliner.

A detachable headliner was introduced at VIN 189293. Additional parts are required to replace the Interior Headliner of vehicles before VIN 189293. Refer to “PARTS INFORMATION” below for details.

ACTION:

If repairs are required to convertible tops, replace only those components required to repair the fault. Refer to Service Manual section 76.86 for repair procedures.

PARTS INFORMATION:

Outer Cloth Replacement: All

DESCRIPTION

Outer Cloth Cover or or or

Rivet 1/8”

Washer (for rivet)

Header Rail Seal

PART NUMBER

BEC 20452/ANR-Beige

BEC 20452/ANF-Brown

BEC 20452/JFF-Blue

BEC 20452/PDM-Black

RA 608313/J

WC 704061/J

BEC 25501

QTY

4

4

1

1

1

1

1


Interior Headliner Replacement: Vehicles BEFORE VIN 189293

DESCRIPTION

First Bow-Red

Second Bow-Yellow

Main Bow-Blue

Screw, Self Tapping

Screw

Cup Washer

Velcro Strip

Foam Seal

PART NUMBER

BEC 17160

BEC 17161

BEC 17162

AC 606044/J

AD 608033/J

WK 60821/J

BBC 1635

BBC 8265

ALSO: One roll double sided adhesive tape 1/2” wide. Obtain locally.

Interior Headliner Replacement: Vehicles AFTER VIN189293

QTY

2

2

19

2

5

1

1

1

DESCRIPTION

Interior Headliner or

PART NUMBER

BEC 17245/LDY-Grey

BEC 17245/AEE-Doeskin

QTY

1

1

WARRANTY POLICY:

Warranty claims for convertible tops and headliners are only accepted for factory defects in material or workmanship. The following are not covered under warranty:

• Stains or blemishes resulting from environmental fall-out, lack of maintenance, or customer abuse.

• Physical damage resulting from vandalism, lack of maintenance, or customer abuse.


FAULT

CODE

9UQ

9UR

R.O. NUMBER

76.86.12

76.86.11

DESCRIPTION

Convertible top outer fabric - Renew

Headliner (Original with detachable) - Replace

TIME

ALLOWANCE

4.90 hrs.

2.30 hrs.



Wind Noise Around Windshield –


76-94


DATE 10/94

From: VIN 687219

To: VIN 704115

ISSUE:

Wind noise around the windshield dependant on vehicle speed, wind strength and wind direction.

This noise is caused by the vibration of the outer edge of the windshield finisher retaining rubber.

ACTION:

If customers complain of wind noise symptoms from the windshield area, apply sealant under the outer edges of the windshield finisher retaining rubber.

WINDSHIELD FINISHER RETAINING RUBBER SEALING PROCEDURE:

1.

Inspect the underside of the windshield finisher retaining rubber to be sure it is clean and dry.

2.

Apply masking tape to protect the retaining rubber in the area to be sealed

(Illustration 1).

WINDSHIELD

AREA

TO BE

SEAL

ED

ILLUSTRATION 1

76-94.1


3.

Apply a bead of 3M Windo Weld Primerless Superfast Urethane sealer (3M number 08609) under the outer edge of the retaining rubber (Illustration 2).

SECTION THROUGH WINDSHIELD FINISHER

RETAINING RUBBER

SEALER

RETAINING RUBBER

BODY

WINDSHIELD

76-94.2

ILLUSTRATION 2

4.

Clean any excess sealant from the retaining rubber and body using 3M General Purpose

Adhesive Cleaner (3M number 051135-08984) or equivilant and remove the masking tape.

PARTS INFORMATION:

Source locally:

3M Windo Weld Primerless Superfast Urethane sealer (3M number 08609)

3M General Purpose Adhesive Cleaner (3M number 051135-08984)


FAULT

CODE

R.O. NUMBER

VD CB QZ 76.92.55

DESCRIPTION

Windshield wind noise modification

TIME

ALLOWANCE

0.40 hrs.



Hood Panel – Difficult To Latch – Revised Latch and Hood Release Lever Guard Introduced –


MODEL XJS Range 1994 - 1995 MY

DATE 11/94

From: VIN 190528

To: VIN 196254

76-96

ISSUE:

Difficulty in latching the “slam shut” hood on XJS vehicles from VIN 190528 to 196254.

This condition is caused by friction in the latch pawl pivots.

Latches are now lubricated and revised latch back plates (cable end retaining brackets) are installed in production beginning with VIN 196255.

The revised latch back plate accomplishes the following:

• Prevents the latch pawl from going over center

• Increases the pawl return spring pressure to aid hood “pop-up” when the hood is released.

To prevent inadvertent operation of the hood release, a release lever guard was introduced in production at VIN 194776.

NOTE: This Service Action is to be implemented with Service Action S447 described in Service Bulletin 84-11.

ACTION:

At the next service opportunity on all 1994 - 1995 MY XJS vehicles, perform the service action procedures as described below.

VIN 190528 - 194775

• Fit hood release lever guard

• Fit revised latch back plates and lubricate hood latch pawl pivots

• Perform Service Action S447 as described in Service Bulletin 84-11

VIN194776 - 196046

• Fit revised hood latch back plates and lubricate hood latch pawl pivots

• Perform Service Action S447 as described in Service Bulletin 84-11

VIN 196048 - 196254

• Fit revised hood latch back plates and lubricate hood latch pawl pivots

IMPORTANT: VIN 186000 - 194774 (4.0L) - Ensure that the automatic transmission tie strap securing the upper and lower transmission hoses behind the radiator has been removed as described in Technical Bulletin 44-22.


FITTING HOOD RELEASE LEVER GUARD:

1.

Remove the lower bolt of the hood release lever.

2.

Align the guard as shown in Illustration 1 and replace the lower bolt.

HOOD RELEASE GUARD

HOOD RELEASE GUARD

LOWER BOLT BEHIND RELEASE

LEVER

ILLUSTRATION 1

76-96.1

FITTING LATCH BACK PLATES:

1.

Mark the position of both hood latches on the engine compartment bulkhead.

2.

Remove the two bolts holding the left side latch assembly to the bulkhead ( Illustration 2 ).

3.

Free the release cable from the latch back plate, then remove and discard the back plate.

LEFT SIDE HOOD LATCH ASSEMBLY

BOLT

LATCH BACK

PLATE

BOLT


FREE CABLE

ILLUSTRATION 2

76-96.2

4.

Place the new latch back plate behind the latch in the position shown in Illustration 3. Insert the left side bolt through the back plate to use as a pivot.

5.

Rotate the right side of the latch down to “wind up” the latch spring and insert the right side bolt.

INSTALLING LATCH BACK PLATE

LEFT SIDE

BOLT

ROTATE

LATCH DOWN

ILLUSTRATION 3

76-96.3

6.

Insert the hood release cables into the slots in the latch back plate.

7.

Align the latch assembly to the marks on the bulkhead and tighten the mounting bolts.

8.

Repeat steps number 2 through 7 for the right side latch assembly.

9.

Grease the latch pawl springs and the pivot points on both latches with multipurpose grease.

10.

Loosen the release cable clamp bolts on both latches. Pull the cable end of the right latch to remove any cable slack, release the cable. Tighten the right side cable clamp bolt first, then tighten the left hand cable clamp bolt.

11.

Place body putty or “dumdum” on both latches as shown in Illustration 4.

12.

Move the hood down until both hood pins make impressions in the putty. The hood pin impressions must be in the center of the latch cutouts (Illustration 4). If necessary, move the latch assembly left or right to center the latch cutout to the hood pin.

CENTERING LATCHES

HOOD PIN IMPRESSION IN

PUTTY

LATCH CUT OUT CENTER

ILLUSTRATION 4

76-96.4


13.

Close the hood. The corners of the hood must be flush with the adjoining bodywork. Move the latch assemblies up or down to align the hood.

14. Open and close the hood to confirm latch adjustment and operation.

PARTS INFORMATION:

PART NUMBER

HHE 2417AA

QTY

2

VIN RANGE

190528 - 196254

DESCRIPTION

Hood latch back plate

(Cable end retaining bracket)

Hood release lever guard 190528 - 194775


Service Action S448

HHD 2573AA 1

VEHICLE

XJS Range 1994-95 MY

VIN 190528 - 194775


VIN 194776 - 196047


VIN 196047 - 196254

SUMMARY

CODE

DQ

DR

DS

DESCRIPTION

TIME

ALLOWANC

E

0.40 hrs.

Replace latch back plates/fit guard to hood release lever. (No drive in/out time. To be performed concurrently with Service Action S447)

Replace latch back plates only. (No drive in/out time.

To be performed concurrently with Service Action

S447)

Replace latch back plates only.

(Includes drive in/out time.)

0.40 hrs.

0.55 hrs.


Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the labor time allowance and parts as indicated.

DCS Dealers


Non-DCS Dealers





Hood Liner – Modification –


MODEL XJ12 1994 MY

VIN 673299 – 704778

DATE 3/95

76-105

ISSUE:

Hood liners may sag causing an unsightly engine bay appearance and abrasion to the liner.

ACTION:

Modify the hood liners of all XJ12 vehicles from VIN 673299 - 704778 at the next service opportunity.

HOOD LINER MODIFICATION PROCEDURE:

1.

Remove the hood liner from the vehicle by removing the 13 expander screws from the hood liner rivet screw assemblies.

2.

Examine the liner for signs of abrasion.

• If there is no evidence of abrasion, modify the existing liner and reinstall.

• If there is evidence of abrasion, replace the hood liner. Modify the new liner before installation.

IMPORTANT: If a new hood liner is installed, the warning plate on the existing hood liner MUST be transferred to the new hood liner.

NOTE: Hood liners with cutouts for under hood lights are not available from parts.

Vehicles originally equipped with under hood lights (VIN 673299 - 678751) will require the following modification to the replacement hood liner to accommodate the lights.

Place the old liner over the replacement liner and trace the outlines of the under hood light cutouts on the replacement liner.

With a sharp utility knife, cut out the holes for the under hood lights.

3.

Place the liner face up on a bench with a piece of wood between the bench and hood liner.


4.

Mark the liner for two new 5/16" (8mm) holes, A and B (Illustration 1).

HOOD LINER DRILLING DIMENSIONS

A

7 mm

REFERENCE

HOLE

B

203mm

45mm

8/23.3.1

ILLUSTRATION 1

5.

With a “wad punch” or similar tool, punch two, clean, 5/16" (8mm) holes as indicated.

HOLE PUNCH

8/23.3.2

ILLUSTRATION 2

6.

Temporarily fit the liner to the hood using seven of the rivet screws along the top edge and around the two new holes. The liner must be in its normal position.

7.

Mark the hood frame at the center of the two new holes and remove the hood liner.

IMPORTANT: The centers of the new holes must be on the hood inner frame.

8.

Set the centers of the two new holes with a center punch.

Bulletin Number 76-105 Page 2 of 4 Date of issue 3/95

9.

Fit a drill stop or a length of hose on a 15/64" (6mm) drill bit to control the hole depth to approximately 3/16" (5mm).

CAUTION: The drill must be controlled so that the drill bit cannot contact the inner side of the hood panel.

DRILL STOP

8/23.3.3

ILLUSTRATION 3

10.

Drill the two new 15/64" (6mm) holes. Deburr the holes and paint any bare metal with a zinc-rich anti corrosive paint.

11.

Install the hood liner starting along the top edge. Maintain proper alignment to ensure that no sagging occurs as the rivet screw assemblies are installed. Install two new rivet screws in the new holes.

PARTS INFORMATION:

DESCRIPTION

Hood liner

Rivet screw assembly

PART NUMBER

GMB 9340AA

KRS 113130

QTY

1

2



Service Action S437

VEHICLE

XJ12 1994 MY

VIN 673299 - 704778

XJ12 1994 MY

VIN 673299 - 678751

XJ12 1994 MY

VIN 678752 - 704778

SUMMARY

CODE

EM

DESCRIPTION

Drill hood liner and fit additional fixings

EN

EP

TIME

ALLOWANCE

0.50 hrs.

Drill and replace hood liner and fit additional fixings - Vehicles with 2 under hood lamps

Drill and replace hood liner and fit additional fixings - Vehicles without under hood lamps

0.50 hrs.

0.50 hrs.

NOTE: No allowance is provided for drive in/out time. Service Action S437 is to be performed in the course of a service visit.



DCS Dealers


Non-DCS Dealers





Re vised Underscuttle – Re vised Mounting

Replacement underscuttle panels have only 3 “fir tree” fasteners and do not fit directly in place of the previous panel with 5 “fir tree” fasteners.

To install the revised replacement part in place of the original design, proceed as follows:

1.

After removing screws, use dash liner tool # JD 188 to remove the underscuttle from the vehicle.

2.

Remove the reinforcement panel.

3.

Remove and discard the two captive nuts indicated in Illustration 1.

EARL Y S TYLE MOUN TING METHOD

REINFORCEMEN T P ANEL


ILLUSTRATION 1


T P ANEL

NEW RET AINERS T O BE INSER TED

P ANEL MOUN

ILLUSTRATION 2

4.

Insert the two new female fir tree retainers (AGU 2522/J) in place of the two captive nuts on the brace as indicated in Illustration 2. (Replace the third female fir tree retainer, if necessary)

5.

Secure the reinforcement panel onto under-dash brace using the remaining screws at the lower left and upper right, Illustration 2.

6.

Secure the new underscuttle panel (BEC 23962/*) to the vehicle.


Underscuttle

Fir tree fastener

Stud retainer (female)


P AR

BEC 23962/*

KTP 100002

AGU 2522/J



Hood P anel – Difficult to Latc

Plenum Grille – Repr h/Contacts ofile Hood

MODEL XJS Range 1994-95 MY

Some XJS Range vehicles within the above VIN range may exhibit hoods that are difficult to latch on both sides and/or contact the plenum chamber grille.

Repeated pressing and slamming of the hood flattens the curvature of the hood causing contact with the grille. The flattening of the hood also causes the striker pins to move apart in relation to each other, make it more difficult to engage both latches.

In case of a customer complaint of difficulty in closing the hood on a vehicle

If so, perform the following repair:

1.

Remove and discard the rear bulkhead to hood seal, Illustration 1.


JSI-2424

ILLUSTRATION 1


TREE F A S TENER

JSI-2421

ILLUSTRATION 2

2.

Remove and discard the hood stop buffers, mounting bolts, nuts, and washers. Apply a suitable sealer to the bolt holes and install fir tree fasteners,

Illustration 2.

3.

Cut two new hood seals to size and install on the engine compartment rear bulkhead ensuring that the joint of the seals is at the center line of the hood.


APPL Y PRESSURE

APPL Y PRESSURE

JSI 2475

ILLUSTRATION 3

4.

Obtain a suitable block of wood, Illustration 3, which will fit in the space between the bulkhead lip and the front edge of the plenum chamber. The block must be deep enough to rest on the drain channel and protrude above both edges. The block should be as long as the plenum grille to spread out the load.

5.

Wrap the block with adhesive tape to prevent damage to the paint during the next operation.

6.

Place the covered wooden block between the bulkhead and the plenum chamber on the car center line.

7.

Insert a suitable smooth object which will not damage the paint or the panel, such as a rubber mallet, between the hood panel and the wooden block to support the hood at a height of approximately 3 in. (7.5 cm), Illustration 3.

8.

Apply pressure to the areas over the striker pins, Illustration 3, to modify the hood curvature and raise the center of the hood panel in relation to the sides.


JSI-2425

ILLUSTRATION 4

9.

Check the fit of the hood to the body at the center, the plenum grille,

(Illustration 4) and both outer edges.

10. Repeat the process until the hood profile matches the body profile.


JSI-2420

ILLUSTRATION 5

11. Loosen the nuts that secure the hood striker pins (Illustration 5) to allow some movement when the hood is closed.

12. Close the hood to check where the catches require adjustment.

13. Open the hood. Loosen the hood catch retaining bolts, reposition the catch assemblies and tighten the retaining bolts.

14. Check the hood position and tighten the striker pin mounting nuts.

15. Check striker and catch operation.


Hood seal

Fir tree fastener


F A U L T

WB BC JC 76.92.73

Reprofile hood

P AR

HHC 5242AA

BBC 7525LEG

A L L O W A N C E

0.60 hrs.

2

2


TECHNIC AL BULLETIN ont Seat Belts –

T

T oo Short and/or wisting – Repair Pr ocedur ee

MODEL XJS Conv ertible 2+2 F

New front seat belt assemblies have been introduced in production on XJS 2+2 convertibles as of VIN 198712. These assemblies address customer complaints that the original seat belts were too short and/or became twisted.

The new design prevents the belt from twisting and has a 200 mm longer belt.

In case of a customer complaint on XJS 2+2 Convertibles within the above VIN range, that the front seat belts are too short or become twisted, install the new style assemblies as follows:

1.

Apply the hand brake, select Park or Neutral on automatic transmissions or neutral on manual transmissions, release the convertible top catches, turn the ignition to position II, and lower the convertible top.

2.

Move both front seats into the fully forward position for better access. Turn the ignition off.

3.

After removing the rear seat cushion securing nuts, reposition the seat belt buckles through the cushion and remove the cushion.

4.

Remove the rear seat squab.

5.

Remove the sill tread plate.

6.

Remove the rear quarter trim assembly.

7.

Disconnect the speaker and interior lamp connectors.

8.

Reposition the carpet edge adjacent to the seat belt lower anchorage bar.

9.

Slide the seat belt off the lower anchorage rail and through the opening in the trim assembly.

10. Remove the upper anchorage bolt and the retractor bolt. Remove the seat belt assembly.


A N TI-RO T A

AN TI-RO T A TION PLA TE

J76-1205

ILLUSTRATION 1

11. Remove and discard the anti-rotation plate from the top of the B post

(Illustration 1).

belt assembly.

12. Install the rub strip edge finisher into the opening in the B post and over the insulation (Illustration 2).


ILLUSTRATION 2

J76-1206


RIGHT FRON T SEA T BEL T A SSEMBL Y INS T ALLED

J76-1207

ILLUSTRATION 3

13. Install the new seat belt retractor unit and torque the bolt to 22.1 - 29.5 lb ft

(30 - 40 Nm).

14. Position the seat belt through the trim panel opening and over the lower securing rail (Illustration 3). Torque the securing bolt to 22.1 - 29.5 lb ft (30 -

40 Nm).

15. Reposition the carpet.

16. Reconnect the speaker and the interior lamp.

17. Reinstall the rear trim panel.

18. Install the sill tread plate.

19. Repeat the procedure for the opposite side seat belt assembly.

20. Install the rear seat squab.

21. Pass the seat belt buckles through the rear seat cushion and install the cushion.

22. Turn the ignition to position II and raise the convertible top.

23. Close the convertible top latches.

24. Return the front seats to their original positions.



P AR

HHE 7004AA /AEE - Doeskin

/AEM - Magnolia

/AFW - Barley

/HEZ - Parchment

/LDY - Saville Grey

/LEG - Warm Charcoal

/AGD - Oatmeal

/LFJ Nimbus Grey

HHE 7005AA /AEE - Doeskin

/AEM - Magnolia

/AFW - Barley

/HEZ - Parchment

/LDY - Saville Grey

/LEG - Warm Charcoal

/AGD - Oatmeal

/LFJ Nimbus Grey

HHE 7155AA

Right side Seat Belt Assembly

Left side Seat Belt Assembly

Edge finisher


F A U L T

TG BC VH 76.92.82

Front seatbelt

- vehicle setreplace/modify

A L L O W A N C E

0.50 hrs.

1

1

2



P aint Colors – Codes –

Du P ont Stoc k Numbers

MODEL All 1995 - 1996 MY

The paint colors for 1995 and 1996 are listed below with cross reference to DuPont stock numbers. The chart below lists the colors by name while the chart on page

2 lists the colors by paint code.

