63 XJS S.III

Transcription

1 JAGUA JA~ 1/ Service Bulletin ill ISSUE NO: JD 04/92 APRIL 1992 SHEET: 1 OF 1 S.R.O: MODEL SUBJECT CUSTOMER CONCERN ADVICE TO CUSTOMER DEALER ACT1 ACTION 0 N REPAIR METHOD SERVICE TOOLS PARTS INFORMATION : XJ6/ XJ61 XJS I / S.111 V12 (AIR CONDITIONED MODELS) : BLOWER MOTOR ASSEMBLIES : Brush gear noisy operation, ie: low speed ticking I /squeak. : Installation of revised blower motor assemblies incorporating a new'p35' motor will overcome noise concerns. incorpo- New blower motors have been introduced from follow following VINs: XJ6 (Air Con) XJS S.III : Yes : Blower Assemblies incorporating new motor are interchangeable on vehicles prior to above VINs VlNs (see Parts Information below for model year variations). inter- Replacement of blower motor assemblies should be carried out in accordance with following Service Manual instructions: car- XJ6 - Volume 4, Section 82, Page 82-38/82-39 XJS - Volume 4, Section 82, Page 82-62/82-63 S.III S.Ill - Section 80-82, Page 82-39/ N/A : Owing to introduction of 'PM5' 'PMS' harness connectors on blower motor assemblies fitted to XJ6 and XJS models from VINs: XJ XJS Part Numbers for replacement units on vehicles PRIOR to abovl3 above ViNs VlNs are as follows: follows; XJ6 XJS RH ebc CBC 8966 cee CCC 5546 LH CBe CBC 8967 cce CCC 5547 Jaguar Cars Limited

2 JD 04/ JA~ JAGUAR % ADMINISTRATION INFORMATION Part Numbers for replacement units on vehicles FROM above VI Vl Ns are as follows: lows: RH lh LH XJ6 CCC 5400 eee CCC 5401 XJS eee CCC 5544 eee CCC 5545 S.III V12 v12 The harness connector on Series III Ill blower motors has not changed. For replacement units incorporating new motor, following Part Numbers apply: RH CCC 5546 lh LH CCC eee 5546 eee 5547 : WARRANTY CODES XJ6 ) 7TAIRH) (RH) XJS ) 1 7TB (LH) ILHI S.III REPAIR OPERATION CODES XJ6/ / XJS MODELS: SRO (RHI (RH) SRO (LHI ILH) (SRO /09 (SRO /09 LESS JDS ALLOWANCE) LESS JDS ALLOWANCE) 5.111: SRO (RH) SRO (lh)

3 III A - 1[----. I.. Service Bulletin DATE: OCTOBER 1991 PAGE: 1 of 7 REF: JD 08/91 XJS ITEM: 49 CODE 90S 8PZ DESCRIPTION Spare Wheel Cover Battery Cover Boot WARRANTY CODES In latest edition of XJS Warranty Code book, codes for battery and spare wheel covers have been duplicated. To rectify this situation and prevent furr confusion when submitting claims, following codes have been removed from warranty system:- Therefore, with immediate effect, Dealers should Id NOTsubrnitfurrctaimsforse subm rr cia i fa r se codes. All future claims for above parts should be submitted, using following codes only:- 9DO 9DR 8NU Battery Cover Battery Cover Support Panel Spare Wheel Cover XJS (FACELlFT) {FACELI FT) ITEM: 50 WARRANTY CODES The following new warranty complaint: code has been allocated to cover fuel gauge "anti-slosh module", introduced on XJS Facelift models. Code Description SRO 7JU U Anti-Slosh Module Jaguar Cars Limited Jaguar Cars Limited

4 JD JO 08/91 / JA~ -h?= JAGUAR ALL MODELS ITEM: CYLINDER PRESSURE CHECK WARNING: Would all technicians please note that before performing a cylinder pressure check, Repair Operation No , all fuel should be purgedfrom fuel rail. Purging of fuel rail may be achieved by disconnecting fuel pump relay and n cranking engine for ten seconds. pres- XJ6 ALL MODELS & XJS 3.6/4.0 1 ITEM: CRUISE CONTROL ACTUATOR LINKAGE ADJUSTMENT Should I d customer complaints be received of ani increase in cruise control response time and a degree of hunting of set speed, cruise control actuator linkage adjustment should be checked in accordance with following procedure, before tak tak- ading any furr action. Dealers should ensure that clearance between end of actuator to throttle link slot: (A Fig 1) and shoulder bolt (8 (0 Fig 1) is O.5mm 0.5mm to lmm Imm {C Fig 1). S.R.O. Allowance Complaint Code hrs 7VCP cq~)} - x FIG 1 2

5 JD 08/91 % JA~ JAGUAR XJS V12 ITEM: TRANSMISSION OIL COOLER CONNECTION There have been a number of oil coolers returned with damaged coupling connector bosses, cause of which can be attributed to poor workshop practice where backing spanners have not been used to support integral hexagon connector of oil cooler. This results in a fracturing of connecting tube when torque is applied upon tightening or loosening connection. Technicians should use a backing spannerto hold integral boss whilsttightening tightening back cooler pipe connection to a torque of Nm. XJ6 I / XJS I / S.llt / LIMOUSINE ITEM: FRONT HUB END FLOAT ADJUSTMENT The following instructions supersede all previous instructions provided in service manuals. Manuals will be updated at next reprint. Front hub end float on above models should be set between 0,0254 to 0,0762mm (0.001 to 0.003in). To achieve this in service use following method: N2te:: Note: Prior to adjusting hub end float an absorbent cloth should be placed around brake fluid reservoir cap. Slacken road wheel nuts 1/ 4 turn each. Jack up front of vehicle and support with axle stands. Remove one wheel nut, mark wheel relative to stud and remove remaining wheel nuts. Remove roadwheel and tyre assembly. Dependent upon model, gently prise brake pads free or manipulate brakecali- caliper to ensure t brake pads are free within ir mountings, ngs, i.e. disc is free to rotate. Prise off hub grease cap (1 Fig. 1). Fit a Dial Test Indicator (DTI) to hub (Fig. 2). Grasp hub unit. Firmly pull pult and push unit, oscillating atsametime,tode- time, to determine OTI DTI end float reading. If reading is within specification quoted re is no need to carry out adjustment. If not, remove hub nut split pin and cover (2, 3 Fig. 1). adjust- Fig. 1 Fig.2 2 D', 'C. 3