Black

British Racing Green

Carnival Red

Flamenco Red

Glacier White

Ice Blue

Jade Green

Kingfisher Blue

Morocco Red

Nautilus

Rose Bronze

Sapphire

Signal Red

Silver Frost

Spindrift White

Spruce

Steel Grey

Titanium

Topaz

Turquoise

Westminster Blue

Y ear

1995-96

1995-96

1996

1995

1995

1995-96

1995-96

1995-96

1995-96

1996

1995

1995-96

1995-96

1995

1996

1996

1995

1995-96

1995-96

1995-96

1995

PDT

HFB

CFS

CFH

NDP

MDP

HEV

HFE

CFG

PDV

SDL

JGE

CFC

MDK

NDM

HFL

LEV

LFA

SDN

UDB

JFG

807

753

811

765

742

821

735

779

778

824

795

806

748

750

731

823

783

810

820

827

712

H9917

L9349

F1407

N9339

H9051

W9881

K9299

K9391

K9390

F1655

H9831

F0669

G8930

L9201

F1721

F1720

F0668

L9858

F0030

F1013

N8669


Code Y ear

CFC 1995-96

CFG

CFH

1995-96

1995

CFS

HEV

HFB

HFE

1996

1995-96

1995-96

1995-96

HFL

JFG

JGE

LEV

1996

1995

1995-96

1995

LFA 1995-96

MDK 1995

MDP 1995-96

NDM 1996

NDP 1995

PDT 1995-96

PDV

SDL

1996

1995

SDN 1995-96

UDB 1995-96

Signal Red

Morocco Red

Flamenco Red

Carnival Red

Jade Green

British Racing Green

Kingfisher Blue

Spruce

Westminster Blue

Sapphire

Steel Grey

Titanium

Silver Frost

Ice Blue

Spindrift White

Glacier White

Black

Nautilus

Rose Bronze

Topaz

Turquoise

712

806

783

810

750

821

731

742

807

824

795

820

827

748

778

765

811

735

753

779

823

G8930

K9390

N9339

F1407

K9299

L9349

K9391

F1720

N8669

F0669

F0668

L9858

L9201

W9881

F1721

H9051

H9917

F1655

H9831

F0030

F1013


TECHNIC AL BULLETIN ont Seat Belt T wisting –

Install Seat Belt Guides

MODEL XJS Conv ertible, 2+2 1994-96 MY

Technical Bulletin 76-110 described the installation of revised seat belt assemblies in case of customer complaints of belt shortness and/or twisting of the original seat belts. The longer belt was installed in production starting with VIN 198712.

Starting with VIN 224736, a seat belt guide is also installed at the top of the B post, to further resist any tendency of the belt to twist.

The seat belt guide is now available for installation together with the longer seat belts or as a modification to the longer seat belts on vehicles before VIN 224736.

In case of a customer complaint of seat belt twisting, install the seat belt guide as described on the next page. To determine whether the longer seat belt assembly is already installed in the vehicle, check for the differences shown in Illustration 1.

If the longer seat belt assemblies also need to be installed, refer to bulletin 76-110

Amended 3/96 for the installation procedure.

IDEN TIFICA TION OF CONVER TIBLE SEA T BEL T A SSEMBLIES

TYLE BEL T NEW S TYLE BEL T

PLA TE WITH SL O T

P L A TE

BEL T EXITS REEL A T T OP


BEL T EXITS REEL A T SIDE

ILLUSTRATION 1


SEA T BEL T GUIDE

Q UAR WINDO W GLA S S

SEA T BEL T GUIDE

ADHESIVE P ADS

JSI-2703

ILLUSTRATION 2

INSTALLING SEAT BELT GUIDES

1.

After lowering the convertible top, move the front seats forward to provide access. Switch off the ignition.

2.

Remove the screws retaining the rear seat cushion, pull the seat belt buckles through the cushion and then remove the cushion.

3.

Remove the screws retaining the rear seat squab and then remove the squab.

4.

Carefully remove the sill tread plate to release the quarter trim pad.

tread plate is not removed first.

5.

Carefully remove the fir tree fastener from the outboard side of the quarter trim using supporting material to protect the trim facing.

6.

Loosen the rear quarter trim to allow access to the upper part of the B post.

7.

Detach the plastic water deflector from the B post to expose the area where the belt guide will be installed.

8.

Clean the area thoroughly to ensure that the guide will adhere to the post.

9.

Remove the backing tape from the adhesive pad. Hold the seat belt to one side, align the guide with the access hole in the post (Illustration 2), and press the guide firmly into position.


10. Place the water deflector in position and mark where the deflector overlaps the belt guide. Cut away the deflector material as necessary to clear the belt guide (angled arrow, Illustration 2). Press the deflector firmly into position.

11. Reattach the rear quarter trim.

12. Reinstall the sill tread plate.

13. Repeat steps 5 through 13 on the opposite side of the vehicle.

14. Reinstall the rear seat squab with its retaining screws.

15. Push the seat belt buckles through the cushion and reinstall the rear seat cushion with its retaining screws.

16. Return the front seats to their original positions.


Seat Belt Guide


F A U L T

TG BC VH

TG HC VH

TG BC VH

TG HC VH

76.93.07

76.93.07

76.92.82

76.92.82

10.10.10

Install seat belt guide driver side

Install seat belt guide passenger side

Install long seat belts & seat belt guides driver side

Install long seat belts & seat belt guides passenger side

Drive in/drive out

P AR

HHF 7155AA

A L L O W A N C E

0.55 hrs.

0.55 hrs.

0.55 hrs.

0.55 hrs.

0.15 hrs.

2



Interior Trim/Convertible Top Cleaning –

Recommended Products & Procedures

MODEL Sedan Range 1988-94 MY

XJS Range

DATE 7/96

76-121

Damage to vehicle interior trim can result if Jaguar-recommended products and procedures are not used.

A CTION:

Ensure that dealer staff are fully aware of the recommended products and procedures for the preparation and cleaning of vehicle cloth and leathers.

Make subcontractor personnel aware of the recommended products and procedures by supplying them a copy of this bulletin to ensure that Jaguar standards are met.

Refer customers to the owner’s handbook for proper care and maintenance of trim.

Observe the following product and procedures grouped by material and application.

CL O

CONVERTIBLE TOP

Products: Fabric Soft Top Cleaner JLM 11333

Cellulose sponge

Polishing cloth

JLM 9878

JLM 9877

Procedure:

• Do not perform this procedure with the vehicle in bright sunlight.

• Thoroughly wash the affected area of the top with clean water. Apply the soft top cleaner to the area using a sponge or absorbent cloth.

• Always use a clean white cloth since dyed materials may leave their color on the affected area. Change the area of the cloth being used frequently, to avoid reapplying dirt to the convertible top. Spread the cleaner evenly over the area and let it soak in for 3 minutes.

• Brush the affected area with a soft brush to remove the dirt. Brush in one direction only to minimize the disturbance of the fabric.

• Thoroughly wash the area with clean water to remove all traces of the soft top cleaner. Wash the vehicle bodywork to remove any runoff of cleaner.


• Soft top cleaner must immediately be washed off any painted surfaces that it may contact.

W ARNING: J aguar S of t top cleaner must be k ept aw ay from c hildren. If the cleaner comes into contact with skin or eyes, w ash thoroughly with clean running w ater . If sw allowed, seek medical at tention.

HEADLINER, UPHOLSTERY, TRIM & CARPETS:

Products: Jaguar Upholstery Cleaner JLM 9870

Cellulose sponge

Polishing cloth

JLM 9878

JLM 9877

Procedure:

Headlining preparation:

The headliner should be lightly brushed with a soft bristle brush and vacuum cleaned regularly to remove any dust from the fabric.

Upholstery and Trim - preparation:

The upholstery and trim should be lightly brushed with a soft bristle brush and vacuum cleaned regularly to remove any dust from the fabric.

Carpets - preparation:

Carpets should be brushed and vacuum cleaned regularly to remove any dust and grit. Except for small areas of dirt, the carpet should be removed from the vehicle to avoid damaging other trim.

Headliner, upholstery, trim & carpets - cleaning:

• Shake the bottle and adjust the nozzle to spray at a distance of 9 in. (24 cm) onto a small area.

• The cleaner will foam. Allow the foam to collapse and then wipe the area clean with a damp absorbent cloth or sponge.

• If further wiping of the area is necessary, rinse the cloth or sponge in clean water before further use.

• Stubborn dirt may require light scrubbing with a soft brush and/or another application of cleaner.

• Always use a clean white cloth since dyed materials may leave their color on the affected area. Change the area of the cloth being used frequently, to avoid reapplying dirt to the fabric.

• Avoid applying to much water to the area being cleaned.


W ARNING: J aguar upholstery cleaner must be k ept aw ay from c hildren. If the cleaner comes into contact with skin or eyes, w ash thoroughly with clean running w ater . If sw allowed, seek medical at tention.

UPHOLSTERY & TRIM:

Products: Jaguar Leather Cleaner

Cellulose sponge

Polishing cloth

LEA THER

JLM 9869

JLM 9878

JLM 9877

Procedure:

Upholstery and Trim - preparation:

Vacuum clean the leather upholstery and trim regularly, to remove dirt and grit from the seams and folds.

Upholstery and Trim - cleaning:

Apply the leather cleaner undiluted to the affected area, with a small brush or clean cloth, and let it soak in for a few minutes.

Wipe the area clean with a slightly damp sponge or cloth.

Change the area of the cloth being used frequently to avoid reapplying dirt to the leather.

Wipe dry with a clean white cloth.

W ARNING: J aguar leather cleaner must be k ept aw ay from c hildren. If the cleaner comes into contact with skin or eyes, w ash thoroughly with clean running w ater . If sw allowed, seek medical at tention.

Do not use any cleaner other than those listed above.

Do not use cleaners on electrical equipment where there is a risk that liquid or foam may enter switches, etc.

Stains are easiest to remove as soon as possible after they occur.

Store cleaners at room temperature and prevent from freezing.



Br oken Door Flap Handle –

Replace Handle Onl yy


When servicing outside front door handles on 1988-89 MY Sedan Range vehicles, within the above VIN range, it is not necessary to replace the entire door handle assembly if the concern is a broken flap handle. The flap handle is available separately to allow a lower cost repair (Illustration 1).

WG72596

ILLUSTRATION 1

A CTION:

In case of a customer complaint of a broken flap handle on a 1988-89 MY Sedan

Range vehicle, within the above VIN range, replace the flap handle as follows:

REPLACING FRONT DOOR FLAP HANDLE

1.

Remove door handle assembly from vehicle. Refer to the XJ6 2.9-3.6 Service

Manual, Volume 4, Section 76, operation 76.58.01.


FRON T DOOR HANDLE A SSEMBL

PIV O T PIN

J76-406

ILLUSTRATION 1

2.

Pull back the rubber protective cover over the pivot pin (Illustration 2).

3.

Remove one of the spring washers securing the pivot pin in the door handle assembly.

4.

Remove the pivot pin and return spring.

5.

Remove the rubber cover from the flap handle arm and then remove the flap handle.

6.

Insert the new flap handle and place the rubber cover over the arm.

7.

Insert the pivot pin with the return spring and secure the pin with the spring washer.

8.

Position the protective cover over the pivot pin.

9.

Reinstall door handle assembly.


RH front flap handle kit

LH front flap handle kit


P AR T NUMBER

JLM 10772

JLM 10773

1

1



Damaged Cupholder –

Replace Mechanism Only –



76-123

Repairing the cup-holder mechanism, which in the past required installing a new console lid assembly, can now be done by installing a replacement mechanism in the existing lid assembly.

The availability of the cup-holder mechanism, as a separate replacement part, allows a more cost effective repair of the lid assembly.

A CTION:

In case of a customer complaint of a broken cup-holder assembly, (shown in

Illustration 1), remove the holder and install a new assembly in the cubby box lid as described on the next page.

L OCA TIONS FOR TRIM P ANEL SCREWS IN CUPHOLDER A SSEMBL Y


ILLUSTRATION 1


CONSOLE LID RET AINING SCREWS

T ORX SCREWS

JSI-3140

ILLUSTRATION 2

REPLACING CUPHOLDER MECHANISM

1.

Open the Console Lid and remove the screw, (C, illustration 2), that secures the check arm to the lid.

2.

Remove the three screws that retain the lid and hinge to the console. Remove the lid from the console. Place the lid assembly on a clean bench area.

3.

Remove the eight phillips-head screws, (A, Illustration 2), and the two T8 Torx head screws, (B, Illustration 2), that hold the inner finisher to the console lid.

Remove the finisher and the hinge from the lid.


RET AINING SCREWS

LA TCH RET AINING SCREW

SLIDER PLA TE SPRING

ILLUSTRATION 3

4.

Remove the cup holder latch retaining screw, (Illustration 3).

5.

Remove the latch and the cup-holder mechanism with its trim panel from the lid.

6.

Remove the five No. T8 Torx head screws, (arrowed in Illustration 1), that retain the trim panel. Remove the panel from the mechanism.

little and then pushing upwards, to disengage the hooked projection on the rear of the trim pad from the mechanism.

CUPHOLDER MECHANISM AND TRIM P ANEL


TRIM P ANEL

ILLUSTRATION 4

Date of issue 11/97

JSI-3142

Page 3 of 4

7.

Discard the damaged mechanism.

ASSEMBLY

Installation of a new Console Lid Assembly is a reversal of the removal procedure.

Note the following points:

• Always refer to the recommended torque settings when assembling the mechanism.

• Ensure that the damper wire, which acts as a check-arm, and the hooked projection, which locates the trim pad to the mechanism, are correctly engaged when the trim panel is installed on the mechanism.

• Check that the slider-plate spring, (Illustration 3), is present and in the correct position and that the latch paddle functions correctly i.e. it must fully latch to the console.

• Ensure that the lock screw, (C, Illustration 2), is present and correctly aligned in the substrate before assembling the lid.

TORQUE SETTINGS

Description

Liner screw

Small Torx head screw

Latch screw

Number

6

2

1

Torque

13 +/- 2Nm

5 + /- 2Nm

9 +/- 2Nm

115.1 +/- 17 lb in

44.3 +/- 17 lb in

79.7 +/- 17 lb in


Cup-holder assembly

P AR T NUMBER

GNA 7692AA 1


Claims for replacement of the entire console lid when only the cupholder is defective will be charged back.


F A UL T

UP FD CH 76.25.27

Cupholder assembly - replace

ALL O W ANCE

0.50 hrs.



Convertible Soft Top –

Replacing Outer Cover – Guidelines

MODEL 1989-96 MY XJS Convertible DATE 12/97

76-124

The XJS service manual provides a procedure for replacing the soft top outer cover on page 76-105 (Convertible Hood - Canopy 76.86.12). This bulletin provides some additional suggestions for replacing the soft top outer cover.

A CTION:

When replacing the soft top outer cover, refer to 76.86.12 - “Convertible Hood suggestions:

• Mark the location of the tonneau loops using masking tape.

• Cut the rear glass out before approach provides better support when cutting the sealant and eliminates the steps required to disconnect the rear window frame webbing and links.

• To avoid contact between the rear window frame and the rear seats on 2+2 models, make sure that the pivots of the links for the frame move freely

(Illustration 1). Lubricate the pivots, if necessary.

• Loosen the mounting bolts of the lower brackets of the rear window frame completely forw ard

(Illustration 1). This full adjustment range may be necessary later if the material between the frame and the body is wrinkling and needs more tension.

REAR WINDO W FRAME LINK

PIV O T


L O WER BRA CKET

J76-904

ILLUSTRATION 1


• Apply masking tape to light colored covers to avoid staining the material during installation work.

• An alternative to fabricating the lever tool ‘B’ (Illustration 2), is to loop a scrap piece of plastic box strapping behind the rear tensioning cable and use it to pull the cable into place in the channel. This avoids the need to pry against the vehicle body.

POSITIONING REAR TENSIONING CABLE

REAR TENSIONING CABLE

J76-911

ILLUSTRATION 2

• To achieve a properly centered rear window, observe the caution and note on page 76-108 regarding installation of the rear window glass.

• Use stainless steel frame to prevent rusting.


F A UL T

WR BB **

R. O . NUMBER

76.86.12

Convertible top outer fabric - renew materials such as adhesives, glass primer, etc.


ALL O W ANCE

6.0 hrs.



Windshield VIN Plate –

Use Caution When

Replacing Windshield


76-125

Care must be used with the VIN plate when replacing the windshield on 1988-94

MY Sedan Range vehicles. Ensure that the VIN plate is not torn off when cutting the old sealant. In addition, the correct windshield must be specified to ensure that the VIN plate is still visible at the lower left corner of 1990-94 MY Sedan Range vehicles.

A CTION:

Observe the information below when replacing windshields. Dealers should ensure that their glass replacement sublet shops are aware of this information.

• When removing the windshield, use care not to destroy the VIN plate while cutting through the old glass sealant.

• The VIN plate is located halfway up the A-pillar of 1988-89 MY Sedan Range vehicles (up to VIN 594575). However, on 1990-94 MY Sedan Range vehicles

(from VIN 594576), the VIN plate is viewed through an opening in the masked replacement windshield. If an earlier style windshield is installed, the VIN plate will no longer be visible.

If the VIN plate is damaged, a new one can be obtained. Contact the Product

Legislation and Compliance Dept. for details at 1-888-JAG-DLRS ext. 8171.


Windshield for 1988-89 MY (Secursiv)

Windshield for 1990-93 MY ( Triplex)

Windshield - heated for 1993 MY ( Triplex)

Windshield for 1994 MY ( Triplex)

Windshield - heated for 1994 MY ( Triplex)

P AR T NUMBER

BDC 4589

BEC 1011

BEC 25248

JLM 11268

JLM 11269



Glass Bonding –

Procedures & Materials


XJS Coupe 1992-96MY & all Conv.

DATE 10/98

76-126

A new glass bonding kit, JLM 20452, containing a high modulus, two part, adhesive, supplied by GURIT ESSEX UK Ltd., has been approved for use as the only glass bonding material to be used in the reglazing of Jaguar vehicles.

Since the structural integrity of the vehicle depends in part on the bond between the fixed glass and the body, the use of incorrect materials or techniques can affect the structural performance of the vehicle.

JLM 20452 conforms to the Jaguar specification and provides the torsional rigidity required.

This is the ONL Y product appro ved by J aguar Car will replace the JLM 1 588 glazing kit.

W ARNING: IF THIS MA TERIAL CON T A CTS THE SKIN, W A SH

THA T AREA. IF THIS MA TERIAL CON T A CTS THE E YES,

IMMEDIA TEL Y FLUSH WITH W A TER AND CON TINUE T O FLUSH

FOR A T LEA S T 1 5 MINUTES.

IF THIS MA TERIAL IS INGES TED, DO NO T INDUCE V OMITING,

CONSUL T A DOCT OR IMMEDIA TEL Y . EXTENSIVE OR REPEA TED

SKIN CON T A CT MA Y LEAD T O IRRIT A TION AND SENSITIZA TION.

IN THE EVEN T OF INFLAMMA TION OR A ‘S TINGING’ SENS A TION

WHICH PERSIS TS, CONSUL T A DOCT OR, EXPLAIN THA T THE

PRODUCT CON T AINS ‘SILANES’ AND SHO W THE SEALED

CON T AINER T O THE DOCT OR.

It is recommended that gloves and safety glasses are worn when handling these materials.


MATERIALS AND TOOLS

The JLM 20452 Glazing Kit consists of the following items:

1 x cartridge

1 x cartridge

X2500A

X2500B

1 x bottle, green cap

1 x bottle, yellow cap

1 x bottle, blue cap

1 x mixer head

5100 universal glass primer

VP 04604 activator for glass

4000 activator for pre-applied sealant

1 x pre-cut cartridge nozzle

1 x wire cutter

1 x primer applicator

( 225ml )

( 225ml )

( 15ml )

( 15ml )

( 15ml )

The following tools and equipment are required in addition to the pack above:

BETAGUN - 501-050*

Gloves

Protective goggles

Knife

Windshield removal tool

Suction cups

Clean lint free cleaning paper

Spacing blocks

Cutting wire

* Available through SPX Kent Moore, refer to page 6 of this bulletin.