6 JD 08/ & JA~ JAGUAR Note: For identification purposes only, Fig.1 1 shows XJS, S III Ill & limo. Limo. type hub. Fig. 2 shows XJ6 hub. Adjust nut, as necessary, to give a reading of O,OS08mm 0,0508mm + /- I - O,0254mm 0,0254mm (O.002in (0.002in + / in). Always try to achieve mid-point of tolerance i.e., O,0508mm 0,0508mm (O.002in). (0.002in). Align hub nut cover and secure with a new split pin. When newsplit pin is fitted, ensure end float is re-checked using DTI gauge (Fig. 2). If necessary, re-adjust using same method, until end float is correct. Alwavs Always finish adjustment by checking with a DTI gauge. Always ensure end float is within limits quoted. Refit grease cap. Refit road wheel. Carry out adjustment procedure on opposite front hub. When finished, lower vehicle from stands. Ensure wheel nuts are tightened to specified torque. Remove absorbent cloth from around brakefjuid fluid reservoir cap, ensuring area is clean and dry. Before moving vehicle, pump brake pedal to centralise pads. ALL MODELS ITEM: BODY REPAIR To avoid risk of causing permanent damage to vehicle ECUs during body repairs, following precautions must be observed prior to using any electrical welding equipment. 1. Disconnect vehicle battery and alternator. 2. Disconnect and removea!1 removeall ECUs in immediatearea area ofany panels to beelectri beelectrically welded. As a general rule, all ECUs within 2 feet of area to be welded should be removed; for more detailed information, refer to relevant Service Manual. 3. When using welding equipment, earth return clamp should be located as close as possible to area of repair. XJ6 ALL MODELS ITEM: DRIVER'S BLOWER MOTOR ASSEMBLY The repair operation time for renewing driver's side blower motor assembly has changed on all XJ6 Vehicles from VIN The repair operation times are now as follows:- 4

7 -k JA~ JAGUAR JD 08/ Left Hand Hand Drive Drive Vehicles: Blower assembly -- Left Hand Hand -- Renew / As (Less (Less J.D.S. Allowance) Hours Hours Hours Right Hand Hand Drive Vehicles: Right Hand Hand -- Renew Blower Assembly -- Right Hours Hours / As (Less (Less J.D.S. J.D.S. Allowance) Hours Hours Please Please amend your repair time schedules accordingly. No No or repair times are affected. To achieve se times in i n service, adhere to following procedure:procedure:remove REMOVE Open bonnet and disconnect battery earth earth lead. Remove Remove driver's side dash dash liner. Remove Remove retaining retaining clip from air conditioning unit's pliable pliable trunking. Displace pliable trunking from air conditioning unit. unit. Displace relay bases from ir mounting mounting brackets. Displace Cut and remove remove ratchet straps securing brake switch switch harness. Disconnect vacuum hose from blower motor assembly servo unit. Disconnect blower motor multi-way multi-way connectors. Undo and remove remove steering column lower mounting mounting securing nuts. nuts. Undo and and remove remove steering column upper mounting securing nuts. Lower steering column column assembly. Retrieve Retrieve column upper packing shims. Remove Remove washer bracket from column. Manoeuvre steering column column towards centre of vehicle for access. Undo and remove remove steering column column outer stabilizer bar's upper and lower securing nuts. nuts. Displace and rem ove steering column remove column stabilizer bar (Fig. (Fig. 1). 1). Reposition Reposition vehicle harness connectorsto connectors to gain access to t o blower motorassembly securing bolts. Undo and and remove blower motor assembly securing bolts. Displace remove blower motor assembly. Displace and remove Remove Remove and discard unit intake gasket. Remove Remove pliable trunking to t o assembly securing tape. Remove trunking from unit. Remove REFIT REFIT Fit and align align trunking trunking to t o new blower motor assembly. tape. Secure trunking to assembly with tape. Smear new intake gasket with a suitable adhesive. Fit gasket to t o blower motor assembly intake. and align align blower motor assembly into its mounting mounting position. position. Fit and Connect pliable trunking to t o air conditioning unit. unit. Refit and tighten blower motor assembly securing bolts. Fit F i t and and align align trunking retaining retaining clip. Connect blower motor multi-way multi-way connectors. Connect vacuum hose to t o blower motor assembly servo unit. 5

8 JD 08/ % JAGUAR JA~ Fit and align steering column stabilizer bar and tighten securing bolts ( Nm). Fit and align washer bracket to column. Loosely fit steering column upper mounting securing nuts. Fit steering column packing shims as necessary. Fit and tighten steering column lower mounting securing nuts (20-22 Nm). Fully tighten steering column upper mounting securing nuts (20-22 Nm). Reposition brake switch harness to blower motor assembly. Secure brake switch harness to unit with ratchet straps. Fully seat relay bases to ir mounting brackets. Refit driver's dash liner assembly. Reconnect battery earth lead and close bonnet. Fig. 1 S.III, S.111, XJS & XJ6 UP TO VINs: USA CANADA R.O.W. ITEM: AIR CONDITIONING COMPRESSOR (GM A6 TYPE) Investigations have confirmed unnecessary replacement of compressors for noise and leaks. If excessive compressor noise exists, check following items:-. Compressor drive belt tension. Compressor mountings.. NC AlC refrigerant hose routing (ensure that hoses are not in contact with or components). ponents),., Ensure that refrigerant charge weight is correct (referto Section 82 of Service Manual for additional information). Ser- 6

9 JD 08/91 / - JAGUAR JA~. Ensure that compressor is filled to correct level with oil. A MAXIMUM of 4 ozs (11414 cc) ee) of refrigerant oil can be added to compressor without discharg- discharging refrigerant. Using an oil injector tool (such as 'Snap-on' oil injector tool ACT 111), 11, add oil in 2 oz (57 cc} increments. (Refer to procedure detailed below). NOTE: LOW low OR EXCESSIVE CHARGE WEIGHT OR A LOW low OIL Oil LEVEL WILL CAUSE COMPRESSOR NOISE.. Clutch drag or bearing noise (refer to clutch replacement procedure, Section 82 of Service Manual).. Compressors which leak oil or Freon must have seals replaced in accordance with procedure detailed in Section 82 of Service Manual. Replace compressor only after checking all of above-mentioned items. NOTE: All returned compressors must be complete and sealed, using blanking plate provided on replacement unit. Procedure for compressor oil injector tool usage:- Operate A/C Ale system. Make sure that system is full of Freon. Referto Set- Section 82 of Service Manual for test procedure.. Remove sealing gaps from high and low pressure A/C Ale charging points.. Check that valve on oil injector tool is closed. Remove threaded end cap from oil injector tool and add 2 ozs (57 I57 ee) cc) of compressor oil. Replace end cap. Attach short flexible hose on oil injector to low pressure fitting of vehicle A/C AlC system.. Attach one end of an A/C AlC system extension hose to fitting on side of valve of oil injector tool. Attach or end oftha extension hose to high pressure fitting of vehicle NAlC C system. Run engine at idle with AIC A/C system operating.. Slowly open oil injector tool valve until it is fully open. Allow oil to flow into compressor for 2 minutes.. Close oil injector tool valve. let Let engine run an additional minute, n switch off ignition.. Carefully remove charging hosesfrom high and low pressure fittings and install sealing caps.. Check AlC A/C system for compressor noise. If noise still exists, repeat procedure once more, adding an additional 2 ozs (57 ee) cc) of compressor oil.. NOTE: NEVER ADD MORE THAN 4 OZS ( cc) OF Oil OIL TO THE Ale A/C SYSTEM.. Attach a self-adhesive label to AlC PJC hose (adjacent to low pressure hose fitting), stating how much oil was added and date. pro- 7