ADHESIVE SEALANT

• The adhesive sealant is supplied as a twin tube pack, as shown in Illustration

1.

• The two components, adhesive and accelerator are supplied in separate tubes but are mixed in equal quantities in the mixer tube of the Betagun.

• Uncured adhesive residues can be easily removed with 3350 or 3500 cleaners.

Cured adhesive can only be removed mechanically.

TWIN P A CK CAR TRIDGE


ILLUSTRATION 1


BET A GUN III ADHESIVE SEALAN T APPLICA TION S YS TEM

ILLUSTRATION 2

BETAGUN - ADHESIVE SEALANT APPLICATION SYSTEM

• The Betagun, adhesive sealant application system (Illustration 2), is an electric motor driven applicator that applies an equal force to both cartridges of the pack, to ensure a controlled mix of the two ingredients of the adhesive sealant.

• The flow rate of the mixed adhesive and accelerator is controlled by trigger pressure.

NOZZLE AND BEAD

ILLUSTRATION 3

• The extruded sealer bead should be triangular in section, (see Illustration 3).

• The application of the adhesive to the glass must be in a single continuous bead, so always position the glass on a suitable support, so that the operator can move around it to extrude the bead without interruption.

• The adhesive bead should be started at the center of the lower edge of the glass so that any possible water leak at the joint is confined to that area.

• The adhesive will begin to ‘cure’, as it contacts the atmosphere so the glass


• Remove any dirt or finger marks from the glass with a proprietary cleaner. If the cleaner is alcohol-based, time must be allowed for it to dry, since alcohol inhibits the curing of the polyurethane sealer.

VP 04604 ACTIVATOR FOR GLASS (YELLOW CAP)

VP 04604, (yellow cap), is applied to the bond-line area of new glass to provide an etched surface key.

CA UTION: When using VP 04604 (yellow cap) use care that this material does not contact the optically or cosmetically impor tant areas of the glass as it will cause instant etc hing damage whic h cannot be reco vered by an y cleaning process.

y’ surface whic h will render the glass

• Apply an even film of the VP 04604, glass etch wipe, to the black ceramic band on the glass, using the cloth supplied in the kit and then immediately wipe it off using a clean cloth.

• Allow 1 to 2 minutes for the glass etch wipe to react fully.

5100 UNIVERSAL GLASS PRIMER (GREEN CAP)

• 5100, (green cap), is an ANTI ULTRAVIOLET primer which is applied over the area where VP 04604, (yellow cap), has previously been applied.

• 5100 is also applied to the bond-line area of a repainted body aperture where all traces of the previous adhesi ve have been remo ved.

• Before applying the primer, tap the base of the container on a solid surface to ensure that the mixing balls are loose and then shake for a minute to ensure that the primer is thoroughly mixed.

• Apply the Primer with a felt applicator to spread an even film over the bondline area and then allow 15 -20 minutes drying time

• Do not back after the removal of old glass, in preparation for reglazing.

the previous glass, the appropriate Jaguar Paint Refinishing processes must be followed to restore the paint in the window opening before reglazing is performed.

4000 ACTIVATOR FOR PRE-APPLIED SEALANT (BLUE CAP)

• If glass has been removed, use the wire felt applicator supplied in the kit to apply 4000 activator (blue cap) to the existing urethane bead, which must be fully bonded to the glass or painted body. The existing urethane bead must also be trimmed back to a maximum thickness of 1 to 2 mm on the glass and the opening.


• Since the activator dries rapidly, the glass, with the adhesive applied, should be positioned and installed within 15 minutes of applying the activator.

NON-URETHANE PRODUCTS

• If a non-urethane glass bonding or sealing material is present, e.g. a siliconereglazing, down to bare metal if necessary.

• Follow Jaguar Paint Refinishing processes to restore the cosmetic finish to the opening before installing the glass.

CURING TIMES

• Urethane products ‘cure’ by the chemical reaction resulting from the combination of the components. The curing rate increases with a rise in temperature.

• Glass bonding should always be carried out at temperatures between 18° to

25°C (65° to 77°F).

• The vehicle should remain stationary stored outside, in lower temperatures or where it may get rained on, until after the curing period.

• Air Bag/SRS systems on Jaguar vehicles rely on the integrity of the windshield being retained to the body shell, so that driving before the urethane is properly cured, could have serious consequences in the event of an accident that is severe enough to cause Air Bag/SRS deployment.

DRIVE AWAY TIME

Single or twin Air Bags - 1 20 minutes at an ambient temperature abo ve 5

No Air Bag - 30 minutes at an ambient temperature abo ve 5

DISPOSAL OF MATERIALS

Excess materials from the glass bonding kit, along with material applicators and shop rags should be disposed of in the same manner as other paint shop waste.


P ar ts Information:

The Glass Bonding Adhesive Kit consists of a 2 X 225 ml. cartridge pack, mixer head, glass primer, wipe and promoter and a primer applicator.

Dealers and body shops should hold an absolute minimum stock of the kit, which has a limited shelf life even under good (cool) conditions. The shelf life is 9 months in unopened containers and the container has a ‘Use by’ date.

Stock ordered on an ‘as required’ basis will ensure that material is supplied and never use a kit whic h is date expired.

Glass bonding adhesive kit

P AR T NUMBER

JLM 20452

T ool Information:

Order tool 501-050 directly from SPX Kent-Moore, not Jaguar Cars.

1-800-345-2233 U.S.

1-810-574-2332 U.S.

F ax:

1-800-578-7375 U.S.

W ar ranty Information:

For S.R.O.s regarding the Renewal of the Windshield, refer to the Warranty Codes and Repair Operation Times manual.



Squeaking Interior Trim –

KRYTOX



Fluid For Trim

Refinement Applications


XJS

DATE 10/98

76-127

KRYTOX



fluid is now available via Jaguar Parts Operations. It is an inert, safe, easy to use material, likened by many to liquid TEFLON, which may be used as a durable fix for squeaks associated with interior trim, weatherstrips and rubber seals and bushes.

A CTION:

Being inert, non-volatile and compatible with most materials, KRYTOX



may be used as a durable solution for squeaks on interior or exterior trim, regardless of location on the vehicle. Once applied, KRYTOX



is not visible and may be used as an alternative to felt pads and tapes, which can be unsightly and difficult to apply.

Typical applications include:

• Leather Seats, Consoles and Trim Eliminates creaking attributed to leather seats and trim.

• Plastic & Elastomeric Trim KRYTOX



lubricates and isolates contact surfaces, eliminating squeaks

• Weather-strip Lubrication

• Sunroofs

KRYTOX



may be used on both flocked and unflocked seals and glass run channels to eliminate noise and window judder

KRYTOX



may prevent squeaks and sticking experienced with sunroofs and their seals.

• Rubber Seals and Bushings

• Components

May be used to eliminate squeaking arising from rubber seals and bushings

KRYTOX



may be applied to provide smooth operation of handles, switches, air vents, controls, cables, etc.


APPLICATION METHOD

KRYTOX



should be applied sparingly to the target surface area using the integral nozzle of the plastic bottle. Only a few drops are required for most applications.

This may be further spread to cover larger surface areas using a cloth, brush, or sponge to leave a very thin film of the fluid on the surface concerned.

Caution:

KRYTOX



is not applied or spread over any surface to which any other trim component is to be fixed using adhesives; the material is extremely adhesive-resistant. Take care that the material is not spread inadvertently by contact with shop cloths, brushes or sponges used in any application, or residual material on a technician’s fingers.

W arning: Wear safety glasses and impervious gloves when handling KRYTOX



. Wash hands thoroughly using soap and water immediately after handling the product and before breaks.

In case of eye contact, rinse with plenty of water. If eye irritation persists, consult a specialist. In case of ingestion, rinse mouth, drink water as a precaution. Do not induce vomiting without medical advice. Consult a physician if irritation occurs or persists.


KRYTOX



fluid

* pro-rate at 10%

P AR T NUMBER

JLM 20289


F A UL T

** 10.10.99

Minimum time

** Refer to Warranty Codes and Repair Operation Times manual

*

ALL O W ANCE

0.10 hrs.



RECALL R469 – Hood Liner –

Change of Specification – Replace

MODEL 1994 MY XJ12

VIN 673299-708757

DATE



1/99

76-128

Amended

3/99

On some 1994 MY XJ12 Sedan Models within the above VIN range, deterioration of the hood liner from excessive moisture (steam cleaning, pressure washing) can cause the sound deadening material to sag so that it can come into contact with the throttle linkage.

The liner could interfere with the throttle linkage, causing the throttle butterflies to be held off their idle stops when the accelerator pedal is released, causing an increase in the idle speed of the engine. This increase could result in an increased tendency of the vehicle to ‘creep’ when Drive or Reverse is selected, requiring the brakes to be more firmly applied than normal to hold the vehicle stationary.

A replacement hood liner, manufactured from a different material which is more moisture resistant, has been developed to eliminate this concern.

Jaguar will contact owners directly to advise them of this recall.

A CTION: if the vehicle had S ervice Action S437 performed.

For those vehicles originally equipped with the engine compartment light feature, this action deletes the feature. This is in the interests of reducing the possibility of water ingress to the liner, by reducing the number of openings to a minimum. You should advise the customer verbally of this, where applicable.

MODIFICATION PROCEDURE

1.

Check the under side of the hood screw fasteners for reuse. On vehicles equipped with twin engine compartment lamps, unclip the lamps and disconnect them at the adjacent multiplug connector. The lamps can be discarded. Ensure that the unused harnesses remain attached to their support clips, to avoid rattles. If a clip is missing and a replacement is not available, wrap the multiplug connectors with soft foam, secured by adhesive tape, so that they will be held against the metal by the replacement liner.

2.

Peel off the protective backing from the replacement hazard warning label.

3.

Carefully align the label with the aluminum foil patch on the replacement liner and adhere the label to the foil.


4.

Position the replacement hood liner. Temporarily retain it in its correct position by installing 4 or 5 of the screw fasteners. Ensure that the liner is

L OCA TION OF TING POIN TS

APPL Y LABEL HERE

JSI-3503

MJSI-3503

ILLUSTRATION 1

5.

Refer to Illustration 1 for the location of the 4 additional

6.

Use a scriber to mark through the locations of the additional on the ribs of the hood reinforcement panel.

7.

Remove the replacement liner. Temporarily place the old liner over the engine, to catch any drill chips from the following operations.

8.

Center punch the reinforcement panel at the centers of the locations marked in step 6 above. Check that the locations line up approximately with the centers of the raised ribs of the reinforcement panel.

JSI-2226

MJSI-2226

ILLUSTRATION 2

9.

Use a drill equipped with a plastic or rubber sleeve (Illustration 2) to act as a

more than 5 mm (3/1 6 inc h) a pilot hole at each of the 4 locations.

of the drill bit can result in serious cosmetic damage to the outer panel of the hood.


10. Enlarge the 4 holes to 6.35 mm diameter (1/4 inch) using a drill bit similarly fitted with a depth limiting sleeve.

11. Clean away all chips from the drilling operations. Remove the old liner from covering the engine.

12. Use zinc-rich paint to treat all bare metal that was exposed by drilling.

13. Check the condition of all existing liner fasteners. Replace any which are not any fasteners that were missing or damaged, if any.

14. Align the hood liner with the hood reinforcement frame.

that the replacement liner is completely in contact with the reinforcement frame at all fastener points.

16. Carefully lower the hood towards the ‘closed’ position, checking as far as

NO T of the throttle mechanism.

17. Partially raise and then completely close the hood, ensuring that it is completely latched.

18. Actuate the accelerator pedal several times through its full travel, to check for free movement and that the pedal returns completely to the idling position.

19. Start the engine and check that the engine settles at its normal idle speed.

Check that it returns normally to idling speed when the pedal is released after having run at 2000 rpm for a few seconds.

20. Briefly accelerate hard, then immediately release the pedal, repeating this action three times to cause the engine to move as much as possible on its

Do NO T exceed 40 0 0 rpm during this action.

REP AIR this condition

NO T

INVES TIGA TE AND

21. Open the hood and check in the area at the lower left-hand of the hazard warning label. Make sure that there is no witness mark from the liner having contacted the throttle pedestal or mechanism during the previous operations.


22. If there is no sign of contact between the liner and throttle pedestal or mechanism, close the hood and remove the fender covers.

W rite the date and your dealer number on the R469 authoriz ed modification

Illustration 1. (This label will immediately indicate to any other dealer that the vehicle concerned has already been rectified).

A UTHORIZED MODIFICA TION LABEL

WRITE IN D A TE

ILLUSTRATION 3


Hood liner (R469 only)

Label, Hazard Warning

Label, Authorized Modification

Plastic screw fastener

* package contains 10 fasteners.

P AR T NUMBER

GMB 9340AB/K

MMD 7700DB

JAG469/STKR

KRS 113130

1

1

1

A/R*


W ar ranty Information:

RECALL R469

SUMMAR Y

XJ12 1994 MY

Model code

2111

TF

Qty

1

1

6

76.93.60

10.10.10

Part #

GMB 9340AB/K

MMD 7700DB

KRS 113130

Replace hood liner (R469 only)

Drive in/drive out

Description

Hood liner

Label, Hazard Warning

Plastic screw fastener

ALL O W ANCE

0.65 hrs.

0.15 hrs.

NO TE: whether this recall has been performed on this vehicle. The warranty selection under the vehicle inquiry will give a listing of all claims against the vehicle. If R469 appears in the fault code field, do not perform this recall.



DCS DEALERS


NON-DCS DEALERS

Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the

Repair Code column. Do not use the W-1 warranty claim form.



Seat Track Assembly –

Repair/Replace Guidelines


76-129

The entire seat track assembly (Illustration 1) on the above vehicles does not need to be replaced when the fore/aft motors or cushion tilt motor, gearbox, or potentiometer is inoperative. These motors/gearboxes/potentiometers are available separately from the seat track assembly. This bulletin describes under what conditions replacing the seat track assembly is not justified.

SEA T TRA CK A SSEMBL Y

FORE/AFT MO T OR

FRON T TIL T MO T OR

REAR TIL T MO T OR

ILLUSTRATION 1

A CTION:

• the cushion tilt motor is damaged.

• the potentiometer for the cushion tilt motor is damaged.

• the transmission of the cushion tilt motor is damaged.

• the fore/aft motor is damaged.

• the potentiometer for the fore/aft motor is damaged.

• the transmission shafts for the fore/aft motor are stripped.

Refer to Volume 4, Section 86, pages 86-77 to 86-88 of the XJ6-XJ12 Saloon Range

Service Manual for the procedures to replace the motors and/or potentiometers.

Since the cushion tilt motors come as an assembly with the gearboxes and potentiometers, (Illustration 2) the relationship between the linkage and the potentiometer is already set.


SEA T CUSHION TIL T MO T

GEARBO X

PO TEN TIOMETER

MO T OR

J86-1748

ILLUSTRATION 2

Refer to the XJ6 Sedan Range 1993/94 Electrical Guide or the XJ12 Sedan 1994

Electrical Guide for test values for the potentiometers.

Replace the complete seat track assembly only under following conditions:

• if the track assembly is cracked.

• if the track assembly has a broken weld.

• if the track assembly allows excessive rocking of the seat.


Tilt (rise and fall) motor - front of cushion includes gearbo x, link

Tilt (rise and fall) motor - rear of cushion includes gearbo x, link age, and potentiometer

Fore/aft motor w/potentiometer

Recline motor w/potentiometer

Headrest motor w/potentiometer

P AR T NUMBER

BEC 24321

BEC 24323

JLM 1729

BEC 17787

BEC 7135

W ARRAN TY INFORMA TION/POLICY

Refer to section SZ of the Warranty Codes and Repair Operations Manual Sedan

Range: though 1994 MY.

Claims for replacement seat track assemblies will be rejected if the failed components can be serviced separately.



V

Climate Contr ibr ol – P

Repair Pr anel ocedur

Assembl ation / Intermittent Oper ee yy ation –



Revisions are marked with a bar.

Climate control panel vibration on 1991 MY Sedan Range vehicles VIN 629286 -

649175.

Air conditioning intermittent operation on 1988 - 1991 MY Sedan Range vehicles

VIN 506664 - 649175.

For complaints of climate control panel vibration on 1991 MY Sedan Range vehicles within the VIN range listed above, install an anti-vibration screw kit (part number JLM 11238) following the procedure beginning on page 1 of this bulletin.

For complaints of intermittent air conditioning operation on 1988 - 1991 Sedan

Range vehicles within the VIN range listed above, install a microswitch replacement kit (part number JLM 11240) following the procedure beginning on page 3 of this bulletin.

CLIMATE CONTROL PANEL ANTI-VIBRATION SCREW KIT INSTALLATION

1.

Record all customer preset radio stations (including X-Mem) and disconnect the battery ground cable.

transmitters are available.

2.

Remove the center console fascia panel assembly.

3.

Remove the climate control panel assembly from the fascia panel assembly

(Illustration 1).

CLIMA TE CONROL P A SSEMBL Y

Bulletin Number 82-38 Amended

J80-044

ILLUSTRATION 1


4.

Remove the four rear cover retaining screws. One screw is located on each side of the control panel assembly, two screws are located at the top of the assembly (Illustration 2).

JSI-1841

ILLUSTRATION 2

5.

Install the two nylon screws from the kit JLM 11238 as shown in Illustration 3.

INS T ALL NYL

NYLON SCREWS

JSI-842

ILLUSTRATION 3

6.

Refit the rear cover panel using the original screws.

7.

Reassemble and install the center console facia assembly.

8.

Connect the battery ground cable and code the radio and security system.

9.

Reset the clock and program the preset radio stations.

10. Verify climate control, radio and security system operation.

Page 2 of 6 Date of issue 7/95 Bulletin Number 82-38 Amended

AIR CONDITIONING MICROSWITCH REPLACEMENT PROCEDURE

1.

Record all customer preset radio stations (including X-Mem) and disconnect the battery ground cable.

transmitters are available:

2.

Remove the center console fascia panel assembly.

3.

Remove the climate control panel assembly from the fascia assembly

(Illustration 4).

CLIMA TE CONROL P A SSEMBL

ILLUSTRATION 4

4.

Remove the fan speed control knob (Illustration 5).

J80-044

REMO VE F AN SPEED KNOB


ILLUSTRATION 5

JSI-2088


5.

Remove the four rear cover panel retaining screws. One screw is located on each side of the control panel assembly, two screws are located at the top of the assembly (Illustration 6).

JSI-1841

ILLUSTRATION 6

6.

Using a sharp knife, carefully cut off the heads of the rivets securing the microswitch to the fan speed control switch assembly (Illustration 7).

and assembly.


ILLUSTRATION 7

JSI-1844


7.

Remove the nut and washer securing the fan speed control to the control panel and remove the switch (Illustration 8).

JSI 2089

ILLUSTRATION 8

8.

With a small flat blade screwdriver, gently pry the microswitch from the fan speed control switch. Remove the remainder of the cut rivets.

9.

Position the microswitch away from the circuit board.

wire connections. Only two terminals have connections.

10. Remove the wires from the microswitch connections by melting the solder.

Do not drop solder on the circuit board.

11. Solder the wires to the correct terminals of the new microswitch (from kit number JLM 11240).

12. Refit the microswitch to the fan speed control switch as shown in Illustration 9 using the hardware from the kit.

microswitch side of the assembly as shown in Illustration 9.

INS T ALLING NEW MICROSWITCH


JSI 2087

ILLUSTRATION 9


13. Fit the fan speed control switch to the control panel using the existing nut and washer.

14. Refit the rear cover panel using the original screws. Install the fan speed control knob to the spindle.

15. Reassemble and install the center console facia assembly.

16. Connect the battery ground cable and code the radio and security system.

17. Reset the clock and program the preset radio stations.

18. Verify climate control, radio and security system operation.


P AR

JLM 11238

JLM 11240

Anti-vibration screw kit

Microswitch replacement kit

W ARRAN TY INFORMA TION

F A UL T CODE

JY BB HR

JY BF GN

86.91.54

86.91.56

O W ANCE

Anti-vibration screw kit installation 0.60 hrs.

Microswitch replacement kit installation 1.05 hrs.



R-134a Retrofits Kits

MODEL V12 w/ Harrison

All w/ Sanden Compressors

DATE 6/94

82-39

Amended

9/97

Remove and destroy Bulletin 82-39, Amended 1/96


Revisions are marked with a bar.

Jaguar engineered kits are available which convert R-12 charged air conditioning refrigerant systems to HFC R-134a systems.

Should Jaguar owners wish to convert their R-12 systems at their own expense, retrofit kits are available as shown below. Retrofitting procedures are shown in the Technical Guide - Air Conditioning System - HFC Refrigerant Retrofit - part

Number JTP 425 (supplied to dealers 6/94).

existing compressor lubricating oil with an oil compatible with both HFC R-134a refrigerant and with the residual R-12 lubricating oil. It is not possible to completely flush R-12 type lubricating oil from the refrigerant system prior to changing to

Ester oil and R-134a. Additionally, it is necessary to replace the input shaft seal of the Sanden compressor with a seal compatible with the R-134a refrigerant and oil as described in the Technical

Guide. Harrison compressors do not require replacement of the shaft seal.

PARTS NUMBERS, APPLICATIONS, REPAIR TIMES

P A R R E P A I R

NUMBER T Y P E

JLM 11610

JLM 11611

Sanden 510/709

Sanden 709

Sanden 709

Harrison

XJ40 - 3.6/4.0

507471 - 667587 3.10 hrs.

1988-93

XJS 4.0

1993-94

XJS 6.0

179740 - 190527 3.35 hrs.

188105 - 190527 3.45 hrs.

1994

Ser. III XJ12 5.3

300001 - on 3.10 hrs.

1979

XJS V12

1979-93

100001 - 188104 3.10 hrs.



P A G Oil for R134a Systems

All v ehicles with R134a systems DATE 6/95



The text has been revised to associate the proper oil to the compressor regardless of vehicle.

Two different types of PAG oil are available for servicing vehicles equipped with

R134a systems. The correct oil can be determined by the compressor installed in the vehicle.

When servicing vehicles with NipponDenso compressors, use PAG oil Part No.

JLM 12260.

When servicing vehicles equipped with R134a systems and Sanden compressors, use PAG oil Part No. JLM 11106.


7.5 fl. oz.

(250 cc)

7.5 fl. oz.

(250 cc)

PAG oil for NipponDenso compressor

PAG oil for Sanden compressor

P AR

JLM 12260

JLM 11106



Climate Contr ol System – Re and Pr ol System – Re vised Pipe essur e Switc h Location

The high-pressure pipe from the condenser to the expansion valve has been superseded to part no. MMD-7360AB plus LMD 3997CA. This pipe separates the single pressure switch from the triple pressure switch to a location at the opposite end of the assembly. The triple pressure switch remains near the expansion valve, while the single pressure switch is relocated to the condenser end of the pipe, Illustration 1.

When installing the later style pipe (MMD-7360AB), obtain the link lead LMD-

3997CA to connect the single pressure switch to the vehicle harness.

OCA TION


ILLUSTRATION 1



A/C Pipe

Link lead

P AR

MMD 7360AB

LMD 3997CA



Receiver/Drier – A/C System Servicing

– Preventing Entry of Moisture


XJS Range

DATE 1/97

82-50

It is not necessary to replace the receiver/drier assembly whenever the refrigeration circuit is opened, provided that the guidelines in this bulletin are followed.

The connections of any refrigeration circuit components must be plugged whenever the circuit is disturbed for servicing, or when replacing components, in order to prevent contamination of the circuit by the entry of moisture and foreign material. This requirement not only applies to on-vehicle components but also to components being returned under warranty. The investigation of returned components is often compromised by contamination of their interiors before they are received by Jaguar Cars.

A CTION:

RECEIVER/DRIER ASSEMBLY

To avoid unnecessary replacement of the receiver/drier, follow these guidelines:

• Install plugs or caps on component and refrigerant line connections immediately after disconnection.

• Remove plugs or caps from component and refrigerant line connections only immediately before they are reconnected.

• Install new O-ring seals, lubricated with the recommended refrigerant oil.

However, you must still replace the receiver/drier assembly if:

• it is suspected that chips or some other contaminant are present in the drier as a result of the failure of a component in the refrigeration circuit.

• the drier is blocked, damaged or leaking.

• there is corrosion in the drier or in the refrigerant lines (indicating the presence of moisture in the system).

PLUGGING REFRIGERATION CIRCUIT CONNECTIONS

Plug components being returned to Jaguar using the plugs installed on the replacement part. Plug components on the vehicle using suitable line plugs and external line caps.

Vacuum and fuel line plug set Part No. THX 312 available from Snap-On Tools is suitable for most of the components in the refrigeration circuit.

Plugs and caps used for refrigeration circuits should be stored separately from those used for other purposes such as plugging fuel or hydraulic lines.


W ARRAN TY POLICY

• Returned parts must be capped.

• Air conditioning components returned under warranty that are not properly sealed will be returned and the claims debited.

• Claims for receiver/driers will only be accepted for the conditions stated on the previous page.



Compressor Refrigerant Leaks –

Sanden 709 R12 Compressors –

Seal & Gasket Kits Available


1993 XJS Range

DATE 9/98

82-51

Sanden 709 A/C R12 compressors (part no. CCC-4929) used in Sedan Range and

XJS vehicles are often replaced needlessly because of seal leakage. Gasket kits and seal kits are available to service these compressors using special tools JD-167 and JD-168 (Illustrations 1 and 2).

A CTION:

After determining the source of refrigerant leakage from the compressor, replace the shaft seal (repair operation number 82.10.11) and/or the compressor valve plate gaskets (repair operation number 82.10.26) as required.

On Sedan Range vehicles refer to the XJ6 Service Manual (part no. JJM100405/90)

Volume 4, page 82-68 or 82-71.

On XJS vehicles, refer to the XJS Service Manual (part no. JJM 100406/20) Volume

4, pages 82-26 or 82-29.

REMO VING COMPRESSOR SEAL SEA T AND SEAL

JD 1 68

THREAD PRO TECT OR T OOL

JD 1 67

ILLUSTRATION 1


REPLA CING A/C COMPRESSOR V AL VE PLA TE GA SKETS

V AL VE PLA

GA SKETS

ILLUSTRATION 2


Sanden 709 (R12) compressor gasket kit

Sanden 709 (R12) compressor seal kit

P AR T NUMBER

JLM 2139

JLM 2137

1

1


Refer to the Warranty Codes and Repair Operation Times manual for labor times and fault codes.



Leak Detection System –

Ultraviolet Dye


1994-96 MY XJS with R134a

DATE 10/98

82-52

A UV-Fluorescent Leak Detection System, manufactured by Tracer Products, has been approved for use in the air conditioning systems of Jaguar Cars.

• The UV fluorescent dye, used in the leak detection system, was introduced into the air conditioning systems of 1998 MY vehicles to assist in the rapid and accurate diagnosis of refrigerant leaks.

• The dye can be added to the air conditioning systems of all vehicles with R-

134a systems using the Tracer Products Universal Connector set.

• This dye is the only product recommended and approved for this purpose.

• The dye will remain in the system, within the lubricant, and has no effect upon the refrigerant. Additional dye does not cause a problem.

• This dye is visible when illuminated by a UV lamp, either directly or by wiping the suspected area with a cloth and then shining the UV lamp on that cloth.

A CTION:

When diagnosing refrigerant leaks, use the leak detection system consisting of:

• A UV fluorescent dye in a transparent tracer stick capsule.

• A Universal Connector Set which is used to add the fluorescent dye to the air conditioning system.

• An Ultraviolet Lamp to enable the operator to determine the source of any leak.

equipment and may be purchased locally or by contacing Tracer

Products 1 (800) 641-1133 (USA) for a local distributor.

W arning: Alw ays wear protecti lamp. Do not direct the rays of the lamp at an yone.


PLACING DYE IN A/C SYSTEM

• The Universal Connect Set and Tracer Stick Capsule are used to introduce dye into the Air Conditioning systems of vehicles which were produced with systems charged with R134a, without the need to discharge the refrigerant.

Side Charging’ and ‘High Side Charging’. The ‘High Side

Charging’ method is recommended: i.e. use Kit no. TP-9887.

• Evacuate or purge the Universal Connect Set hose assembly. Close all valves

• While holding the tracer stick capsule, (A, Illustration 1), vertically, so that the upw ards

• Turn the control valve and capsule assembly so that the embossed arrow is down w ards. capsule and screw the service valve fitting, (C, Illustration 1), to the capsule, finger tight .....

• Connect the quick coupler, (D, Illustration 1), to the high side service port of the air-conditioning system.

UNIVERS AL CONNECT SET/TRA CER S TICK CAPSULE

B E C

A

ILLUSTRATION 1

D

JSI-3196

• Ensure that the control valve (B, Illustration 1) is closed.

• Connect the service valve fitting, (C, Illustration 1), to the high side quick coupler on the manifold or the recovery unit.

charging/recovery apparatus.


• Open the control valve, (B, Illustration 1), and the line to the charging/recovery apparatus to allow refrigerant to flow through the capsule, carrying the UV fluorescent dye into the system.

• After the dye has been flushed from the capsule, close the control valve and disconnect the connector set from the system and the charging/recovery apparatus.

• Remove the service valve fitting, (C, Illustration 1), from the capsule and retain it.

• Remove the capsule from the control valve, (B, Illustration 1), and discard it.

• Using suitable disposable, clean material and the water-based Glo-Away

Fluorescent Dye Cleaner/Remover, wipe the service valve fitting and the control valve to remove surplus dye and so avoid handling contamination.

• Check, with a beam of ultraviolet light, that the dye has been removed.

• When the system has been filled, the label, (Illustration 2), must be fixed to the radiator crossmember, in the position shown.

Fluoro-Lite/P © Fluorescent Tracer Dye

This R-134a/PAG air conditioning or refrigeration system contains Fluoro-Lite/P fluorescent leak detection tracer dye.

Just inspect with a high-intensity Tracerline ultraviolet lamp to pinpoint the exact source of every refrigerant leak.

Date Installed / /

1-800-641-1133

TRACER PRODUCTS

A Division of Spectronics Corporation

Westbury, New York U.S.A.

1-516-333-1254

JSI-3200

ILLUSTRATION 2

LEAK DETECTION

• Run the air conditioning system for 5 to 10 minutes to thoroughly distribute the dye throughout the system.

• Inspect the system by projecting a beam of Ultra-Violet light on to the system components, searching for a bright green glow which will indicate an escape of refrigerant carrying the dye.


• If the escape of refrigerant is not apparent, i.e. the escape is of a small amount, check the system 24 - 48 hours later, after the customer has operated the system as much as possible.

• After all the repairs are completed, thoroughly clean the areas where the dye was visible so that any remaining traces are not mistaken for a new leak.

• Recheck the area, with the Ultra-Violet light, to ensure no traces of dye are remaining.

TP -1 60 0 UL TRA VIOLET LAMP

JSI-3197

ILLUSTRATION 3

• When operating the TP-1600 110 VAC lamp (Illustration 3), 3 to 5 minutes must be allowed for warm-up.

• If the lamp is switched off, 10 to 15 minutes cool-down must be allowed before it is switched on again.

• The heat guard/stand allows the lamp to be left in the position illustrated, while the lamp is switched on, so that the beam is not directed at any person.

• TP-1600 UV bulb life is 5,000 hours.

TP -820 0 UL TRA

JSI-3199

ILLUSTRATION 4

• When operating the TP-8200, (12 VDC, 50 Watts, 5 Amps, Illustration 4), UV lamp, for every 5 minutes of operation there must be a 15 minute, (switched off), cool down interval.

• Use only TP-1510 bulb as a replacement.


REFERENCE CHAR T

TP-3887

TP-9887

Tracer-Stick Capsule Accessories

Low Side Charging Universal Connector Set for use with R-134A/PAG

High Side Charging Universal Connector Set for use with R-134A/PAG

Tracer-Stick Capsule Kit

TP-3863

TP-3864

R-134A/PAG Systems, (Low Side Charging) 6 x TP-3860 capsules & TP-3887 universal connector set

R-134A/PAG Systems, (High Side Charging) 6 x TP-3860 capsules & TP-9887 universal connector set

Tracer-Stick Capsules for Mobile A/C Systems

TP-3860-0601 R-134a/PAG Systems - 6 x 1.8 ml. (0.06 oz.) capsulesfor systems with up to 1.3

Kg. (2.9 lb.) of refrigerant

Tracerline UV Lamp Kit

TP-1620

TP-8220

TP-8020

TP-1600 lamp, (110 VAC), TP-9940 spectacles, TP-1640 Carry case

TP-8200 TITAN lamp, (12 VDC 50 W), UV enhancing spectacles, Carry case

TP-8000 TITAN lamp, (12 VDC 100W), UV enhancing spectacles, Carry case

Tracerline Replacement Parts

TP-1050

TP-8211

UV lens filter for TP-1600 lamp

UV lens filter for TP-8200 lamp

TP-8011 UV lens filter for TP-8000 lamp

TP-1510-0003 12 V 50 W bulb for TP-8000 lamp 12 V 50 W bulb for TP-8200 lamp 12 V 50 W bulb for TP-1700A lamp

TP-1610 115 V 150 W bulb for TP-1600 lamp

TP-1660A Heat guard lamp stand for TP-1600 lamp


REFERENCE CHAR T

TP-8200

TP-8000

TP-1600

TP-1600R/F

Tracerline UV Lamps

TITAN, (12 VDC), UV/Blue lamp, 50 W ‘instant on’ bulb, 4.25m. (14’) cable, UV absorbing spectacles

TITAN, (12 VDC), UV/Blue lamp, 100 W ‘instant on’ bulb, 4.25m. (14’) cable, UV absorbing spectacles

Super high intensity UV lamp, (110VAC), 150 W self ballasted bulb, 2.5m. (8’) cable, Heat guard lamp stand, TP-9940 UV absorbing spectacles

Super high intensity UV lamp, (110VAC), 150 W self ballasted bulb, 9.0m. (30’) retractable cable, Heat guard lamp stand, TP-9940 UV absorbing spectacles

Tracerline Accessories

TP-1640

TP-1740

TP-9940

Plastic carrying/storage case for TP 1600 lamp

Plastic carrying/storage case for TP 800 & TP 8200 lamps

UV absorbing spectacles

Glo-Away Fluorescent Dye Cleaner/Remover

TP-9000-0008 1 x 240 ml, (8 oz) bottle with spray nozzle

TP-9000-0016 1 x 480 ml, (16 oz) refill bottle

TP-9000-1208 12 x 240 ml, (8 oz) bottle with spray nozzle

TP-9000-1216 12 x 480 ml, (16 oz) refill bottle

TRACER PRODUCTS

956 Brush Hollow Road, P. O. Box 483

Westbury, NY 11590

1 (800) 641-1133



Heated Windshield Washer (Screenwash)

Jets – Ambient Temperature Sensor Added –


84-12

Amended

1/95

MODEL XJS Range 1994 - 1995 MY DATE 12/94

VIN 188105 - 196046

Remove and destroy Bulletin 84-12, Date 12/94. Replace with this Amended Bulletin.

New information is in bold faced type and marked with a bar.

ISSUE:

Heated windshield washer jets may cause distortion of the washer jet housings or the plenum grille during prolonged use.. An ambient temperature sensor was added to the system in production at

VIN 196047.

NOTE: This Service Action is to be implemented with Service Action S448 described in Service Bulletin 76-96.

ACTION:

At the next service opportunity on all 1994 - 1995 MY XJS vehicles from VIN 188105 - 196046, perform the service action as described below.

AMBIENT TEMPERATURE SENSOR INSTALLATION PROCEDURE:

1.

Ensure that the radio code is available. Record all preset radio stations (including X-mem) and disconnect the negative cable of the battery.

2.

Remove the windshield wiper motor/linkage assembly following the instructions in the XJS

Service Manual section 84.15.12.

3.

Cut the tie straps, remove and discard the washer jets and the washer jet link harness.

4.

Fit the temperature sensor clip and chafing protection strip to the wiper motor/linkage assembly frame (Illustration 1).

5.

Route the new washer jet link harness and fully seat the temperature sensor under the clip.

WINDSHIELD WIPER MOTOR/LINKAGE ASSEMBLY

NEW TIE

CLIP

NEW TIE STRAP

NEW

TIE

STRAP

PROTECTION

STRIP

TEMPERATURE

SENSOR

84-12.1,2

ILLUSTRATION 1


6.

Fit new washer jet assemblies, connecting them to the washer fluid lines and the link harness.

7.

Connect the link harness to the wiper harness multi plug and fit the “blanking plug” to the open connector of the link harness (red and black wires).

8.

Position the washer jets with the link harness and washer fluid lines in the frame channels.

9.

Use three tie straps, in the positions indicated in Illustration 1, to secure the washer fluid lines and link harness.

IMPORTANT: Ensure that the washer fluid lines are not pinched. Ensure that the washer lines and link harness cannot chafe on the edges of the wiper motor frame channels.

10.

Install the wiper motor/assembly frame, plenum grille and wipers.

11.

Connect the battery, recode the radio and reset the radio stations and clock.

12.

Check the operation of the wipers and washers.

PARTS INFORMATION;

DESCRIPTION

Heated washer jet

Temperature sensor link lead

Harness tie strap

Protection strip

Clip

PART NUMBER

LHE 7096AA/K

LHF 3005BA/K

ADU 9028

DAC 4027/8

JEP 117001

QTY

2

1

3

1

1


Service Action S447

VEHICLE

XJS Range 1994 - 95 MY

VIN 188105 - 196046

XJS Range 1994 - 95 MY

VIN 188105 - 196046

SUMMARY

CODE

ER

ES

DESCRIPTION

TIME

ALLOWANCE

0.60 hrs.

Fit temperature sensor link lead and heated washer jets - (No drive in/out time. To be performed concurrently with Service Action S448 or at time of other service)

Fit temperature sensor link lead and heated washer jets - (Only repair performed / with drive in/out time)

0.75 hrs.




DCS Dealers


Non-DCS Dealers





Security Control Module –


MODEL

Sedan Range 1993-94 MY

DATE

7/94

86-130

ISSUE:

Unnecessary replacement of Security Control Modules to cure a variety of system malfunctions attributable to connector problems. Malfunction symptoms include the following:

• Vehicle will not crank

• Loss of door lock or unlock functions

• Exterior lighting staying on

• Erratic system operation

ACTION:

If vehicles display the above symptoms, it is necessary to perform the following procedure before

JDS diagnosis.

NOTE: Always advise the customer to bring in ALL Security System

Transmitters whenever the system is being serviced.

PROCEDURE

1. Ensure that the radio code is available. Record all preset radio stations (including X-mem) and disconnect the negative cable of the battery.

2. Disconnect and connect the Security Control Module and Central Microprocessor harness connectors several times to clean the connections.

3. Protect the surrounding trim and carpeting.

4. Clean the contacts in the harness connectors of the Central Microprocessor and Security Control Module with electrical contact cleaner

CAUTION: Use only electrical contact cleaner. Other solvents may damage the contacts or components.

5. Thoroughly dry all connectors with a low pressure flow of dry compressed air.

6. Reconnect module and microprocessor connectors. Do not reinstall the module, microprocessor or trim panels.

7. Connect the battery ground cable and test for proper Security System operation. If the original symptoms persist, proceed with JDS diagnosis and repair as necessary.

8. When the system is repaired, reinstall all components, recode the radio, and reset all radio stations and the clock.

WARRANTY POLICY:

All replaced parts submitted under warranty must be accompanied by a JDS printout. Parts not accompanied by a JDS printout will be returned for resubmittal.



Security System – Transmitter – Diagnostic

Procedure

MODEL XJ6 1993-94 MY, XJ12 1994 MY DATE 7/94

XJS Range 1994 MY

86-133

ISSUE:

Intermittent or no operation of Security System Transmitter. Transmitter operating range is consistently below 30 feet.