10 1 IIr I I I III Service Bulletin Service Bulletin JA~ DATE: NOVEMBER 1991 PAGE: 1 of 5 REF: JD 09/91 ERRATA Would Dealers please note that in Service Bulletin Iletin JD 05/91, Item 31 "Forged Alloy Wheels", Part No. for XJS road wheels should be CSC CBC 6175 (not CSC CBC 9175). XJ6 MODELS ITEM: TRANSMISSION FRONT PUMP ASSEMBLY A new front pump assembly has been introduced which cannot be retro-fitted to earlier models as intermediate plate is not compatible. Should this later type be fitted inadvertently to an earlier transmission unit, internal pressures created will blow-out pump seal (this {this is because ventilation channel is now in a different position). inter- Part No. I Qty Q~Y Description 2.9,3.2 & 3.6 Litre Models Up to Gearbox Serial No : JLM 1957 JLM Front Pump Assembly Intermediate Plate From Gearbox Serial No ; 53 JLM Front Pump Assembly JLM Intermediate Plate I, I 4.0 Litre Models Up to Gearbox Serial No : JlM JLM JLM Front Pump Assembly Intermediate Plate From Gearbox Serial No : 35366; JLM 10716, 1 Front Pump p Assembly JLM '1 Intermediate Plate Jaguar Cars Can Limited

11 II III.,. Service Bulletin III Service Bulletin JA~ =Q% ~ A G U A DATE: OCTOBER 1992 PAGE: 1 ofs 8 REF: JD 16/92 ERRATA Owing to revised information, torque figure far for coolant cooiant temperature transmitter to engine, XJS models, is 14,5 to 19,5 Nm. The torque figure given in Service Bulletin JD 10/ and Section 88 of XJS Service Manual, JJM /20, 04 06/20, should be ignored and only revised figure used. Service Manuals will be amended at next reprint. trans- XJ6 93 MY (FROM VIN ) ITEM: 44 BATIERY BA-TTERY TRANSIT RELAY - REMOVAL Owing to relocation of battery into boot at 93 MY, a revised battery transit relay has been introduced, (see {see Fig 1). FIG 1 The procedure for removal of this new relay is as follows: WITH THE IGNITION OFF: 1. Open boot and remove battery cover, (see Fig 2). 2. Remove negative lead from battery. 3. Disconnect transit relay from battery. 4. Remove white I /yellow (W/Y) (WN) ignition wire from transit relay.

12 J:'... I~IIDI:' TU AT TUIC I I:'An Cl!I:'MAII\IC C1 n I v 11\1<:111 ATl:n \li.n.ii:::1\i <:I:rl u:u::::n JD 16/92 JA~ JAGUAR FIG 2 5. Remove positive lead from transit relay terminal post, (A, Fig 3). 6. Reverse positive lead clamp and refit clamp to positive lead (B, (6, Fig 3). =-=-===' ====-::~ FIG 3 7. Displace battery. 8. Tie back and secure white I /yellow (W/Y) (WH) ignition wire, (see Fig 4). J'S117t!ol FIG 4

13 JD 16/ JAGUAR JA~ 9. Refit battery. 10. Refit: and secu.re secu,re positive and n negative lead of battery. 11. Replace battery cover. NOTE: ALL UKOEALERS DEALERS MUSTCONTINUETORETURNTHE TO THE DISPLACEDTRANSlT TRANSIT RELAYS. REMOVAL OF THE TRANSIT RELAY SHOULD BE CARRIED OUT NO LONGER THAN 24 HOURS BEFORE THE VEHICLE IS HANDED OVERTOTHE THE CUSTOMER. THE RADIO AND TIME CLOCK MUST BE RESET AFTER THE RELAY IS 1s RE RE- MOVED. IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD THE RELAY BE USED OR RE RE- TAINED AS AN ISOLATION DEVICE FOR ROAD USE. XJS ITEM: REPAIR OPERATION TIMES Air Conditioning Blower Motor Assembly The repair operation times for renewing air conditioning blower motor assem assernblies have been re-studied on 1992 MY vehicles. The new operation times for vehicles from VIN are as follows: Right-hand drive vehicles Blower Assembly -left-hand - Left-Hand - Renew 0.95 Hrs /09 As (Less JDS Allowance) 0.60 Hrs BlowerAssembly-Right-Hand-Renew - - Renew Hrs /09 As (Less JDS Allowance) 1.25 Hrs H Left-hand drive vehicles Blower Assembly - Left-Hand - Renew 1.60 Hrs / As (less (Less JDS Allowance) 1.25 Hrs Blower Assembly - Right-Hand - Renew 0.95 Hrs Blower Assembly - Right-Hand - Renew 0.95 Hrs / /09 As (Less JDS Allowance) 0.60 Hrs Please amend your repair times accordingly. No or repair times are affected.

14 JO JD /92 JA~ =+b JAGUAR XJ6/ 1 XJS ITEM: BRAKE SYSTEM SERVICE RECOMMENDAT1ONS RECOMMENDATIONS Note: This bulletin supersedes Item 21 of Service Bulletin JD 03/92. With introduction of ABS brake system, from following VINs, brake servicing recommendations have changed: 1. XJ6 from VIN XJS (5.3 convertible) from VIN XJS (5.3coupe) from VIN XJS (3.6 coupe) from VIN V1N No routine replacement of system seals is necessary. The system and components, which are sealed for life, require no maintenance. Repair is by replacement. The braking system must still be inspected for satisfactory operation and condition at regular service intervals. Because of its hygroscopic nature, brake fluid must be renewed at 2 year or mile I48 ( km) intervals, whichever is sooner. XJ6 ALL MODELS ITEM: LAMBDA SENSOR SPLASH-SHIELD Following reports of intermittent display of "Fuel Failure failure 44" on instrument pack, it was found that this symptom could be caused bywater penetrating lambda sensor. A lambda sensor splash-shield has been introduced from VIN V1N , which can be fitted retrospectively and should be installed whenever a lambda sensor is changed. This will reduce possibility of water ingress. lamb- /~