ACTION:

If customers complain that the security system transmitter operates the system intermittently, not at all, or its range is consistently below 30 feet, perform the Security System Diagnostic Procedure on page 2.

NOTE: Ensure that ALL customer transmitters are available when the security system is being serviced. If the security system control module (SCM) requires recoding, all transmitter codes must be entered into the SCM.

Coding Security System Transmitters

Two transmitters are supplied with each new vehicle; however, the security system control module

(SCM) may be coded for use with up to five transmitters. If new or additional transmitters are requested, or an existing transmitter requires recoding, the system must be recoded with all of the transmitters for the vehicle at hand (from two to five transmitters).

PARTS INFORMATION:

DESCRIPTION

Transmitter

Transmitter cover

Battery


PART NUMBER

DBC 10084

LMB 2610AA

JAG 569

FAULT CODE

SEDAN RANGE XJS RANGE

3MD*

3MDG

3MDE

3MD*

N/A

3MDE

R.O. NUMBER

86.52.19

86.91.78

86.52.28

DESCRIPTION

Transmitter cover

Battery

* Use appropriate 4th digit codes for diagnosis and repair.

TIME ALLOWANCE

0.10 hrs.

0.10 hrs.


SECURITY SYSTEM TRANSMITTER

DIAGNOSTIC PROCEDURE

START TEST

OPERATE THE TRANSMITTER AT 30 FEET FROM THE DRIVER SIDE OF THE VEHICLE.

DOES THE SECURITY SYSTEM RESPOND?

YES NO

V ERIFY THAT REVISED TRANSMITTER COVER

(P/N LMB 2610AA) IS INSTALLED.

OPERATE THE TRANSMITTER AT 3 FEET FROM THE DRIVER SIDE OF THE VEHICLE

DOES THE SECURITY SYSTEM RESPOND?

YES NO

END

HAS THE TRANSMITTER BATTERY BEEN RE-

PLACED?

YES NO

HAS THE VEHICLE SCM BEEN RECODED TO THE

TRANSMITTER?

YES NO

REPLACE TRANSMITTER BATTERY.

HAS THE TRANSMITTER BEEN REPLACED

YES NO

RESTART TEST

NO

RECODE THE VEHICLE SCM TO THE

TRANSMITTER.

RESTART TEST

HAS THE TRANSMITTER BATTERY BEEN RE P LACED?

YES NO

REPLACE TRANSMITTER.

RECODE THE VEHICLE SCM TO THE TRANSMIT-

TER.

RESTART TEST

DIAGNOSE AND REPAIR SECURITY SYS-

TEM WITH JDS.

RESTART TEST

YES

REPLACE TRANSMITTER BATTERY.

HAS THE TRANSMITTER BEEN REPLACED

NO

RESTART TEST

DIAGNOSE AND REPAIR SECURITY

SYSTEM WITH JDS.

RESTART TEST

REPLACE TRANSMITTER,

RECODE THE VEHICLE SCM TO THE NEW TRANSMIT-

TER.

RESTART TEST



Cooling Fans – Inoperative or Operate

With Ignition Off – Reseal Ground Wires

MODEL Sedan Range 1992 – 1994 MY DATE 12/94

VIN 667579 - 708757

86-140

ISSUE:

Cooling fans that are inoperative or operate while the ignition is switched off can be the result of corrosion in the cooling fan control module. The corrosion is caused by water entering the ground wire cores and traveling inside the wire insulation to the module.

ACTION:

After repairing Sedan Range vehicle fans that were inoperative or operated with the ignition off, seal the ground wire eyelet connectors to prevent further moisture from entering the cooling fan module. Use the following procedure.

NOTE: Ensure that the radio security code is available and record the preset radio stations (including X-mem) before disconnecting the battery ground cable.

SEALING COOLING FAN GROUND WIRES

1.

With the battery ground cable disconnected, disconnect the cruise control pump harness plug and the two ground eyelets on the left inner front fender panel (Illustration 1).

GROUND WIRE LOCATION

CRUISE CONTROL PLUG

GROUND EYELETS

86-140.1

ILLUSTRATION 1

2.

Spread the two ground eyelets apart. Thoroughly clean and degrease the eyelets and wires.


3.

Cut a heatshrink sleeve (part number JLM 12166) in half. Fit one piece over the first ground eyelet (Illustration 2).

NOTE: The heatshrink must fully cover the exposed end of the wire insulation at the eyelet to seal the wires from water.

4.

Shrink the sleeve using a heat gun. The adhesive in the sleeve must completely seal the end of the ground wires.

Caution: Protect the inner fender paint work and surrounding components from excessive heat.

SEALING GROUND EYELETS

COMPLETELY SEAL HERE

HEAT-

SHRINK

86-140.2

ILLUSTRATION 2

5.

Repeat the sealing procedure on the second ground eyelet.

6.

Clean both eyelets to assure good connections and apply multi purpose grease to the eyelets and the ground stud.

7.

Connect the cruise control pump harness plug and ground eyelets.

8.

Connect the battery, recode the radio, preprogram the radio stations, and reset the clock.

PARTS INFORMATION:

DESCRIPTION

Heat shrink sleeve

PART NUMBER

JLM 12166

QTY

1


FAULT

CODE

LB GH CC

R.O. NUMBER

86.91.85

DESCRIPTION

Left side harness - Fit heatshrink

TIME

ALLOWANCE

0.20 hrs.



CELLULAR TELEPHONE –

TRANSCEIVER MULTIPLUG – RELOCATED


VIN 695867 -719999

DATE 2/95

Remove and destroy Bulletin 86-144 , Date 2/95.



86-144

AMENDED

3/95

ISSUE:

The cellular telephone transceiver multiplug in 1994 MY Sedan Range vehicles was relocated in production to improve service accessibility. The multiplug is now behind the fuel tank trim panel adjacent to the battery tray casing in vehicles from VIN 695867 - 719999.

ACTION:

To access the cellular telephone transceiver multiplug, remove the spare tire and fuel tank trim panel.



Automatic Transmission Gearshift Interlock

– Gear Selector Locks in Park

– Repair Procedure

MODEL Sedan Range 1993-94 MY DATE 3/95

86-146

Remove and destroy Bulletin 86-132, Amended 12/94.

The information contained in this bulletin supersedes previously published information.

ISSUE:

The gear selector locks in the PARK position with the ignition switched ON and the brake applied.

The automatic transmission gearshift interlock is designed to prevent movement of the gear selector from the PARK position unless the ignition switch is in position II and the brake pedal is applied. In addition, the ignition key cannot be removed from the ignition switch unless the gear selector is in PARK.

This system is installed in all Sedan Range vehicles from VIN 667829 ON.

ACTION:

If a customer complains of difficulty getting the gear selector lever out of the PARK position, follow the instructions in the Gearshift Interlock Diagnosis Guide on page 2 of this bulletin.

IMPORTANT: The selector may appear to lock in PARK if the customer puts pressure on the selector lever before applying the brake.

Advise the customer of the following procedure for moving the gear selector out of PARK.

1. Do not attempt to move the gear selector

2. Switch the ignition to position II or start the engine

3. Press the brake pedal

4. Move the gear selector from PARK to the required position.


GEAR SHIFT INTERLOCK DIAGNOSIS GUIDE

Apply the parking brake.

Select PARK.

Switch the ignition to position II

(the instrument pack should illuminate).

With no pressure on the brake pedal, can the gear selector be move into REVERSE?

NO

YES

Check the gearshift interlock mechanism as described in the XJ6-XJ12 Service Manual

Section 44.15.49.

Hold down the brake pedal.

Can the gear selector be moved from PARK into REVERSE?

NO

YES

Select PARK.

Switch OFF the ignition.

Disconnect connector LB66 (black 20-way

AMP PBC POWER) from the cruise control module.

Switch the ignition to position II.

With the brake pedal depressed, measure the voltage drop across pins LB66-15 and LB66-

11 of the cruise control module harness connector.

If the reading is more than 0.7 V, replace the brake pedal / cruise control switch.

Follow the instructions on page 3 of this bulletin.

With the gear selector fully in the PARK position, apply and release the brake pedal several times.

When the brake is applied and released, does the shift solenoid (located in the J gate assembly) make a clicking noise?

NO

Do not apply the foot brake!

In the PARK position, pull the gear selector back to its limit several times.

YES

Remaining in the PARK position, move the gear selector from its back limit to its forward limit in the J gate.

Does the key lock solenoid (located in the steering column above the lock assembly) click?

NO

Perform a JDS/PDU Gearshift Interlock

System diagnosis.

Repair as necessary.

YES

Electrical function is OK.

Adjust the gearshift interlock mechanism as described in the XJ6-XJ12 Service Manual,

Section 44.15.49.

Check the operation of the gearshift park microswitch.

The switch should provide a logic ground for the Body Processor Module (BPM) pin

LB61-19 when the gear selector is in the

PARK position.


BRAKE PEDAL / CRUISE CONTROL SWITCH REPLACEMENT PROCEDURE

1.

Remove the driver side dash liner assembly to access the pedal housing.

2.

Cut the brake pedal / cruise control switch harness tie strap and disconnect the harness from the switch.

3.

Remove the nut and bolt retaining the switch assembly to the pedal housing

(Illustration 1). Remove the switch assembly.

BRAKE PEDAL / CRUISE CONTROL SWITCH LOCATION

BRAKE PEDAL

SWITCH ASSEMBLY

LOCATION

SWITCH ASSEMBLY

NUT & BOLT

2/21.2.1

ILLUSTRATION 1

4.

On the new switch assembly, check that only 2 teeth are engaged in the ratchet

(Illustration 2). If necessary gently disengage the ratchet and reset until two teeth are engaged.

BRAKE PEDAL / CRUISE CONTROL SWITCH

SWITCH RATCHET


2 TEETH ENGAGED

2/21.2

ILLUSTRATION 2


5.

With the brake pedal held down, fit and fully tighten the new switch assembly.

6.

Slowly release the brake pedal. The switch will click several times as the ratchet mechanism self adjusts.

7.

Connect the harness to the switch and fit a new tie strap.

8.

Switch the ignition to position II.

9.

Check the stop light operation.

10. Check the operation of the gear shift interlock system.

• The system prevents movement of the gear selector from PARK unless the ignition switch is in position II and the brake pedal is depressed. In addition, the ignition key cannot be removed from the ignition switch unless the gear selector is in park.

11.

Refit the dash liner assembly.


DESCRIPTION

Brake pedal/cruise control switch

Tie strap

PART NUMBER

DBC 10800

AGU 1058/J

WARRANTY INFORMATION:

MODEL

Sedan Range

1995 MY

Sedan Range

1993-94 MY

FAULT

CODE

BL BJ

LF

BL BJ

LF

R.O. NUMBER DESCRIPTION

86.65.52

86.65.52/09

86.65.52

86.65.52/09

Brake pedal/cruise control switch -

Renew - With diagnostic time


Renew - Without diagnostic time


Renew - With diagnostic time


Renew - Without diagnostic time

TIME

ALLOWANCE

0.55 hrs.

0.20 hrs.

0.60 hrs.

0.25 hrs.



Driver’s Seat and Mirrors Control Module –

Loss of Seat or Mirror Functions –



VIN 687219 - 701123

DATE 4/95

86-148

ISSUE:

Loss of any driver seat adjustment function, door mirror adjustment function, or any combination of seat and mirror adjustment functions in 1994 MY Sedan Range vehicles from VIN 687219 -

701123, may be caused by a failure of the driver’s seat and mirrors control module (ECM). If a function fails, it would cause the adjustment controlled by that function to remain at its last position. To prevent repeat failure of the ECM, perform the following action.

ACTION:

If the driver’s seat and mirrors control module fails on a 1994 MY Sedan Range vehicle within the

VIN range listed above, BOTH door mirrors must be replaced with revised mirror units (left mirror, part number HMD 3043AC) (right mirror, part number HMD 3042CC) when the ECM is replaced.

NOTE: A production change within the VIN range added capacitors to the door mirror motors. The capacitors, which were added to reduce radio interference, may induce an electrical resonance in the mirror circuit causing ECM failure.

The supply of revised door mirrors is limited. Use revised mirrors ONLY on vehicles that have a failure of the control module.

PARTS INFORMATION:

Do not order revised mirrors for dealer stock. Please order on a VOR basis only.

DESCRIPTION

Driver’s seat and mirrors control module

Door mirror - left side

Door mirror - right side

PART NO.

LHB 2165AA

HMD 3043AC

HMD 3042CC

QTY

1

1

1


FAULT

CODE

SX CC JY

WH BB RN

WH DB RN

R.O. NUMBER

86.75.15.09

76.10.52.09

76.10.52.09

DESCRIPTION

Driver seat/mirror ECM - Renew (w/out JDS test)

Door mirror, driver - Renew (w/out JDS test)

Door mirror, passenger - Renew (w/out JDS test)

TIME

ALLOWANCE

0.15 hrs.

0.35 hrs

0.35 hrs



In-Car Entertainment System –

CD Button Inoper ati vv

Data Cable Diagnostic Pr e – ocedur ee

All with CD A uto Changer

The CD button fails to operate the CD Auto Changer or operates intermittently.

The button may correctly operate the Auto Changer after the data cable connectors are disconnected and reconnected.

If the data cable has been stressed, the internal strain relief may come loose causing intermittent short or open circuits in the cable wires or ground connection.

If the CD Auto Changer fails to operate when the CD button is pushed, or the system operates intermittently, follow the procedure outlined below.

CD AUTO CHANGER DATA CABLE DIAGNOSIS PROCEDURE

1 Disconnect the shielded data cable from the CD Auto Changer and the radio.

2 Check the continuity of each wire in the cable (Illustration 1).

A UT O CHANGER D A T A CABLE END CONNECT ORS

1/3.2

ILLUSTRATION 1

3 Check the continuity of the ground shield.

4 Check each pin in the connector for short circuits to any other connector pin, the ground shield or the vehicle.

tug the cable and twist the connector end to check for intermittent faults.

5 If a short, open or intermittent fault is found, do not attempt to repair the cable. Complete a Product Quality Report S-94 explaining the fault, area of damage and repair. Fax the completed report to Jaguar Cars as instructed on the report.



Deletion of Mirror Memory -

Identifying Modification

86-151


See VlNs listed below

DATE 6/95

The door mirror memory function was factory deleted on all 1994 model year

Sedan Range vehicles as of VIN 701123 as described in Technical Bulletin 04-14 of

3/94.

Approximately 500 Sedan Range vehicles from VIN 687219 to 701123 had the memory specification change performed in service.

On all vehicles, the seat memory remains fully functional. The mirror position memory and the passenger side door mirror dip function in reverse are the only functions deleted.

If the mirror positions are not retained in the memory function, check if the memory feature was deleted. Vehicles without the mirror memory function can be identified by checking near the Seat Control Module (SCM). An additional

48-pin connector with only 10 wires will be present. This additional connector has a shorting plug installed, Illustration I.

NOTE: The deleted mirror memory function is the correct specification for the vehicle. Do not attempt to modify the system to allow mirror memory operation since the individual vehicle was not sold with this feature.

SHORTING PLUG CONNECTOR

SCM CONNECTOR


ADDITIONAL CONNECTOR DRIVER’S SEAT

JSl-2148

ILLUSTRATION 1


A Sedan Range vehicle without mirror memory will function as follows:

OPERATION RESULT

Select driver mirror on switch pack Driver’s mirror switch enabled

Operate switch up/down Driver’s mirror moves up/down

Operate switch left/right Driver’s mirror moves left/right

Select passenger mirror on switch pack

Operate switch up/down

Operate switch left/right

Passenger’s mirror switch enabled

Passenger’s mirror moves up/down

Passenger’s mirror moves left/right

Switch ignition on

Operate seat using seat switch pack

Slide towards rear

Cushion front down

Cushion rear down

Recline towards rear

Headrest down

Seat slide moves toward rear

Front of seat cushion moves down

Rear of seat cushion moves down

Seat recline moves toward rear

Headrest moves down

Press ‘M’ and ‘1’ buttons simultaneously Memory set 1

Operate seat using seat switch pack

Slide towards front

Cushion front up

Cushion rear up

Recline towards front

Headrest up

Seat slide moves toward front

Front of seat cushion moves up

Rear of seat cushion moves up

Seat reline moves toward front

Headrest moves up

Press ‘M’ and ‘2’ buttons simultaneously Memory set 2

Press ‘1’ button

Press ‘2’ button

Recalls memory 1 excluding mirrors

Recalls memory 2 excluding mirrors

Switch ignition off

Press entry switch Seat moves down/rearward

Page 2 of 2 Date of issue 6/95 9



Seat Control Module –

Loss of Seat or Mirror Functions –


MODEL XJS Range 1994 MY

VIN 190528 - 192880

DATE 7/95

86-159

ISSUE:

Loss of any driver seat adjustment, door mirror adjustment, or any combination of seat and mirror adjustments in 1994 MY XJS Range vehicles from VIN 190528 - 192880, may be caused by a failure of the seat control module (SCM). If a function fails, it would cause the adjustment that it controls to remain at its last set position. To prevent repeat failure of the SCM, the mirrors must also be replaced.

ACTION:

If the seat control module fails on a 1994 MY XJS Range vehicle within the VIN range listed above, BOTH door mirrors must be replaced with revised mirror units when the SCM is replaced.

NOTE: A production change within the VIN range added capacitors to the door mirror motors. The capacitors, which were added to reduce radio interference, may induce an electrical resonance in the mirror circuit causing SCM failure.


DESCRIPTION

Seat control module (SCM)

Door mirror - left side (chrome)

Door mirror - left side (primed)

Door mirror - right side (chrome)

Door mirror - right side (primed)

PART NO.

LHB 2165AA

HHE 3043AA

HHC 3043AB/XXX

HHE 3042CA

HHC 3042CB/XXX

QTY

1

1

1

1

1


FAULT

CODE

SX CC JY

WH BB RN

WH DB RN

R.O. NUMBER

86.75.15.09

76.10.52.09

76.10.52.09

DESCRIPTION

SCM - Replace (w/out JDS test)

Door mirror, driver - Replace (w/out JDS test)

Door mirror, passenger - Replace (w/out JDS test)

TIME

ALLOWANCE

0.15 hrs.

0.30 hrs

0.30 hrs



Cooling F ans – Run Continuousl

Switc h Harness Repair y –




Some XJ6 and XJ12 vehicles in the above VIN range may experience continuous running of the cooling fans caused by corrosion in the harness connector of the fan switch.

A replacement link harness is available to repair a corroded connector without replacing the side harness.

If corrosion of the fan switch harness connector is determined to be the cause of continuous cooling fan operation, proceed as follows:

FAN SWITCH HARNESS REPAIR

1.

Obtain the radio code from dealer records or the customer.

2.

Disconnect the vehicle battery after positioning the vehicle on a hoist.

3.

Disconnect the harness from the fan switch located on the left radiator tank above the coolant outlet.

4.

Raise the vehicle on the hoist.

5.

Remove the left side front fog lamp harness from the mounting bracket.

Bulletin Number 86-163 Amended Date of issue 1/96 Page 1 of 4

6.

Remove the left side front turn signal lamp from the bumper aperture.

7.

Remove the fan switch harness (illustration 1) and the front fog lamp harness through the turn signal lamp opening.

COMP ARING LINK HARNESS LENGTH

F AN SWITCH HARNESS

JSI-2632

ILLUSTRATION 1

8.

Carefully unwrap the harness tape (inset, Illustration 1) to expose the fan switch wiring and the fog lamp wiring.

9.

Compare the length of the replacement link harness to the existing fan switch harness to mark the point where the existing harness should be cut. Unwrap the tape beyond the mark and then cut the harness at the mark to ensure that the length of the harness will remain the same after the repair.

the black wire for the fog lamp harness.


10. Cut the insulation back 9/32 in. (7 mm) on the cut ends of the fan switch wiring. The insulation on the replacement link harness is already cut back

(Illustration 2).