15 % JA~ JAGUAR JD16/92 JD heat-proof sleeve sleeve is fitted by sliding it over sensor, prior to its its The six-inch silver heat-proof replacement. After sensor has been been fined, fitted, Dealers Dealers should ensure that that sleeve is SOL i s pushed pushed fully back down to cover whole sen sensor- ALL MODELS MODELS ITEM: IGNITION SPARK PLUGS PLUGS Spark plugs plugs have been been returned returned under warranty with a yellow I/ brown brown stain stain visible on insulator housing. Dealers Dealers have have incorrectly interpreted interpreted this as leakage leakage of comcornbustion bustion gases between between insulator and and metal metal housing and and cause cause for for spark plug plug misfire. Thefollowing The following is i s an explanation for for staining and and more more likely cause for spark plug plug misfire. During mostatmospheric most atmospheric conditions a form of o f static staticdischarge, c o m m o n to high high voltduring discharge, common conductors, can occur. occur, which IS is commonly known known as "Corona discharge". age conductors, Ignition prone t o this effect during wet wear, when air Ignition systems are particularly proneto space surrounding surrounding spark plugs becomes becomes charged with a gas composed composed of elecelectrons, ions and and air particles, particles, forming forming a state of general general ionization. ionization. Too much much ionizionization counteracts spark plug plug insulation and causes a partial partial discharge, which in in turn gives out a blue blue light. light. in no way affect running running of of car, providcircumstances this will in Under normal circumstances ing ing spark plug plug insulators irlsulators are kept clean. onlyoccur if spark plug insulators were coated Running Runni n9 problems would normally only occur if in a film of dirt, which would allow high high voltage tracking, known known as "flashover", "Rashover", bein plug terminal stud stud and earth, thus causing causing a misfire. tween spark plug However, provided against this eventuality by inclusion inclusion of "ribs" "ribs" However, protection protection is provided body. To identify wher or not not spark plugs have been been subsubalong insulator body. jected to Corona Corona discharge. discharge, plugs should be examined examined in in daylight for presence presence brown stain stain at base of insulator, next to metal metal housing. housing. of a yellow I/ brown The actual stain stain is caused caused by oil-contaminated oil-contaminated particles, particles, in in suspension suspension around around spark plug plug insulator, receiving electrostatic charge of ionization ionization and and fusing mmselves to plug. The stain wiped off easily. stain is quite harmless harmless and can can usually be be wiped Corona discharge discharge will cause cause no deterioration in i n service service or malfunction of spark Corona plug. plug. Corona discharge does not. Cleanliness Cleanliness Moisture or dirt may cause "flashover" but Corona is is vital, refore, spark plug plug insulators insulators should should be kept clean clean and and dry at all times. Note: Note: returned under warranty may be rejected rejected as "no fault found" Spark plugs returned for reasons reasons given given above. XJ6 ALL MODELS MODELS REAR SHOCK ABSORBERS ITEM~ 49 From VIN VIN , a new rear shock absorber is fitted to t o all all non-ride-ievelling non-ride-levelling vefrom interchangeable with all previous previous components when hicles. This new part is fully interchangeable

16 '==-% JA~ JD 16/92 16 / 92 JAGUAR This new part, number CCC 6923, should be be used used in in all cases where rear shock absorbers are replaced, with immediate effect. Under no circumstances should this new part be mixed mixed with old condition parts on on a vehicle axle. When failures are identified identified in in service, single shock absorbers only need need to t o be be changed if parts have less than 25,000 miles (40,OOOkm} (40,000km) service use. The new units, which have have a black finish, can can be be easily distinguished from previous parts by a new sealed gaiter, which will reduce dirt ingress. ingress. XJS 6CYl/ GCYL I V12 AND SERIES III 111 V12 ITEM: ITEM: RECEIVER RECEIVER DRIER BOTTLE BOTTLE When replacing replacing receiver drier bottle, Part Number CAe CAC 1881, 1881, it is essential that receiver drier bottle vertical. This is bottle is mounted mounted with w i t h sight glass glassvertical. is to ensure that pick-up pick-up tube inside inside drier bottle is always immersed immersed in in liquid liquid refrigerant. refrigerant. If If receiver drier bottle is mounted at angles in excess of +j~ 20 degrees from vertical, mounted in degreesfrom re is a risk, under certain conditions, that vapour rar than liquid liquid may enter pick-up pick-up tube. Should this occur. occur, erratic air conditioning performance performance may result. result. ITEM: ITEM: XJS 4.0l 4.01 I/ V LOW COOLANT WARNING LIGHT LIGHT FAULT FAULT DIAGNOSIS DIAGNOSIS Dealer investigations into low coolant warning light concerns have resulted resulted in in a high high number of low coolant probes probes and control units being being rep/aced replaced unnecessarily, unnecessarily, as most probes probes and and control units tested by supplier reveal reveal no no faults. In In order to re~ reduce this unnecessary replacement. replacement, following following electrical checks should be be carried out by Dealers before condemning condemning or replacing components where cause is found to should include inspection of t o be loweoolant low coolant level. The checks checksshould of coolant system tern for leaks. leaks, which is best achieved achieved by pressure testing coolant system to t o locate source of leak. Coolant leaks may be caused by: loose hose clip connections, connections, worn or damaged damaged pressure cap seals, or damaged hoses. Lack of coolant recovery from f r o m atmospheric recovery bottle may be be a furr reason reason for low tow coolant level level in in header tank. Transfer of coolant from f r o m atmospheric recovery bottle relies relies on presence of a vacuum, as coolant contracts when engine is turned off. Checks should should be be made to ensure that recovery bottle and and its connections through to header made tank are leak-free leak-free and and unrestricted. unrestricted. In In addition, vacuum valve in in header tank should be be checked checked to t o ensure that it operates correctly and does not stick. ELECTRICAL CHECK PROCEDURE PROCEDURE CIRCUIT I SYSTEM S Y S f EM DETAILS DETAILS The system operates by measuring t h e resistance resistance of coolant. coolant. With resistance below 5,000 Ohm, Ohm, warning light is off. The light will illuminate with resistance

17 JD 16/92 % JA~ JAGUAR,.;..:w'--_-----, II 1--_--..:8=------, W/R w/u 2 6 COMPONENT I / CIRCUIT CODE WIRING CODE 1 -Ignition - (lgn) (IGN) supply W - White 2 -low - Law coolant control unit W/R - White I / Red 3 --Warning light (Will (W/L) W/U - White I / Blue 4 - Header tank B - Black 5 - low Low coolant probe 6 - Header tank earth via fixing bolts FAULT CAUSE ACTION ACT1 0 N W/l WfL does not illuminate at Blown W/l W/L or open circuit Check by shorting white f I any time. (Bulb check on W/L wire blue (W/U) wire to earth- - does not occur Le. 1 sec W/l W/L should come on. on following ign) Earth wire at unit open cir- cuit Check resistance to good chassis ground -less than 2 Ohm. Ign lgn supply to unit opencir- Check supply at unit, cuit should be battery voltage. If above checks are satisfactory sarisfactorv replace faulty faultv low coolant unit. W/l W/L on all time with Low coolant 'Check and top up as required retgn ign If If coolant level is satisfactory, following check will II determine i which part of circuit is at fault. Disconnect probe wire at tank and short to ground. If W/L goes out, pro pro- ceed to (A). If W/L stays on, go to (B). (A) Poor connection, tank Check resistance of tank body to earth body to good chassis earth -should be less than 20hm. 2 Ohm. Poor connection on Lucar Visual check - clean, reconnector Red I / White place as required. wire. Lucar rivet loose on low coolant probe low Low coolant probe / plat- Remove probe from tanking contaminated clean with wire wool - if probe Lucar is damaged : or loosened durina re-

18 JD 16/ JAGUAR JA~ (B) I B Short to earth in W/L wire Unplug low coolant unit. If or W/L bulb-holder pack W/L goes off, circuit OK-IfW/Lremains WjL illuminated-locate short circuit. Short to earth on probe With unit and probe diswire White I / Red (W/R) connected, check White I / Red wire resistance to good chassis earth - should be above 20,000 Ohm. 0 hrn. If all of above checks are satisfactory, satisfactorv, replace redace faulty faultv low coolant unit. W/L WIL flashes on, n goes Low coolant level Check - top up as reoff quired. Less likely causes but may in certain conditions, with Interrnittent Intermittent open circuit, Ground probe wire at tank on White I / Red (W/R} (W/R) low -test drive vehicle. If fault coolant probe wire recurs, check harness I / connectors, locate open circuit Less likely causes but may Bad connection tank body Check resistance of tank in certain conditions, with to earth body to good chassis an out of specification n earth-should be less than unit, cause a fault 2 Ohm. Poor connection on Lucar Visual check - clean reconnector Red I / White (RI IR/ place as required., W) wire. Lucar rivet loose on low coolant probe Low coolant Dt - probe I / plat- Remove probe from tank, ing contaminated clean with wire wool - if probe Lucar is damaged or loosened during removal replace probe.

19 III III Service Bulletin JA~ DATE: APRIL 1992 PAGE: 1 of 4 REF: JD 03/92 Owing to revised information received from Engineering, pages 11 of Service Bulletin JD 01/92,3/4 and 9/ of Service Bulletin JD 02/92 are being re-issued and are provided at end of this Bulletin, marked" " *Issue 2* 2' ". Existing pages of above should shoutd be removed and discarded to be replaced with revised version. pro- XJ6 3.2 & 4.0 ITEM: ADDITIONAL REPAIR OPERATION TIME The following Repair Operation limes Times are now available: Cylinder Head Gasket Rear Blanking Plate - Renew Hrs Gasket Cylinder Head Rear Blanking Plate - Renew Hrs Please amend your Repair Operation Time Schedule accordingly. No or Repair Times nmes are affected. XJ6/ / XJS ITEM: BRAKE SYSTEM SERVICE RECOMMENDATIONS With introduction of new brake components on above models, brake servicing recommendations have changed. No routine replacement of system seals is necessary as seals are designed to last for life tife of vehicle. The braking system must still be inspected for satisfactory operation and condition at regular service intervals. Brake fluid to be renewed at 2 years or miles (48000 km) intervals, whichever is sooner. For North America only, 18 months or miles ( km). N.2:te..; N9te; Service Manuals will be up-dated at next reprint. Jaguar Cars Limited

20 JD 03/92 / % JA~ JAGUAR ALL AJ~ENGINED AJGENGINED VEHICLES ITEM: WATER PUMPS A revised water pump assembly has been introduced on AJ6 engines. The assembly now has a gasket between two halves, instead of RTV sealant as previously used. The revised assembly is fitted Rtted from following engine numbers: 3.2 : : The part number of new assembly is ESC EBC 8550 and replaces EBC The part number of gasket is ESC EBC Note: THE GASKET CANNOT BE RETRO-FITTED TO RTV-SEALED WATER PUMPS. IF A LEAK BETWEEN THE TWO HALVES IS APPARENT, THE OLD STYLE PUMP ASSEMBLY MUST BE REPLACED BY EBC When ESC EBC 8550 has been fitted to an engine, bolts securing two halves toger must be re-torqued to 21.5 Nm Nm, to overcome possibility of gasket relaxation. to- XJ6 / XJ-S I / S.III ITEM: AIR CONDITIONING/HEATER CONDITIONING/!-IEATER MICROPROCESSOR 82 Refe[ Refer to Service Bulletin JD 09/91, Item 62. To improve retention of air conditioning/heater servo drive motor les ICs (integrated circuits) secured to to' microprocessor unit heatsink, supplier has now changed process to "Rivscrews". This modification commenced during mid-november 1991 and.raplaced replaced previ previ- (inteous bolt-type fixings. Air conditioning/heater units fitted with revised microprocessors were progressively introduced from VINs: XJ XJS S.l1I S.III XJ6 ITEM: WINDSCREEN WIPER ARM AND BLADE From VIN VlN , all XJ6vehicies vehicles have been fitted with a revised wiper arm and blade assembly. These new parts are interchangeable with cars built prior to this VIN. VIN, when changed as an assembly only. Dimensional changes prevent fitment fitrnent of a mixed condition of arm and blades. Dealers are reminded that wiper blade replacement remains a part of 7500 mile (12000 km) service schedule for all vehicles. 2

21 JD03 03/92 / JA~ JAGUAR % XJS ITEM: STOP LIGHT FAILURE SENSOR MODULE - LOCATION LOCATlON From VIN VlN (92MY Facelift XJS). XJS), stop light failure sensor module is located in boot of vehicle, attached to inside of boot side reinforcement panel (drainage channel) L.H. (Fig. 1). FIG. 1 Prior to VIN (90MY XJSJ, XJS), module is located beneath centre console veneer finisher, attached to a bracket in front of stowage compartment (Fig. 2). FIG. 2 3

22 JD 03/ =h+ JA~ JAGUAR XJ6 ITEM: EXTERNAL SPEED SENSOR BRACKETS - IDENTIFICATION 1DENTlFlCATlON Twoexternal a I speed sensor bracketsareavailablefor are avai use on XJ6 models. models, To avoid any confusion, y are identified as follows: fojlows: Bracket Description Of Use Part No CAC 9884 For all Drive Units prior to introduction of EBC 9750 and ESC EBC 9751 (no colour identification). EBC 9820 For all Drive Units from introduction of EBC 9750 and ESC EBC 9751 (identified by a "spot" of blue paint). 4

23 Ii JA~l Service Bulletin I I ~~~~==~~~~~~~~~~~~~ DATE: SEPTEMBER 1993 PAGE: 1 of5 5 REF: JD 26/93 00 ERRATA PLEASE NOTE THE FOLLOWING ERRATA IN RECENT SERVICE BULLETINS: I. JD 17/93 dated August 1993 Page 6 FOURTH DIGITS 1. JD 17/93 dated August 1993 Page 6 FOURTH DIGITS The Fourth Digit codes J and V have been duplicated. Please deletecode J, so that in future only code V will be used for "Thread Dam- Dam age".. 2. JD 17/93 dated August 1993 Page 7 Lines 21 & 22 The entry 9YV is duplicated on se lines. The first entry should read: 9YU gyu - Engine Compartment 3. JD 24/93 dated September 1993 Page 2 Line 12 This line should read: /09 44-'~39/09 As ~39 (Less JDS.. etc) XJ6 AND XJ MY ALL VARIANTS ITEM: INFORMATION ADDITIONAL ADDlTlONAL TO THE 94 MY TECHNICAL GUIDE The 1994 Model Year specificatron specification is enhanced by Inclusion inclusion of two new features designed to refine both handling and cosmetic qualities of Jaguar saloons. INTRODUCTION OF THE ZF PHASE 2 STEERING RACK FIG. 1 Jaguar Cars Limited