JSI-2633

ILLUSTRATION 2

11. Crimp the “Duraseal” connectors onto the bare wire ends of the replacement harness.

12. Crimp the connectors on the bare wire ends of the vehicle harness to connect the replacement link harness to the vehicle harness.

13. Use a suitable heat gun to shrink the insulating sleeves on the connectors.

14. Apply electrical insulation tape to the harness to cover the connectors and wrap the harness together. Wrap the harness only up to point where the fog lamp and fan switch wiring branched previously.

15. Reinstall the fog lamp harness connector on the mounting bracket.

16. Reconnect the fog lamp.

17. Reconnect the fan switch harness to the fan switch located on the radiator.

18. Reinstall the turn signal lamp into the bumper opening.

19. Lower the vehicle hoist.


21. Enter the radio code and reset the clock.

Bulletin Number 86-163 Amended Date of issue 1/96 Page 3 of 4


Radiator fan switch kit (XJ6)

Radiator fan switch kit (XJ12)

P AR

JLM 12040

JLM 12041


F A U L T

86.92.04

10.10.10

Install link harness

Drive in/drive out

A L L O W A N C E

0.50 hrs.

0.15 hrs.

1

1



Inadv ertent Radio

Hands-fr

Antenna Oper ee Oper

Cellular T ation –

T elephone ation –


On vehicles equipped with cellular phones that feature hands-free operation, certain circumstances can cause the radio antenna to extend unintentionally. If the antenna extends in an automatic car wash or in an area with restricted overhead clearance, damage can occur to the antenna mast.

The cellular telephone and the radio are linked to provide radio muting when the phone is in use. If the radio is off, use of the phone will switch on the radio so that the rear door speakers can be used for hands-free telephone operation. This action will also cause the antenna to extend even though the radio was not in use.

The antenna will extend under the following set of circumstances:

••••• Radio OFF.

••••• Ignition switch in position I or II.

••••• Phone switched ON (standby).

••••• Incoming phone call is received (or an outgoing call is made).

The antenna mast will remain extended for the duration of the telephone call and the timed power down.

Customers whose vehicles are equipped to use hands-free phone operation should be informed of the above situation and be advised of the following suggested action.

To ensure that the antenna mast remains down to avoid damage, the customer should be advised to:

••••• Switch the radio OFF

••••• Switch the ignition OFF.

- OR if the engine is left running:

••••• Switch the radio OFF

••••• Switch the telephone OFF using the telephone key pad.



Compact Disc Changer – LXF 4160C A –

1993-94 MY Sedan Range Installation


A unique bracket has been developed to allow the installation of third generation

(1995-96 MY Sedan Range) CD autochangers (part no. LXF 4160CA) in the 1993-94

MY Sedan Range vehicles.

The instructions have been written specifically for 1993-94 MY Sedan Range vehicles and must not be used for installing the autochanger in any other vehicle.

A CTION:

PRE-INSTALLATION REQUIREMENTS

1.

Remove the battery cover and spare tire assembly.

2.

Loosen and lower the top of the luggage compartment forward liner to gain access to the fuel tank area.

INSTALLING THE CD AUTOCHANGER

1.

Route the data cable over the luggage compartment forward liner, then reposition and fully seat the liner; ensuring that the data cable is positioned so it cannot be trapped by the trunk lid hinge.

2.

Remove the three transit screws (Illustration 1) from the base of the autochanger unit and install them in the three storage holes provided on the

A UT OCHANGER


S T ORA GE HOLES

T OP OF CHANGER

ILLUSTRATION 1


back of the autochanger to prevent their loss.

3.

Using the screws provided, attach the bracket to the left and right hand securing screws.

4.

Remove the protective cap from the data cable, then connect the data cable to the flylead on the CD autochanger.

5.

Place the assembled unit against the underside of the upper panel, aligning the holes in the mounting brackets with those in the upper panel. Install the vehicle.

6.

Position any left over data cable behind the luggage compartment forward liner.

7.

Reinstall the spare tire assembly, and the battery cover.

8.

Check the CD autochanger unit for the correct operation; refer to the detailed information in the Sound System Handbook supplied in the Driver’s

Literature Pack.

Mounting bracket

Mounting bracket to body bolts

Mounting bracket to CD autochanger screws

1

4

4


CD autochanger mounting bracket

CD autochanger

P AR T NUMBER

JAG 523

LXF 4160CA

1

1



T runk Latc h – Modified P

Install Using Short Scr art – ee


The original trunk latch (BEC 4829 or BEC 19331) for 1990-93 MY Sedan Range vehicles within the above VIN range is no longer serviced. The 1994 MY Sedan

Range trunk latch (GMB 3500AB) can be installed together with a shorter screw

(SE 604031/J).

A CTION:

Install trunk latch GMB 3500AB (Illustration 1) using screw SE 604031/J in place of the longer screw originally used on the vehicle. Reuse the plain washer and the lockwasher (Illustration 1) originally on the vehicle with the shorter screw.

TRUNK LA TCH

L OCKW A SHER

W A

TRUNK LA TCH

ILLUSTRATION 1


Trunk latch

Screw


P AR T NUMBER

GMB 3500AB

SE 604031/J

Date of issue 9/96

1

1

Page 1 of 1


Inoperative Blue Relay –

Oxidized or Damaged Terminals –

Checking/Replacement Guidelines


XJS Range

DATE 5/97

86-178

Amended

8/97

Remove and destroy Bulletin 86-178 dated 5/97.


The blue Hella relay (part no. DAC 7686) was used in a variety of locations and

XJS and S edan R ang

In many cases relays have been replaced without being diagnosed properly. In other cases, the relay has been replaced with the identical relay in a location where the use of the new sealed relay (part no. LHF 6703AA) is more suitable.

This bulletin outlines what to check before replacing a relay and where to use a

Malfunction of the relay while installed on the vehicle can be caused by:

• An invisible oxide film on the relay terminals.

• Loose or damaged terminals in the relay base.

NO TE: relay controlling the AIR pump clutch should be checked or replaced as outlined in bulletin 17-9 Service Action S 458.

A CTION:

CHECKS TO PERFORM BEFORE REPLACING RELAY

Before replacing a relay, check the following:

• Remove and reinstall the relay for the affected circuit. This action is often enough to clean off the oxide-film and allow the relay to operate correctly.

This is particularly the case in circuits where the relay switches a current of only a few milliamps.


• If the relay still does not operate correctly, check the condition of the terminals in the relay’s base. Check the force required to insert a terminal blade in each individual terminal of the relay base by using a spare ‘Lucar’ male terminal

(Illustration 1) or by removing the relay and turning it so that one blade can be inserted into each terminal of the relay base, one at a time.

CHECKING TERMINAL INSER TION FORCE

RELA Y POSITIONED

INDIVIDUAL TERMINALS

LUCAR TERMINAL

RELA Y BA

JSI-3127 JSI-3126

ILLUSTRATION 1

Tighten any loose terminals by pulling the terminal out of the relay base using the previously supplied Jaguar special tools (or equivalent such as Snap-On

GA500A) and carefully closing the terminal with pliers to tighten the grip on the relay blade. Do not attempt to tighten the terminal while it is still in the relay base. Insert the terminal back into the relay base. Reinstall the relay and recheck its operation.


EXCESSIVE PROBE INSER TION

JSI-3128

ILLUSTRATION 2

Loose terminals can be caused by forcing multimeter probes deep into the terminals (Illustration 2). To avoid this condition, lightly contact the terminals with the probes (Illustration 3).

CORRECT PROBE INSER TION

JSI-3129

ILLUSTRATION 3

If the relay still does not operate after checking the above, replace the relay after noting the valid applications for the sealed relay as listed on the following page.


APPLICATIONS FOR SEALED RELAYS

A sealed relay (part no. LHF 6703AA) is now available which is interchangeable with part no DAC 7686. When replacing a failed relay in any of the applications listed below (mainly engine compartment) use LHF 6703AA instead of DAC 7686.

The sealed relay is more resistant to the entry of water and silicone solutions.

A/C compressor clutch

ECM controls (XJS)

Headlights

Radiator fan (XJS)

Air injection pump clutch ECM controls (XJS)

Fuel injection

Horn

Sidelights

Fuel pump (Sedan trunk)

Oxygen sensor

Transmission power

For additional information, refer to the vehicle-specific Electrical Guide.

In all other applications, continue to replace the relay with the original type.

NO TE:

AGU 1070 relays used for high load applications on XJS models.


Relay

Sealed relay

IDEN TIFICA TION

Hella DAC 7686 (blue)

Hella (black)


F A UL T

JZ FB ** A/C compressor clutc h relay

BG CC ** Air injection pump clutc h relay*

BJ BJ ** Breather heater relay

BX CB ** ECM control relay (XJS)

BC CC ** F uel injection relay

CZ BC ** F uel pump relay -

CZ BB ** F uel pumps relay - V1 2 (sedan trunk)

QB MB ** Headlight relay

MD BF ** Horn relay

BB GH ** Oxygen sensor relay

DN GB ** R adiator fan relay (XJS)

MD HB ** Sidelight relay

FZ QB ** T ransmission power relay

P AR T NUMBER

DAC 7686

LHF 6703AA

R efer to the appropriate W ar ranty Codes & R epair Operation T imes Manual for applicable



Poor Antenna Mast Operation –

Cleaning – Replacing


XJS Range

DATE 7/97

86-179

Poor operation of the power antenna is most frequently caused by a jammed mast. Any movement of the mast, when switching the radio on or off, indicates that the power antenna motor is operating. A time-out function shuts the motor off if there is no further movement of the antenna mast. As a result, power antenna motor units must not be replaced without proper diagnosis and inspection of the antenna mast.

A CTION:

When diagnosing a customer complaint of poor extending or retracting of the antenna mast on the above listed vehicles, proceed as follows:

1.

Check the telescopic section for cleanliness. A mast cleaning kit is available, part no. JLM 9830.

2.

If cleaning does not result in proper operation, or if the mast is physically damaged, replace the mast section.

REPLACING ANTENNA MAST

1.

Switch the radio off. Loosen the locking nut between the grommet and the mast guide tube, Illustration 1.

2.

Have an assistant switch on the ignition and radio.

L OOSENING TENNA MA S T L


ILLUSTRATION 1

Date of issue 7/97

JSI-383

Page 1 of 4

3.

As the mast extends fully, loosen the locking nut completely and simultaneously pull the mast gently upwards.

4.

The mast and drive cable will be released by the motor (Illustration 2). Full extension of the mast should take approximately 7 seconds. A built in timer will shut off the drive motor after approximately 12 seconds.

REMO VING AN TENNA MA S T A S CABLE IS RELEA SED

JSI-383A

ILLUSTRATION 2

5.

If the drive cable is not released from the drive mechanism, the assistant should switch the radio off and on again immediately. Do not let go of the mast after locking nut is fully loosened and do not exert excessive force on the cable in attempts to release it.

NO TE: which direction the teeth on the cable are facing (forward or toward the driver’s side, so that the replacement can be aligned correctly during installation.

Leave the ignition and the radio switched on.


INSTALLING REPLACEMENT MAST

1.

Insert the drive cable into the tube with the teeth aligned in the same direction as the old cable, Illustration 3. Push the cable in until it contacts the drive mechanism (Illustration 4).

INSER TING AN TENNA DRIVE CABLE

ILLUSTRATION 3

2.

Have an assistant switch the radio off. After a brief delay, the antenna drive motor should start.

3.

Maintain slight pressure on the drive cable, so that as the motor starts, the cable engages with the mechanism, Illustration 4. If the cable does not engage, twist the cable slightly from side to side until it engages.

ENGA GING CABLE


ILLUSTRATION 4

Date of issue 7/97

JSI-383B

Page 3 of 4

4.

After allowing the mast to retract fully, tighten the locking nut (Illustration 5) and check antenna operation. If the motor stops before the antenna is fully retracted, tighten the locking nut, switch the radio on again to fully extend the mast. Switch the radio off again. The mast should now retract fully.

TIGHTENING AN TENNA MA S T L OCK NUT

JSI-383D

ILLUSTRATION 5


Antenna cleaning kit

Replacement mast assembly

Sedan Range up to VIN 687218

XJS Range up to VIN 190527

Replacement mast assembly

Sedan Range from VIN 687219

XJS Range from VIN 190528

P AR T NUMBER

JLM 9830

DBC 2200

LNA 4134AA

A/R

1

1


F A UL T

PD BC ** 86.50.29

Replace antenna mast

ALL O W ANCE

0.10 hrs.

NO TE: only. Replacement of bent or broken masts is not covered.

Antenna mast cleaning is part of routine service.



Erratic Fuel Gauge - Sender Unit Float Rod

Sticking - Replace Sender Unit

MODEL All 1994 MY

DATE 9/94

88-19

ISSUE:

The fuel gauge on the following vehicles may indicate more fuel than is in the tank, then suddenly drop to the correct reading. A tight float rod bushing in the fuel tank sender unit causes the float to stick.

• Sedan Range 1994 MY from VIN 687219 to VIN 694093

• XJS Range 1994 MY from VIN 190528 to VIN 191261.

NOTE: Sender units that may have tight float rod bushings are labeled with date codes 2893 to 3693 (week 28 to week 36, 1993). Not all sender units within this date code range have tight bushings.

The date code label is on the outside of the sender unit, visible from the luggage compartment

ACTION:

If vehicles within the affected VIN range exhibit erratic fuel gauge readings, replace the fuel tank sender unit. Refer to the appropriate Service Manual section 19 for repair instructions.


DESCRIPTION

Sedan Range 1994 MY fuel tank sender

XJS Convertible 1994 MY fuel tank sender

XJS Coupe 1994 MY fuel tank sender

PART NUMBER

DBC 12042

DAC 7942

DAC 7943

NOTE: Jaguar Cars Parts Department stock has been purged of affected fuel tank sender units.


FAULT

CODE

R.O. NUMBER

MC CB NS 88.25.32/09

DESCRIPTION

Fuel tank sender Sedan Range - Renew

Fuel tank sender XJS Range - Renew

TIME

ALLOWANCE

0.30 hrs.

0.25 hrs.



Engine Oil Pressure – Incorrect Low Oil

Pressure Warning – Repair Procedure

MODEL XJ12 Sedan 1994 MY DATE 1/95



The model information has been revised to indicate 1994 MY

XJ12 only.

88-20

Amended

9/95

ISSUE:

The low oil pressure warning light on XJ12 Sedan vehicles may illuminate at idle with the engine at normal operating temperature and idle oil pressure within specification (minimum idle oil pressure - 7 psi [0.5 bar]).

This condition is caused by thinner, energy efficient engine oils.

ACTION:

If a customer complains of a low oil pressure warning at idle and the oil pressure is within specification, replace the existing oil pressure transducer with an oil pressure sensor switch.

NOTE: The oil pressure switch will affect the operation of the oil pressure gauge.

The oil pressure gauge will read at mid-scale under all normal driving conditions. It will only move (to zero) if a low oil pressure warning occurs.

Follow the procedure below to replace the oil pressure transducer with an oil pressure sensor switch.

ENGINE OIL PRESSURE TRANSDUCER REPLACEMENT PROCEDURE

1.

Check engine oil level.

2.

At normal operating temperature, check that engine idle speed and oil pressure are within specification.

Engine idle speed:

Engine oil pressure at idle:

700 ± 25 rpm

7 psi (0.5 bar) minimum.

3.

If the idle speed and oil pressure are within specification, replace the engine oil pressure transducer with an engine oil pressure sensor switch (part number LMC 5642AA).

4.

Connect an engine harness link lead (part number LMD 3325AA) between the oil pressure sensor switch and the engine harness transducer connector. Tape the link lead to the harness.

5.

Run the engine at idle (normal operating temperature). The pressure gauge should be at mid-scale and there should be no low oil pressure warning.


PARTS INFORMATION:

PART NUMBER

LMC 5642AA

LMD 3325AA

DESCRIPTION

Oil pressure sensor switch

Engine harness link lead


FAULT

CODE

R.O. NUMBER

MC DB FW 88.25.07

DESCRIPTION

Renew oil pressure transmitter

QTY

1

1

TIME

ALLOWANCE

0.50 hrs.


Sedan Range

DATE

2/95 01-03


MODEL

Winter (Snow) Tire Specifications – XJR

Sedan

VIN

1995 MY

XJR Sedan

720001-ON

ISSUE:

The winter (snow) tires specified in the 1995 MY XJR Vehicle Care handbook are not available.

The alternative tire, Pirelli 235/45 R 17 93H Winter 210P, is slightly smaller in diameter than the original equipment Pirelli P Zero 255/45 ZR 17 tire. This difference will result in a slight speedometer error.

ACTION:

If customers with XJR vehicles require winter (snow) tires, Pirelli 235/45 R 17 93H Winter 210P tires may be fitted.

IMPORTANT: Winter (snow) tires MUST be fitted to all four wheels.

Advise the customer of the following:

• Pirelli 235/45 R 17 93H Winter 210P must be fitted to all four wheels of the vehicle in order to preserve vehicle handling characteristics and the operation of the ABS and traction control systems.

• Pirelli 235/45 R 17 93H Winter 210P tires are speed rated for 100 mph with the tire pressure set at 28 psi.

• Tire pressure should be set as follows:

Comfort setting

Normal setting

FRONT

28 psi

34 psi

REAR

28 psi

34 psi

SPEED RATING

100 mph

130 mph

PARTS INFORMATION:

Source tires from a Pirelli tire dealer.

TIRE DESIGNATION

235/45 R 17 93H Winter 210P

PIRELLI CATALOG NUMBER

9C600F



Tires and Wheels – Tires “Flat Spotting” –

Wheel Balance Procedure

MODEL All

DATE 8/94

04-15

ISSUE:

Symptoms of road wheel and vehicle vibration caused by tire “flat spotting” may be confused with vibration symptoms caused by out of balance tire/wheel assemblies.

Tire flat spots develop when the vehicle is at rest. They are characteristic of high performance tires and develop more rapidly when the tires are hot.

Tire “flat spotting” symptoms:

• A shaking motion of the vehicle at 30 MPH

• Road wheel vibration at 60-64 MPH - Front tire “flat spotting”

• Road wheel vibration at 68-72 MPH - Rear tire “flat spotting”

ACTION:

If customers complain of vehicle or road wheel vibration, perform the following procedure to determine if the symptoms are caused by tire “flat spotting” or out of balance tire/wheel assemblies.

Diagnostic procedure:

1.

Set cold tire pressure to “comfort settings”.

2.

Drive the vehicle for 10 to 15 miles.

3.

If the vibration symptoms are caused by “flat spotting”, the vibration will decrease as the tires “run off” the “flat spotting”.

NOTE: In extreme cases it may take 15 to 20 miles to “run off” the flat spots.

No repair is necessary for “flat spotting”. Advise the customer that the condition is a characteristic of high performance tires.

4.

If the vibration symptoms do not diminish, the tire/wheel assemblies should be balanced.

IMPORTANT: If the tire/wheel assemblies are out of balance after the road test, immediately raise the vehicle on a lift until its tires are off the ground. This will avoid the risk of the tires developing flat spots before balance is checked.

Tire/wheel balance procedure:

1.

Set cold tire pressure to “comfort settings”.

2.

Mount the tire and wheel assembly on the wheel balancer. Ensure the correct adapters are used and the assembly is mounted correctly on the balancer.

3.

Check the tire and wheel assembly balance.


4.

If the assembly is out of balance, remove all existing balance weights and clips and recheck balance.

NOTE: For vehicles 1993 MY On use only Jaguar specification two piece, clipon wheel weights (Illustration 1).

TWO PIECE WHEEL WEIGHT

ILLUSTRATION 1

04.15.1

5.

Install required wheel weights and recheck balance.

Two piece, clip-on wheel weight installation procedure:

NOTE: This procedure is demonstrated in the XJS Range 1994 Model Year Update video tape at 8 minutes and 45 seconds from the beginning of the program.

1.

Compress the inflated tire at the bead, and the shoulder with compression tool HAW 900

(Illustration 2).