24 =+% JAGUAR JA~ JD 26/ 93 The The ZF ZF Phase Phase 2 Steering Steering Rack (Fig. (Fig. 1) 1) is is added added to MY M Y specification. specification. The The rack rack body body consists of two two aluminium aluminium pressure pressure diecastings; diecastings; rack rack mounting mounting is Is ununchanged. changed. The The pinion pinion height (1, (1, Fig. Fig. 1) 1) is is increased increased by by 7mm; 7mm; steering steering column column is is altered change. The valve block altered toaccommodatethis toaccommodate thischange. The fluid fluid pipe pipe union union positions positions in in valve are are also also altered. altered, with with fluid fluid pipes pipes being being modified modified accordingly. The The steering steering raci< rack assembly assembly is is a non-serviceable non-serviceable item. item. INTRODUCTION OF OF REAR REAR WHEEL WHEEL ALIGNMENT ADJUSTMENT ADJUSTMENT INTRODUCTION A system of rear Asystern rear wheel wheel alignment adjustment is is now now incorporated incorporated in in rearsuspenrearsuspensian sion assembly. assembly. The The lower lower suspension arm arm has has a plate, plate, with with a rectangular recess recess machined machined in i n centre, added added to to rear rear pivot pivot eye eye (1, (1, Fig. Fig. 2), 2 ). The The suspension arm arm pivot pivot bolt bolt hole hole (2, (2, Fig. Fig. 2) 2)is is elongated, horizontaly. horizontaly, at this this point. The The pivot pivot bolt bolt has has an an integral integral eccentric eccentric (3, (3, Fig. Fig. 2) 2) below below bolt bolt head, which. which, when when in in position position in in plate, plate, has has a slight clearance clearance at a t sides sides but but full clearance clearance at top top and and bottom. bottom. Rotation Rotation of bolt bolt head, head, with with eccentric constrained constrained between between vertical thusdisplacvertical faces, faces, causes causes bolt bolt shank to to be be moved moved in in horizontal horizontal plane. plane,thusdisplacing ing hub hub carrier carrier and and effecting effecting wheel wheel alignment alignment adjustment. FIG. FIG. 2 XJS XJS FROM FROM VIN VIN ITEM: ITEM: EXHAUST SYSTEM SYSTEM - DETAIL DETAIL CHANGES CHANGES 30 EXHAUST From From above above VIN VIN a number number of changes, mainly mainly to to dimensions, have have been been introintroduced duced to t o exhaust exhaust systems. The The object object of changes changes is is to to improve improve clearance clearance bebetween tween exhaust exhaust system system components, components, seat seat pan pan heat heat shield shield and and rear rear axle, axle, thus thus giving giving less less possibility possibility of offouling. fouling. The The items items affected affected are: are: 1. Intermediate Intermediate pipe pipe -- shortened shortened by by 10mm. 10mm New New 'Tarca' 'Torca' clamp clamp-tack-welded tack-welded in in production production (for (for ease ease of ofassembly) assembly) to to rear rear catalytic catalytic convertor, convertor, to to clamp clamp to to intermediate intermediate pipe. pipe. Note Note that that in in service service tack-welds tack-welds may may be be cut cut away away with with aa chisel, chisel, enabling enabling clampto clamp to be bediscarded. discarded. Newclamps New clampsshould should always always be beused usedwhen when exhaust exhaust syssystem tem is is being being re-assembled. re-assembled The The rear rear catalytic catalytic convertors convertors (with (with attached attached clamps, clamps, as as above) above) have have aa longer longer outlet outlet pipe. pipe. The The convertors convertors fit fit lower lower in in vehicle vehicle than than previously, previously, improving improving clearance clearance between between convertors convertors and and seat seat pan pan heat heat shield. shield. 2

25 JA~ JD 26/93 New Part Part Nos. Nos. New Description Description Market Application Application Market NMB NMB 6740AA 6740AA Intermediate pipe pipe Intermediate All markets markets All EBC EBC 9257n Clamp Clamp All All markets markets EBC EBC Catalytic Catalytic Convertor Convertor RH RH EEC EEC (inc. (inc. GB), GB),Middle Middle East, East, EBC EBC Catalytic Catalytic Convertor Convertor lh LH Malta, Malta, Cyprus, Cyprus, Poland. Poland. EBC EBC Catalytic Catalytic Convertor Convertor RH RH All All or or markets markets EBC EBC Catalytic Catalvtic Convertor Convertor lh LH All All or or markets markets XJ6 XJ6 AND AND XJ12 XJ12 ITEM:28 28 ITEM: IDENTIFICATION OF OF FINAL FINAL DRIVE DRIVE UNITS UNITS I/ LIMITED LIMlTED SLIP SLIP DIFFERENTIALS DIFFERENTIALS 51 IDENTIFICATION 51 Dea lers may certa i n owners, Jarly those who maya Iso drive ig h-perdealers mayfind findthat thatcertain owners, particu particularly thosewho may also drivehhigh-performance vehicles vehicles under under sporting sporting or or competition competition conditions, conditions, express express concern concern that that formance irsaloon saloonvehicle vehicleappears appearsto tohave haveaadefective defectiveor or inoperative inoperativelim limited slip differential differentiat ir ited slip unit, unit, or or that that final final drive drive appears appears to to be be of of aa "plain" "plain" or or conventional conventional type. type. Someclarification clarification isisrefore refore necessary necessaryconcerning concerning performance performancecharacteristics characteristics Some aflimited limitedslip slip differential differential units. units. and identification identification of and Powr-Lok differential differential essentially essentiallyvaries variesfrom fromaaconventional conventional bevel bevelgear gear unit unit in in havhavaa Powr-Lok ing addition additionof offriction friction plates platesbetween between output output bevel bevelgears gearsand anddifferential differential cascasing ing; friction friction plates plates are are loaded loaded by by input input torque torque to to differential differential unit, unit, in in addition addition ing; t oaa static staticpre-load. p r e l o a d.the Themode modeof ofoperation operationof ofsuch suchaa unit unitisisthat that speed speedof of rotation rotation to of aa slipping slipping road road wheel wheel isis limited limited by by braking braking action action of of friction friction plates, plates, and and of greatertorque torque isisapplied appliedto to road roadwheel wheel having having better bettergripon g r i p o n road roadsurface. surface. greater This principle principle isiscommon comrnon~to all friction friction plate plate differential differential units. units. This,to all Thecapacity capacityto totra transfer torque isisexpressed expressed as as "Bias "Bias Ratio", Ratio", which which can can be bemodimodithe nsfer torque fiedto tosuitvehicle suitvehicleapplication. application. Theselection Theselectionofl/Bias of "Bias Ratio" Ratio" isisaacomplex complex process, process, fied being aa compromise compromise between between vehicle vehicle handling, handling, refinement, refinement, and and traction. traction. AA HIGH being HIGH "Bias Ratio" Ratio" will will tend tend towards towards aa locked lockeddifferential differential condition, condition, as as may may be besuited suited to to aa "Bias hig h-performance vehicle vehicle tuned tuned for for competition competition purposes; purposes; aa vehicle vehicle so so fitted fitted will will high-performance from greater greatertraction traction capabilities capabilitiesthan than one onefitted fittedwith withaa low low "Bias "Bias Ratio" Ratio" unit, unit, benefitfrom benefit but but at at expense expenseof of refinement refinement and andease ease of of handling. handtjng. basicallyin in interests interests of of refinement refinementthat that Powr-Lok Powr-Lok differential differential units unitsfitted fitted ItIt isisbasically t o current currentjaguar Jaguar Saloon Saloon models models isisof of LOW LOW "Bias "Bias Ratio" Ratio" type, type, whilst whilst still still conferconferto ring benefit benefit of of partial partial locking locking between between rear rear wheels wheels under under conditions conditions of of low low ring tyre tyre adhesion. adhesion. mayconfirm confirmthat thataa Powr-Lok Powr-Lok differential differential isisfitted fittedto to aa particular particularvehicle vehicle by byaa Dealers may Dealers BLACKCROSS CROSSon on identification identificationlabel labelon on rear rearcover coverof of differential differential housing. housing. BLACK In addition, addition, from from VIN VIN , , all all Powr-Lok Powr-Lok differentials differentials have have aa metal metal tag, tag, stamped stamped In "P/l", "P/L", attached attachedto to one oneof of bolts boltssecuring securing fear rear cover. cover. XJS MODELS MODELS XJS ITEM:29 29 ITEM: STEERING STEERING RACK RACK ASSEMBLY ASSEMBLY Commencingat at VIN VtN aa revised revisedpattern patternof ofsteering steering rack rackassembly assembly has hasbeen been inincommencing troduced on on all allxjs XJS models. models. troduced 3

26 JA~ JD 26/93 These units with steering units (identified (identified below) below) are fully interchangeable interchangeablewith sreering rackassemrackassemblies on on all earlier XJS derivatives. derivatives. In In common common with XJ6IXJ12 XJGDCJ12 steering steering racks racks supplied supplied through through Jaguar Parts Parts Operations, racks racks will be be supplied supplied with a Centralising Centralising Pin Pin installed. installed. Upon Upon fitment of rack assembly to vehicle, this pin pin must be be removed removed and and replaced replaced by a screw and and special washer, as listed listed below. below. an Exchange Exchange Programme Programme of rack assemblies assemblies will be be introduced, initial initial units units Whilst an be new. The appropriate suffix, N N or E, E l should be be used. will all be NEW Part No. No. REPLACES Part Nos. eec CCC 6012 eee CCC & & cee CCC 5666 CCC 6013 eee CCC & & cee CCC 5667 eec CCC 6014 eee CCC 5662 & & eec CCC 5668 eee CCC 6015 eee CCC 5663 & & eec CCC ",., JZS JZW J Z W Screw Washer Appl icatians Applications RHO V12 Sportspack RHD & & 3.6/ Litre Litre Coupe RHO RHD & V12 Sportspack LHD & 3.8/ Litre Litre Coupe LHD LHD V12 (Standard (Standard Spec.) Spec.) RHD RHD & & 4.0 litre Litre Convertible RHD RHD V12 (Standard (Standard Spec.) Spec.) LHD LHD & & 4.0 Litre Litre Convertible LHD LHD All above applications All above applications common with XJ6 and and XJ12 models, above assemblies can can not be be serviced. In common reto assist identification where warranty claims are submitted for fitment of reshould be be utilised: urilised: placement units, following NEW warranty codes should 5PA 5PD 5PF 5PG 5PH 5PJ 5PK 5PL 5PM 5PN 5PO 5PR 5PS 5PT Power Steering Steering Rack & Pinion Pinion Rubber Gaiter Rack Pipes Pipes Rack Pipe Pipe Unions Unions Track Rod Rod LH LH Track Rod RH RH Rack Mou Mounting nting Bush Bush LH LH Rack Mounting Bush Bush RH RH Rack Mounting Mounting Bracket Bracket LH th Rack Mounting Mounting Bracket RH RH Front Wheel Tracking Tracking Outer Track Rod Rod Ball Ball Joint LH LH Rod Ball Ball Joint RH RH Outer Track Rod Mounting Bracket Fixings Fixings Rack Mounting XJ61993 MY ITEM: ITEM: HUB HUB CAP DAMAGE DAMAGE To prevent distortion distortion to hub caps, arising from from over-tightening over-tightening of securing screw, a new plastic "snap on" on'' pattern pattern of hub cap has been been introduced introduced from VIN VIN The road wheels wheels affected are 'Roullet' 'Roullet' alloy (Part (Part No. eee CCC 2708) 2708) and 'Radial' alloy wheel (Part (Part No. No. CCC 3524) The new pattern pattern of hub hub cap is available as a s Part No. No. eee CCC

27 JD 26/93 JA~ ALL XJ6, XJ12, XJS MODELS ITEM: 31 FROM VIN XJ12, XJ6, XJS INCH ALLOY WHEELS A new surface finish is now being applied to 16 inch Alloy wheels which will provide increased protection against corrosion and pitting arising from brake dust. Dealers should bring to attention of owners concerned that ONLY Jaguar-approved wheel cleaner should be used; acid-based cleaning products may lead to dis dis- Jaguar-apcoloration of alloy wheels. The revised--condition revised+ondition wheels are available through Jaguar Parts Operations under Part Number MHB 6115AA. 15AA. XJS FROM VIN VtN ITEM: DOOR ARM REST ESCUTCHEON A re-designed chrome escutcheon (securing screw concealer) for door arm rests has been introduced from VIN This revised item (Part No. BEC 23781) provides an increased clearance between escutcheon and trim cover of arm rest, compared to previous condition. XJ6 4.0 & 3.2, XJ12 ITEM: HEATER MATRIX - COOLANT LEAKS Investigations into heater matrix units returned with complaint of coolant leakage have resulted in design changes. Modifications to top and bottom tanks and collector plates have been introduced to correct this concern. Heater units incorporating modified matrix assemblies were introduced at VIN All current stock held by Jaguar Parts Operations is to revised condition. col- XJ6/ 1 XJ12 XJl2 SERVICE MANUAL ITEM: ERRATUM - SECTION 82 PAGE Your attention is drawn to an error in text on above page, in Issue 2, dated January The correct version of text is included below; a revision bar is placed to left of changed text, which is also underlined. Until this section is re-issued, please amend Service Manual page concerned. Jan- See for removal... etc , Reassembly and fitting is reversal of this procedure noting that special tool JD 164 must be placed over compressor shaft for seal seai installation and that replacement seal must be fitted with aid of JD