COMPRESSION TOOL HAW 900

BEAD

SEE NOTE A

SHOULDER

SEE NOTE B

LIFT TO COMPRESS TIRE BEAD COMPRESSED TIRE BEAD

ILLUSTRATION 2

NOTE A: Inner edge of compression tool must be placed close to rim.

NOTE B: Outer swivel foot of compression tool must be placed onto shoulder of tire.

04-15.2


2.

Insert the wheel weight clip between the tire bead and the road wheel as shown in Illustration 3. Release the compression tool.

3.

Spread the wheel weight clip using the two piece clip tool HAW 900/1. Slide the weight under the clip. Ensure that the weight is fully seated.

INSTALLING WHEEL WEIGHT

CLIP

HAW 900

CLIP

WHEEL RIM

ILLUSTRATION 3

WEIGHT

04-15.3

4.

Recheck balance.

TOOL INFORMATION:

TOOL NUMBER

HAW 900

HAW 900/1

PARTS INFORMATION:

PART NUMBER

CCC 6890 1

CCC 6890 2

CCC 6890 3

CCC 6890 4

CCC 6890 5

CCC 6890 6

CCC 6890 7

DESCRIPTION

5g Wheel weight

10g Wheel weight

15g Wheel weight

20g Wheel weight

25g Wheel weight

30g Wheel weight

35g Wheel weight


FAULT

CODE

5MBM

R.O. NUMBER

74.20.

DESCRIPTION

Compression tool

Two piece clip tool

PART NUMBER

CCC 6890 8

CCC 6890 9

CCC 6890 10

CCC 6890 11

CCC 6890 12

CCC 6890 13

DESCRIPTION

40g Wheel weight

45g Wheel weight

50g Wheel weight

55g Wheel weight

60g Wheel weight

70g Wheel weight

DESCRIPTION

Use shop time



Transit Spark Plugs –

No Longer Fitted To XJ12/XJS (V12)

MODEL XJ12 SEDAN, XJS (V12) 1995 MY DATE 12/94

04-17

ISSUE:

Transit spark plugs are no longer fitted to XJ12 Sedan and XJS Range (V12) vehicles from the

VINs listed below.

MODEL

XJ12 Sedan 1995 MY

XJS Range (V12) 1995 MY

VIN

From 720001

From 198335

ACTION:

Do not replace the spark plugs of 1995 MY XJ12 Sedan vehicles from VIN 720001 or 1995 MY

XJS (V12) vehicles from VIN 198335 at PDI.


Warranty claims under Summary Code XJ will not be accepted for XJ12 Sedan vehicles after VIN

708757.

Warranty claims under Summary Code XJ will not be accepted for XJS (V12) vehicles after VIN

198335.



Automatic Transmission – Defaults To

“Limp Home” in Wet Weather –


MODEL

Sedan Range (4.0L) up to 93 MY

DATE

12/94

04-18

ISSUE:

The Transmission Failure malfunction indicator lamp (MIL) illuminates and the transmission defaults to the “Limp Home” mode during rain or after using a car wash.

Water can enter the vehicle through the engine management harness grommet in the vacuum tank under the battery tray. The water can drip onto the Transmission Control Module (TCM) causing it to illuminate the transmission MIL and default to the “Limp Home” mode.

ACTION:

If 4.0L Sedan Range vehicles up to 1993 MY (VIN 667829) illuminate the transmission MIL and default to “Limp Home” mode during rainy weather or after using a car wash, seal the EMS harness grommet as described below.

1.

Record the preset radio stations (including X-mem) and remove the battery from the vehicle.

2.

Remove the battery tray, disconnect the EMS harness from the vacuum tank and remove the vacuum tank

3.

Inject a liberal amount of Bostik Alpha Seal 132 or an equivilant sealant into the areas shown in Illustration 1.

A. - Around the vacuum tank inner recess for the grommet.

B. - Around the EMS harness at the front and back of the grommet

C. - Between the EMS harness grommet and the body panel face

ENGINE MANAGEMENT HARNESS GROMMET LOCATION

A

B

C

B

9/6.1.1

ILLUSTRATION 1

4.

Replace the vacuum tank and press down firmly to squeeze the sealant around all of the


joints

5.

Clip the EMS harness into place.

6.

Reassemble the battery tray before the sealant sets. Torque the mounting bolts to 12 - 16 lb ft (15.5 to 20.5 Nm).

7.

Install the battery, code the radio, and reset the radio stations and clock.

PARTS INFORMATION:

Bostik Alpha Seal 132 or equivilant - source locally

Source sealant locally


FAULT

CODE

FX CB PS

R.O. NUMBER

86.91.58

DESCRIPTION

Seal EMS harness

TIME

ALLOWANCE

0.40 hrs.



Clutc h Hydr aulic Hose –

Install Pr otecti vv

Ser vice e Slee vv vice Action S 452

Manual T ansmission onl yy

Some 4.0L XJS Range manual transmission vehicles within the above VIN range may experience interference between the clutch hose and the bulkhead heatshield. This condition may lead to abrasion of the clutch hydraulic hose.

Inspect the hose at the next service opportunity or in the event of a customer complaint. On all vehicles, install a protective sleeve over the clutch hose as described below. Replace the clutch hose if abrasion has occurred.

1. Examine the clutch hydraulic hose between points A and B, Illustration 1. Check for signs of abrasion caused by contact with the bulkhead heat shield.

found, proceed to step 3.

3. On all vehicles, wrap the spiral protective sleeve (part number CCC 5388) around the existing or replacement clutch hydraulic hose from point A, the bulkhead attachment point, to point B where the rubber sleeve starts. Apply the wrapping so that no part of the flexible hose remains visible between points A and B, Illustration 1.


JSI-2576

ILLUSTRATION 1


XJS CONVERTIBLE AND CONVERTIBLE 2 + 2

190605, 190608, 190755, 190762, 190768,

190786, 190852, 190869, 190887, 190974,

190981, 191095, 191215, 191372, 191390,

191393, 191400, 191410, 191415, 191418,

191419, 191457, 191571, 191604, 191617,

191734, 192139, 192317, 192605, 192655,

192665, 192751, 192767, 192805, 192845,

192873, 192897, 193089, 193217, 193240,

193281, 193292, 193528, 193693, 193792,

193893, 193944, 193952, 193957, 193996,

194011, 194020, 194049, 194129, 194428,

194469, 194472

XJS COUPE

190925, 191417, 191447, 191462, 191579,

191762, 191789, 191909, 192290, 192318,

192770, 193030, 193086, 193126, 193182,

193562, 193586, 194062, 194070


P AR TS INFORMA

Clutch Hose Protection (all vehicles)

Hydraulic Clutch hose (as required)

P AR T NUMBER Q T Y

CCC 5388

CCC 2678

1

1


Service Action S452

XJS (4.0L)

1994 MY

Manual Trans.

VIN 190528-194774

Model codes

3000, 3030, 4234

S U M M A RY DESCRIPTION

HW

A L L O W A N C E

Check clutch hydraulic hose - if not chafed, 0.20 hrs.

install protective sleeve without drive-in/out time

Check clutch hydraulic hose - if not chafed, 0.35 hrs.

install protective sleeve with drive-in/out time

XJS (4.0L)

1994 MY

Manual Trans.

VIN 190528-194774

Model codes

3000, 3030, 4234

HX

XJS (4.0L)

1994 MY

Manual Trans.

VIN 190528-194774

Model codes

3000, 3030, 4234

HY Clutch hydraulic hose - replace, install protective sleeve without drive-in/out time

0.30 hrs.

XJS (4.0L)

1994 MY

Manual Trans.

VIN 190528-194774

Model codes

3000, 3030, 4234

HZ Clutch hydraulic hose - replace, install protective sleeve with drive-in/out time

0.45 hrs.




DCS DEALERS


NON-DCS DEALERS




Pir elli P5 Discontinued –

Replace with P4000 Super T ouring

MODEL All 1984-92 MY

The Pirelli P5 tire is being discontinued. As a replacement Pirelli is now offering the P4000 Super Touring with a V speed rating in the 15” sizes Jaguar has previously used. The replacement tire has been approved by Jaguar Cars.

The model applications affected are:

1988-92 Sedan Range equipped with P5 in size 205/70 VR 15.

1984-88 XJS

1984-86 Series III equipped with P5 in size 215/70 VR 15.

equipped with P5 in size 215/70 VR 15.

The tire manufacturer recommends the following:

••••• Tires should be replaced in pairs when not being replaced as a set of four.

••••• New tires should be installed on the rear axle.

••••• Inflation pressures are the same as recommended by Jaguar for the P5 (see owner’s manual or door sticker).

For additional information, contact:

ORDERING INFORMA TION:

205/70R15 95V

215/70R15 97V

P4000 Super Touring

P4000 Super Touring

CA T AL OG NO

9E604A

9E602A


Sedan Range

DATE

11/94 13-04


Interior Protection – Changes

Removal

MODEL

1995 MY

Sedan Range

VIN

720001-ON

ISSUE:

The interior protection kit, fitted to new vehicles since the 1993 MY, has been improved. The following areas are protected for the 1995 MY.

• Carpet

• Footwell tray

• Front door casing

• Front door top roll

• Console tray

• Center console cover

• Center console rear extension

• Gear selector knob

• Sill carpet and tread plate

• Steering wheel

• Lower “A” post

• Parking brake

• Roof console

Note: Interior protection components are manufactured from recyclable clear PVC

(polyvinylchloride).

ACTION:

Vehicle interior protection should remain in place during PDI. Interior protection components are designed for easy removal, however the following instructions must be followed.

IMPORTANT: Interior protection should remain in place until just before delivery to the customer. DO NOT CUT ANY OF THE INTERIOR PROTECTION

TO REMOVE IT. REMOVE BY HAND ONLY.

CARPET PROTECTION

Carpet protection can be easily peeled from the carpet and eased from under the tread plate. The tread plate does not require removal.


FOOTWELL TRAY

Unscrew the carpet fastener 1/4 turn and remove to lift out the tray (Illustration 1). Replace the carpet fastener.

CARPET PROTECTION

04-16.1

ILLUSTRATION 1

DOOR CASING

Remove door casing protection (Illustration 2) in the following sequence.

1.

Remove the tape from the armrest.

2.

Pull the protection down from under the top roll.

3.

Pull the protection away from the door.

4.

Pull the cover down from the door.

5.

Pull the cover forward, away from the door. Tabs on the cover align with the door casing clips.

DOOR CASING

2

1

2

3

5

4

ILLUSTRATION 2

04-16.2


FRONT AND REAR SILL AND TREAD PLATE

Pull the sill cover down while gently easing the tread plate up (Illustration 3).

SILL AND TREAD PLATE

2

1

STEERING WHEEL

Remove the paper tape by hand only

ILLUSTRATION 3

04-16.3



Rough Idle – Install Softer Front Engine

Mounts

MODEL Sedan (4.0L) Range

Up to VIN 683923

DATE 1/94

Remove and destroy Bulletin 12-47 Amended 1/95, Date 1/94.



12-47

AMENDED

6/95

ISSUE:

To reduce engine vibration on 4.0L Sedans when the engine is idling in "Drive," softer front engine mounts have been introduced on production vehicles beginning with VIN 683924.

Factory installed soft engine mounts are marked with paint; the right side mount is marked with orange paint, the left side mount is marked with brown paint.

The new engine mounts can be installed on earlier 4.0L sedans. Soft mounts from parts stock have a unique number but are not marked with paint.

ACTION:

For customer complaints of engine vibration or rough idle in "Drive" on 4.0L sedans up to VIN

683923, install new left and right engine mounts using the part numbers below.

For replacement procedures, refer to the XJ6 Service Manual sections 12.45.01 and 12.45.03.


Warranty claims for this repair may be submitted for vehicles within the normal warranty period.

FAULT

CODE

R.O. NUMBER

GF DC HR 12.91.13/20

DESCRIPTION

Engine Vibration at idle/Replace front engine mounts

TIME

ALLOWANCE

1.65 hrs.

PARTS INFORMATION:

PART NUMBER

MMB 7520BA

MHC 7521AA

DESCRIPTION

Right side engine mount.

Left side engine mount

QTY.

1

1

Bulletin Number 12-47 AMENDED 6/95 Page 1 of 1


Oil Leak – Generator Bracket Bolts – Seal

With Loctite 545

12-50

Amended

11/94

MODEL

AJ6 Engine All

DATE

7/94


Replace with this Amended Bulletin.


ISSUE:

Oil leakage from the front left side of the engine sump may originate from the generator mounting bracket bolts. Two of the four mounting bolts are threaded into the sump housing, the other two thread through the sump.

Beginning with VINs listed below, sealer has been applied to all generator mounting bracket bolt threads in order to prevent leaks in this area.

Sedan Range (4.0L)

XJS Range (4.0L)

From VIN 686340

From VIN 189532

ACTION:

On vehicles with oil leaking from the generator bracket bolts, seal all bolts with Loctite Thread

Sealer #545 (Jaguar P/N 54531) using the following procedure:

1. Ensure that the radio code is available. Record all preset radio stations (including X-mem) and disconnect the negative cable of the battery.

2. Remove the generator following the procedures in Service Manual section 86.10.12

CAUTION: Do not allow the generator cables to support the weight of the generator.

3. Remove the bolts holding the lower generator mounting bracket to the engine sump.

4. Remove the mounting bracket.

5. Using solvent and a brush, thoroughly clean the four generator mounting bracket holes on the engine. Blow out the holes with compressed air.

6. Using a clean cloth and brush, apply Loctite Primer. Allow to dry.

CAUTION: The holes must be thoroughly degreased or the sealer will not cure and leaks will reoccur.

7. Thoroughly clean and dry the lower generator mounting bracket and the sump mating face.

8. Thoroughly clean and degrease the original bolts and apply Loctite to the first five threads of the bolts.

9. Install the mounting bracket and tighten the bolts to 29 - 39 lbft (21.5 - 28.5 Nm).

10. Install the generator following the instructions in the Service Manual.

GENERATOR DRIVE BELT TENSION

NEW BELT

IN-SERVICE BELT

135 lbs. LOAD

115 lbs. LOAD

11. Recode the radio and reset all radio stations and the clock.


PARTS INFORMATION:

DESCRIPTION

Loctite 545


FAULT CODE R.O. NUMBER

AQ DB HJ 12.91.14

PART NUMBER

54531

DESCRIPTION

Oil leak - generator bracket bolts

TIME ALLOWANCE

0.70 hrs.

NOTE: Four vehicles can be serviced with one bottle of Loctite #545

(Jaguar P/N 54531).

Claim reimbursement as follows:

Dealers with DCS version 6 release JG14

Claim P/N 54531 and a 25% parts prorate. The dealer will be reimbursed 25% of the part cost plus handling.

Dealers with DCS version 5 or non-DCS dealers.

Claim a sublet amount of $9.00



Tappet Block to Cylinder Head Joint – Use

Loctite 518 “Master Gasket”

MODEL

All V12 Engines

DATE

8/94

12-51

ISSUE:

Loctite 518 “Master Gasket” is the specified sealant for the Tappet Block to Cylinder Head joint.

ACTION;

For all V12 engines, use Loctite 518 “Master Gasket” to seal the tappet block to cylinder head joint.

The sealing surface must be clean and dry before applying the sealant.

Use Hylosil RTV sealant on the half moon seal at the rear of the camshaft carrier.

Do not use a sealant on the camshaft cover gasket.

TAPPET BLOCK/CYLINDER HEAD

NO SEALANT

HYLOSIL

LOCTITE 518

“MASTER GASKET”



Engine Sump Drain Plug –

All AJ6 Engines –

Revised Torque Specification

MODEL

All with AJ6 Engine

DATE

10/94

12-52

ISSUE:

The torque setting for the engine sump drain plug on all AJ6 engines has been reduced to

35.5 - 46.5 lb ft (48-63 Nm).

The revised torque setting has been used in production of all AJ6 engines from the following VINs:

Sedan Range VIN 684700

XJS Range VIN 189150

ACTION:

When installing AJ6 engine sump drain plugs, torque the sump drain plug to 35.5 - 46.5 lb ft. Use only the latest washer, which has a rubber sealing ring (part number EBC 9044).

NOTE: AJ16 engine sump drain plugs should be torqued to 50.5 - 58.5 lb ft (64.8

- 79.2 Nm).



Engine Crankcase – Oil Leaks – Sealing

Procedure

MODEL All V12 DATE 12/94

12-53

ISSUE:

Oil leakage at the crankcase joints of V12 engines.

ACTION:

Before replacing any gaskets to correct crankcase oil leaks on V12 engines, perform the following:

1.

Retorque the oil pan (sump) to sandwich plate, and sandwich plate to engine block bolts to

16 - 20 lb ft (21 - 27 Nm).

2.

Clean all residual oil from the engine block, sandwich plate, and oil pan.

3.

Road test the vehicle; examine the crankcase gaskets for signs of oil leakage. Oil may also leak upwards along the threads of the bolts securing the baffle tray and sandwich plate and appear on top of the engine block or sandwich plate gasket flanges.

For oil leaks at the oil pan gasket or at the baffle tray and sandwich plate bolts, perform the following:

1.

Remove the oil pan.

2.

Remove the sandwich plate and baffle tray bolts shown in Illustration 1.

• XJ12 - 7 bolts

• XJS V12 - 9 bolts

SANDWICH PLATE BOLTS (LOOKING UP)

L

T

B

O

S

L

T

B

O

S

XJ12 XJS V12

12-53.1

ILLUSTRATION 1

3.

Thoroughly clean the bolts and bolt hole threads.

4.

Apply Loctite Primer to the bolt hole threads.

5.

Apply Loctite 545 to the sandwich plate and baffle tray bolts. Install and torque the bolts to


16 - 20 lb ft (21 - 27 Nm).

6.

Install the oil pan with a new gasket and torque to 6 - 20 lb ft (21 - 27 Nm).

IMPORTANT: When repairing V12 engines up to the engine numbers listed below, upgrade the fasteners and gaskets according to the information in Service Bulletin 12-35 “Oil Leaks – Improved Gaskets/Bolts – Installation Instructions” published 8/92.

• XJS V12

• XJR-S

All up to Engine Number 8S 86317

All up to Engine Number 8W 10641

PARTS INFORMATION:

DESCRIPTION

Loctite 545

PART NUMBER

54531


Refer to Section AQ of the appropriate Warranty Codes and Repair Operation Times manual.



Spark Plugs – AJ16 Engine –

Change in Specification

MODEL All (4.0L) Normally Aspirated 1995 MY DATE 2/95

12-54

ISSUE:

The spark plug specification is updated on all AJ16 (4.0L) normally aspirated 1995 MY vehicles.

Hotter spark plugs (part number EBC 8143) are installed in production from the following VINs.

Sedan (4.0L N/A) Range 1995 MY From VIN 720189

XJS (4.0L) 1995 MY From VIN 194775

NOTE:XJR Sedan (4.0L supercharged) vehicles continue to use the previous spark plug specification (part number EBC 11480/1).

ACTION:

Use the following spark plugs as service replacements in AJ16 engines.

ENGINE

AJ16 (4.0L) normally aspirated

AJ16 (4.0L) supercharged

PART NUMBER

EBC 8143

EBC 11480/1

PLUG GAP TORQUE

0.035 in (0.9 mm) 16.2 - 20.6 lb ft

(22-28 Nm)

0.035 in (0.9 mm) 16.2 - 20.6 lb ft

(22-28 Nm)



Spark Plugs – Revised Specification

MODEL V12 Engines (Except XJR-S) DATE 4/95

Remove and destroy Bulletin 12-55 Amended, Date 4/95.



12-55

Amended

5/95

ISSUE:

The spark plug specification for 5.3L and 6.0L (except XJR-S) V12 engines has been revised.

The new specification spark plugs are installed in production from the engine numbers listed below.

XJ12 Engine number 8E 11071

XJS (V12) Range Engine number 8D 12479

The temperature characteristics of the revised spark plugs enable deposits to be more readily burned off during normal driving.

ACTION:

The revised specification spark plugs may be fitted to all XJ12 Sedans and to all 1990 MY ON XJS

(V12) Range vehicles, except XJR-S, at the next required spark plug change.

PARTS INFORMATION:

MODEL

XJ12 Sedan

XJS (V12) Range 1990 MY ON

XJR-S

SPARK PLUG PART NUMBER

NAB 3850DA

NAB 3850DA

SPE 1007

Date of issue 4/95 Bulletin Number 12-55 Amended 5/95 Page 1 of 1

Camshaft and

Re

V alv e Clear visions ance –

All 6.0L V12 1995 MY



The camshafts of all 1995 MY V12 engines have been revised from the following engine numbers.

XJ12 Sedan

XJS (6.0L) Range

From engine number 8E 11129

From engine number 8D 12334

The camshaft lobe base circle has been increased in diameter by 0.002 in (0.05

mm). The revised camshaft lobe profile does not change valve lift or overlap.

Valve clearance for engines with the revised camshafts must be set to 0.010 in -

If valve adjustment is required on a 6.0L V12 engine, use the following procedure to positively identify the correct valve clearance.

VALVE CLEARANCE IDENTIFICATION PROCEDURE

1 Identify the camshaft by the part number on the camshaft front face.

2 Refer to the table on page 2 of this bulletin to identify the required valve clearance specification.

3 Adjust the valve clearance only to the values specified in the table.

NOTE: Do not use the revised valve clearance settings on engines produced before the engine numbers listed above.

Do not fit revised camshafts to engines produced before the engine numbers listed above. Camshafts for these engines will continue to be available.


XJ12 SEDAN VALVE CLEARANCE SPECIFICATIONS

ENGINE NUMBER

UP TO 8E 11128

FROM 8E 11129

CAMSHAFT NUMBER

A Bank - EBC 11415

B Bank - EBC 10907

A Bank - NAC 2652AA

B Bank - NAC 2653AA

VALVE CLEARANCE

0.012 in - 0.014 in

(0.30 mm - 0.35 mm)

0.012 in - 0.014 in

(0.30 mm - 0.35 mm)

0.010 in - 0.012 in

(0.25 mm - 0.30 mm)

0.010 in - 0.012 in

(0.25 mm - 0.30 mm)

XJS(6.0L) RANGE VALVE CLEARANCE SPECIFICATIONS

ENGINE NUMBER CAMSHAFT NUMBER

UP TO 8D 12333 A Bank - EBC 10906 or NAB 2548AA

B Bank - EBC 10907

FROM 8E 11129 A Bank - NAB 2652AA

B Bank - NAC 2653AA

VALVE CLEARANCE

0.012 in - 0.014 in

(0.30 mm - 0.35 mm)

0.012 in - 0.014 in

(0.30 mm - 0.35 mm)

0.010 in - 0.012 in

(0.25 mm - 0.30 mm)

0.010 in - 0.012 in

(0.25 mm - 0.30 mm)



V

P oor Idle Quality –

Normall alv y e

Aspir

T ated AJ16 Engine –

T iming Modification

MODEL 4.0L Normall y Aspir ated 1995 MY

Engine numbers listed belo w

To improve idle quality, revised camshafts with reduced valve timing overlap were introduced on the normally aspirated engines as running change 95/13.

The original camshafts, with a maximum opening position of 110 degrees have been superseded by camshafts with a maximum opening position of 114 degrees.

This change is accomplished by machining the camshaft slot in a different

TIMING COMP ARISON

IN T

IN T AKE OPENS

T A K E

I N T A K E

M . O . P

I N T A K E

T A K E

J12 879 position. The valve timing overlap is reduced from 22 degrees on the 110 camshafts to 14 degrees on the 114 camshafts, Illustration 1.

The maximum opening position of the 114 intake camshaft is 114 degrees after top dead center (ATDC) while the maximum opening position of the exhaust camshaft is 114 degrees before top dead center (BTDC).


Normally aspirated engines with the 110 camshafts, that exhibit poor idle quality, can be modified to achieve the same reduction in valve timing overlap as with the

114 camshafts.

camshafts that have already been modified.

The 114 camshafts were introduced for a period, withdrawn, and then reintroduced as a permanent change.

The following table lists the change points by engine number:

114 camshafts 110 camshafts 114 camshafts

Sedan 4.0L 9JPFRB129204 9JPFRB130241 9JPFNB133653

XJS 4.0L

9LPFLB129209 9LPFLB130243 9LPFLB133745

In case of a customer complaint of poor idle quality on a vehicle equipped with the 110 camshafts only, first check for punch marks on the timing cover near the camshaft position sensor, Illustration 5, to determine if the timing modification has already been performed. If not, reset the camshaft timing and spark plug gap as described below.

In addition, on engines with numbers below 9L103934 (XJS Range) or 9J103935

(Sedan Range), modify the bolts retaining the upper chain damper to the upper damper saddle as described at the appropriate point in the procedure.

1.

Disconnect the battery negative cable.

2.

Remove the coil cover and the on-plug coils. Discard the seal and gaskets.

3.

Remove the camshaft cover and discard the seal. Remove all six spark plugs.

4.

Check the tappet clearances with the engine at room temperature. If necessary, adjust any that are not within the specifications of 0.012 - 0.014

inch (0.30 - 0.36 mm). Refer to section 12.29.48 of the AJ16 Engine Service

Manual.


CAMSHAFT SETTING T AND DIAL INDICA T OR

T OOL T A B

J12 877

ILLUSTRATION 1

5.

Turn the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC) on the compression stroke, i.e. with the cam lobes on the No. 1 cylinder pointing upwards as in Illustration 1. This position can be checked by temporarily inserting the camshaft setting tool 18G-1433/A into the slot on each camshaft.

6.

On engines with numbers below 9L103934 (XJS Range) or 9J103935 (Sedan

Range) only, remove the upper chain damper and saddle assembly and set aside for modification.

7.

On all engines, attach an engine lifting eye to the intake camshaft cap as shown in Illustration 1.

8.

Position the magnetic base of a dial indicator gauge on the lifting eye.

9.

Install the dial indicator gauge with an extension pointing downward, into the spark plug bore, contacting the top of the piston.

10. Bend back the locking tabs that lock the bolts holding the camshaft sprocket vernier couplings to the camshafts. Loosen the bolts slightly, but do not remove them.

11. Remove the camshaft setting tool. Rotate the crankshaft back and forth slightly across the TDC position to determine the true TDC point for the no. 1 piston and then zero the gauge.


J12 881

ILLUSTRATION 2

12. Check that the pointer on the front timing cover is in line with the arrowed

(TDC) tooth edge on the timing ring, Illustration 2. Realign the pointer if necessary.

13. The crankshaft positions for resetting the camshafts are one and a half teeth on either side of the arrowed (TDC) tooth edge on the timing ring as shown in

Illustration 2.

14. Rotate the crankshaft two revolutions in a clockwise direction (viewed from the front of the engine) until the pointer is one and a half teeth before the arrowed (TDC) tooth edge on the timing ring, position A, Illustration 2.

operation since the accuracy of the valve timing depends on maximum chain tension.

15. Remove the retaining bolts and the camshaft sprocket vernier coupling,

Illustration 3, from the exhaust camshaft, but do not detach the sprocket from the camshaft flange. The camshaft is free to rotate inside the sprocket with the coupling removed.

16. Position the camshaft setting tool 18G-1433/A across the camshafts with the positioning tab on the exhaust camshaft, Illustration 1.

17. Turn the exhaust camshaft until the tab on the setting tool engages the slot in the camshaft.

18. With the camshaft in this position, reinstall the sprocket vernier coupling to the exhaust camshaft. This step will require several attempts to find the exact alignment of the vernier splines and the bolt holes.


IN T AKE CAMSHAFT

J12 881

ILLUSTRATION 3

19. Install the locking tabs and the coupling bolts. Lightly tighten the bolts.

20. Remove the setting tool and turn the crankshaft in a clockwise direction

(viewed from the front of the engine) until the pointer is one and a half teeth after the arrowed (TDC) tooth edge on the timing ring, position B,

Illustration 2.

operation since the accuracy of the valve timing depends on maximum chain tension.

21. Remove the retaining bolts and the camshaft sprocket vernier coupling,

Illustration 3, from the intake camshaft, but do not detach the sprocket from the camshaft flange. The camshaft is free to rotate inside the sprocket with the coupling removed.

22. Position the camshaft setting tool 18G-1433/A across the camshafts with the positioning tab on the intake camshaft.

23. Turn the intake camshaft until the tab on the setting tool engages the slot in the camshaft.

24. With the camshaft in this position, reinstall the sprocket vernier coupling to the intake camshaft. This step will require several attempts to find the exact alignment of the vernier splines and the bolt holes.

25. Install the locking tabs and the coupling bolts. Lightly tighten the bolts.


J12 876

ILLUSTRATION 4

26. Remove the setting tool and final tighten the camshaft sprocket vernier coupling bolts to 16.2 - 20.6 lb ft (22 - 28 Nm). Bend the lock tabs against the bolt heads.

27. Check both the settings of one and a half teeth before and after the arrowed

(TDC) tooth edge on the timing ring, Illustration 2. The tab of the setting gauge should fit in the slot of the camshaft being checked.

28. Remove the setting tool, the dial indicator gauge, and the lifting eye. Torque camshaft bearing cap bolt to 12.5 - 16.9 lb ft (17 - 23 Nm).

29. On engines with numbers below 9L103934 (XJS Range) or 9J103935 (Sedan

Range) only, remove the damper saddle retaining bolts, Illustration 4.

Thoroughly degrease the bolts and the saddle. Apply Loctite 545, part number 54531 to the bolt threads and torque to 15.8 - 21 lb ft (21.5 - 28.5 Nm).

Install the damper saddle using new cylinder head bolts and torque to 43.5 -

44.9 lb ft (59 - 61 Nm) plus 90 degrees as described in section 2.1 of the AJ16

Engine Service Manual.

(Sedan Range) do not require modification since the damper saddles are equipped with self locking bolts.


30. Reset the spark plug gaps to 0.038 inch (0.97 mm) and reinstall the spark plugs.

31. Install the camshaft cover using a new seal and new spark plug boss seals.

32. Install the on-plug coils using new gaskets. Install the coil cover using a new seal.

PUNCH MARKS T O IDEN TIFY MODIFICA TION

J18-214

ILLUSTRATION 5

33. Place two punch marks approximately 1/4 inch apart on the timing cover parallel to the lip, Illustration 5, to indicate that the modification was done.

34. Connect the battery negative cable and reset the clock.



Cylinder head bolt (if needed)

Loctite 545 (if needed)

Camshaft cover seal

Sprocket coupling tab washer

Spark plug boss seal

On-plug coil gasket

P AR T NUMBER

JZB 100053

54531

NBC 2525AA

C 33917

NBC 2579AA

DAC 11510


F A U L

AD BB LH 12.91.19

10.10.10

Camshaft timing modification (including check tappet clearance)

Drive in/out

A L L O W A N C E

2.75 hrs.

0.15 hrs.

claim.

1

4

2

-

6

6



Engine Oil – V iscosity/T

Ranges – Re emper visions atur ee

MODEL All 4.0 and 6.0 1995-96 MY

Sedan VIN 720001 - on

XJS VIN 194775 - on

Jaguar has approved the use of grade 0W/30 low viscosity engine oils, subject to certain limitations regarding ambient temperature and oil specifications, in both

V12 and AJ16 engines.

In addition, the ambient temperature range for the use of 5W/30 oils has been extended from 50ºF (10ºC) to 104ºF (40ºC) subject to certain limitations on oil specifications on AJ16 normally aspirated engines ONLY.

Refer to the following charts when selecting engine oils.

AJ1 6 NORMALL Y A SPIRA VISCOSITY/TEMPERA TURE CHAR

JLX-139 ambient temperatures of 50-104ºF (10-40ºC) ONLY if:

••••• the oil is purely synthetic

••••• the oil meets API SH/CF and CCMC G5 specifications.


V1 2 & VISCOSITY/TEMPERA TURE CHAR T

JLX-140

ALL ENGINES

Fully synthetic oil can be used to top up engines containing partly synthetic 0W/30 or 5W/30 engine oil.

Partly synthetic oil MUST NOT be used to top up engines filled with purely synthetic oil. The engine must be topped up with purely synthetic oil only, or it will no longer qualify for operation in ambient temperatures from 50-104ºF (10-

40ºC).



Camshaft Co vv

Re er Oil Leaks – vised Bolt T or

AJ16 Engine – que Specification

MODEL 4.0L 1995-96 MY

Sedan VIN 720001 - 767554

DATE 1/96

The torque specification for the camshaft cover retaining bolts has been revised beginning with VIN 767555 (Sedan Range) and VIN 225600 (XJS). The revised torque specification ensures that the shoulder on the shank of the bolt bottoms against the surface of the cylinder head (Illustration 1) to achieve even compression of the camshaft cover gasket and to reduce the incidence of oil leakage.

In case of oil leakage or when removing and installing the camshaft cover for any reason, follow the procedure below.

INSTALLING CAMSHAFT COVER

1.

Discard the ”on-plug” ignition coil gaskets, the spark plug well seals, and the camshaft cover gasket.

2.

Wipe clean all seal faces on both the camshaft cover and the cylinder head.

CAMSHAFT CO VER RET AINING BOL T

RET AINING BOL T

A SHER

ISOLA T OR A SHER


BOL T SHANK SHOULDER

ILLUSTRATION 1

Date of issue 1/96

JSI-2702

Page 1 of 2

3.

Install new

4.

Install a new

5.

Install the camshaft cover and tighten the 13 retaining bolts “finger-tight.”

6.

Final tighten the retaining bolts in the sequence shown in Illustration 2

Torque the bolts to 5 lb. ft. (6.5 Nm).

7.

Install new seals when reinstalling the “on-plug” ignition coils.

CAMSHAFT CO VER BOL T T ORQ

ILLUSTRATION 2


Refer to the Parts Microfiche.


F A U L T

AB DC HJ 12.29.39

A L L O W A N C E

Camshaft cover gasket 1.00 hrs.

replace

JSI-2701



Rattle After Start – Upper

Install Re vised T

T iming Chain – ensioner

MODEL All AJ6

AJ16 up to engine no. gi vv en belo w

Some vehicles with AJ6 or AJ16 engines may exhibit engine noise immediately after a cold or hot start. This noise has been identified as relaxation of the upper

(secondary) timing chain tensioner resulting in temporary chain slack.

A non-return valve in the tensioner is designed to trap pressurized engine oil to maintain tension on the timing chain to prevent rattling. If the oil bleeds past the piston in the tensioner, the tension on the upper timing chain is temporarily lost.

When the engine is then started, the chain will rattle until oil pressure builds up and recharges the tensioner (at which point the rattle will stop.)

A revised tensioner with an integral oil reservoir has been introduced to overcome this condition starting with the following engine numbers:

4.0L NA

4.0L SC

9J160552

9K160558

In case of a customer complaint of engine rattle immediately after start on vehicles with AJ6 or AJ16 engines, determine if the rattle comes from the upper

(secondary) timing chain. If the upper timing chain is verified as the source of the rattle, replace the upper timing chain tension with the revised tensioner as described below.

REPLACING UPPER (SECONDARY) TIMING CHAIN TENSIONER

1.

Remove the fuel pump relay and run the engine at idle to depressurize the fuel system.

2.

Remove the longer bolt (Illustration 1), remove the valve clamp and remove the valve.

V A L V E

L ONGER BOL T

V A L VE CLAMP

B O L T

ILLUSTRATION 1

Date of issue 5/96

J12 617


INS T ALLING REVISED TENSIONER

JSI-2730

ILLUSTRATION 2

3.

Use a 3 mm Allen wrench to wind back the tensioner (clockwise) until the snail engages in the park position.

4.

Remove the tensioner housing securing bolt and withdraw the tensioner assembly.

since they are not required with the revised tensioner.

5.

Place the O-ring on the revised tensioner (Illustration 2) and lubricate it with engine oil.

6.

Check that the mechanical tensioner within the piston is fully retracted (fully closed position.)

7.

Install the tensioner assembly with a new gasket on the engine. Ensure that the arrow is pointing up and that the slotted head of the piston is aligned with the tensioner blade. (The bolt listed in the part information replaces the longer bolt previously discarded.) Torque the bolts to 16.2 - 20.7 lb. ft. (22 - 28 Nm.)


8.

Use the starter to turn the engine - the movement of the chain against the tensioner blade and piston will release the mechanical tensioner.

point for retracting the mechanical tensioner. If the revised tensioner has to be removed from the engine, the camshaft cover must first be removed to allow access to the tensioner piston and blade to ensure that the piston is withdrawn with the tensioner body.

9.

Reinstall the fuel pump relay and start the engine to repressurize the fuel system.

10. Verify that the chain rattle is no longer present on hot or cold restarts.


Upper (secondary) tensioner assembly

O-ring

Housing gasket

Bolt

P AR

NBC 2031AA

EAC 4540

EAC 4557

FS 108251/J

1

1

1

1


F A U L T

AN DH BJ 12.65.29

AN DH BJ 12.65.29

10.10.10

A L L O W A N C E

Remove & install tensioner - Sedan Range 0.40 hrs.

Remove & install tensioner - XJS 0.60 hrs.

Drive in/drive out 0.15 hrs.



Cylinder Head Bolts –

Reuse Twice – Conditions

MODEL 1988-94 MY Sedan (3.6L & 4.0L)

1993-96 MY XJS (4.0L)

DATE 11/97

12-62

Amended

2/98



It is now Jaguar Cars policy that the cylinder head bolts of AJ6 and AJ16 engines the cylinder head.

To be able to identify the number of times a bolt has been reinstalled, it is

A CTION:

After reinstalling and fully tightening a used cylinder head bolt (EXCEPT when a

A UT OMA TIC center -punc h.

A second removal and reinstallation is permissible. A bolt showing one punch and mark ed with a second punc h mark

MUS T discarded.

Any bolt showing obvious signs of damage must be replaced.



Bolt, cylinder head - AJ6

Bolt, cylinder head - AJ16

P AR T NUMBER

EBC-1 771

JZB 100053 A/R

W ARRAN TY POLICY

Claims for bolt replacement will not be honored unless the bolts have already been re-used twice.


The above has no effect on Repair Operation Times.



Main Bearing Cap Bolts –

Reuse Twice – Conditions

MODEL 1988-94 MY Sedan (3.6L & 4.0L)

1993-96 XJS (4.0L)

DATE 11/97

12-63

It is now Jaguar Cars policy that the crankshaft main bearing cap bolts of AJ16 involving removal of the main bearing cap bolts.

To be able to identify the number of times a bolt has been reinstalled, it is

A CTION:

After reinstalling and fully tightening any main bearing cap bolt (EXCEPT where a

A UT OMA TIC center -punc h.

A second removal and reinstallation is permissible. A bolt showing one punch and mark ed with a second punc h mark

MUS T discarded.

Any bolt showing obvious signs of damage must be replaced.



Bolt, main bearing cap

P AR T NUMBER

EAC 4119 A/R

W ARRAN TY POLICY

Claims for bolt replacement will not be honored unless the bolts have already been re-used twice.


The above has no effect on Repair Operation Times.



Upper Chain Guide Bolts –

Apply Locking Compound

MODEL 1988-94 MY Sedan (3.6 L & 4.0L)

1993-94 XJS (4.0L)

DATE 3/98

12-64

Upper chain guide bolts on AJ6 engines should be checked whenever any service is performed on the cylinder head such as replacing the cam cover gasket.

A CTION:

When performing cylinder head repairs on vehicles within the above VIN range, apply locking compound (Loctite 243) to the bolts securing the timing chain upper guide. Torque the bolts to 23-27 Nm (17-20 lb ft). Mark the head of each bolt with one punch mark using an automatic center punch.

UPPER CHAIN GUIDE BOL TS

UPPER CHAIN GUIDE BOL TS


ILLUSTRATION 1



Loctite 243 locking compound

P AR T NUMBER obtain locally


The above is included in cylinder head repair operations.