28 F-II~~ '--~ ---~- - ' ~" ~~'~- ~~~-~-~ 7 - Service Bulletin I U_. -_-~~s~e-r-vi-c-e-b-u-lle-t~in~~~~jaguar DATE: DECEMBER 1993 DATE: DECEMBER 1993 PAGE: 1 of 6 PAGE: 1 of 6 REF: FEF: JD 44/93 XJS IUS 4.0 LrTRE IZIRE 1994 MY FROM VIN I'I'EM: EXHAUsr EXHAUST SYsrEM SYSTl3l - DETAIL CHANGES, USA & CANADA ONLY Prior to alxjve above VIN, I for USA and canada Canada markets ONLY, exhaust system basically bsically consisted of: - downpipe dmpipe - plain intermediate int-iate ('Y') pipe - twin catalytic catalflic convertors - over-axle pipes - rear silencer assemblies commencing C m c i n g at above abve VIN, LEN, exhaust system layout becomes: -: -- - downpipe - intermediate intdiate ('Y') pipe with integral single sble catalytic convertor - twin min plain silencers - over-axle pipes - rear silencer assemblies '!be The following part numbers nunbxs are applicable to later condition, from VIN : NEW PARr PART NOs NOS DESCRIPTION MARKEl' MARKFT APPLICATION EBC Intermediate Intdiate (''i') ( ' Y ' ) pipe with integral intqral USA & CANADA catalytic convertor APPLICATION USA & CANAIXl me 9782 Intermediate silencer assembly RH USA & CANADA me 9783 Intennediate Intermediate silencer assembly LH UI USA & CANADA (omw!a Jaguar Cars limited Limited

29 XJS mm YEAR - m alara2 XJS KDEL YEAR - ~ ClJ1\NGE ITEM: OONNEI' BONNET RELEASE RELEwE MECHANISM MECWlNISM Coinciding approximate.ly approximately with intred.uction intrduction of XJS XSS Mcx:lel Mdel Year vehicles, a revised pattern of oonnet bonnet release catch has been introduced as a rurming mfnq charge. change. In course of development developrent of new type of catch, a med. methd of gaining access to engine compartment (mrprbmt has been established establish& to overcome problem which mich would arise in rare event of release cable failure. 'This rnethcd method allows oonnet bonnet to be released and opened oped without panel or paintwork damage to oonnet bonnet itself or adjacent panels.'ihe panels.the oonnet hnnet release problem may nay n be traced tracd and rectified. strict Strict observance obsmce of following method rraethod is essential to avoid cosmetic msetic damage: 1. Ensure m e that radio code is known prior to disconnection dismnnedion of battery. Open toot. boot. Remove battery cover and disconnect tattery. battery. 2. Apply masking tape to outside edges of bonnet bnnet and adjacent panels, 'WTapping wrapping tape as far as possible around panel edges. Fit wing covers. 3. Remove F?m-ove front grille. 4. Remove bolts retaining retain* bonnet bnnet hinges. Thp:n:t.ant : Have an assistant ready to prevent front end of bonnet being raised raid by action of gas struts as 1::01 bolts are removed. removed, 5. Allow front end of bonnet bannet to be raised through a short distance by gas struts, rear end meanwhile pivoting on strikers still engaged to catches. Continue to raise front end slowly and carefully until access is available to bonnet bnnet ball-joint kll-joint of each gas strut. carefully Carefully release each ball joint from its pivot ball. Ensure Wure that assistant holding bonnet appreciates that as each strut is released (and allowed allow& to extend), re will be k a change from holding ronnet bonnet down to need to supp:jrt support bonnet. bmet. 6. Have assistant raise front end of bonnet a short distance furr, I until access is available to catches. care Care is required that rear corners comers of tx:>rmet bonnet do not contact plenum panel below. - :2 -

30 Release RXS 7. Release RHS catch catch by by operating operating latch latch ann arm directly directly by by hand. hand. 8. Using Us locally-made lccally-made release release tool tml illustrated illustrated in in Fig. Fig. 1. below, 1. belcw, lhs 1l15 catch catch may may ke released after passing release tool be released after passing release tool across top of engine. The notch on across top of engine. The notch on end face of end face of tool tool prevents prevents slippage slippage from from catch. catch. 9. Remove Rwave bonnet bonnet by by lifting lifting it it up up and and away away from from engine erqine compartment cmprbent apert1..l.te. aperture Trace Trace and and rectify rectify release release problem. problem Refit Refit and and adjust adjust bonnet bnnet to to aperture. aperture Refit Refit front front grille. grille Reconnect Remnnect battery battery and and ref refit it battery battery cover. cover Re-code Re-code radio; radio; re-set re-set clock. clmk. A--~ ~~;= ~ J ~ 190,., 1000 t Fig. Fig Ihe tool illustrated abve should be locally mufarturd frcm a locally manufactured from a length of steel rcd, 6.00mn diameter, approximately looorrm long.?he overall length, however, is not critical, provided that +he tool 1s sufficiently long to provide access across engine conpxbent. 'llle tool illustrated abjve should l::e length of steel rod, 6.0Omrn diameter, approximately looomm long. The overall length, hohever, is not critical, provided that tool is sufficiently long to provide access across engine compartment

31 I'l'fH: 48 USE OF LCSTED ' PIASTIC PADDING ' WDY REPAIR PRODUCTS 76 USE OF LISTED 'PIASTIe PADDTh'G I BODY REPAIR PRODUCTS Being widely available through Body Refinishing ~efinishirq trade suppliers, Jaguar make following followinq recommendations reconrmendations as a result of laboratory tests lxzsts carried out on two prcducts concerned:- 'Plastic Padding' 'Plastic Padding' Paddhq WB2000 Stonechip 'ULTIMA' 'ULm' Universal Body Filler WE S'roNECHIP '!his This is a sill-coat repair product, prduct, spray applied as a water-based emulsion. mlsion. Though prin:arily prkily an air dried prrouct, product, it rroay my be force dried if necessary. It is confirmed confkrmd that this material mterial MAY be employed as a repair product prociuct on Jaguar and Daimler IXimler vehicles, where repair will be subject: of warranty. Warranty. Tests indicate, however, that procluct product will give a coarser finish than that given by original factory finish sill-coating. sill-coatiq. 'TWo Ttm coats of product are recommended reco-ed to give a minimum mininun dry-film thickness thiclmess of 400 microns. Colour mlour finishing by conventional convesltional 2K process prmess should be force-dried forcedried at 60"C 6O0C rrrudmum. mimum. (LoW (Low bake at 90 C may procluce produce I 'fine-boil' fine-roil' effects.) It should be bs noted that repairs adjacent to clear coat must be preceded by thorough flatting of clear coat mat (360 grit paper) paper] to achieve satisfactory adhesion and anti-chip performance. 'ULTIMA t UNIVERSAL BODY FIlLER This is a filler product, to be knife-applied over etch-primed metal surfaces. After appropriate sanding, a conventional 2K colour process may be k applied. applid. 'Ihis This product is Nor NOI' APPROVED APPROW for J::cdy m y repairs which carry Wan-anty. Warranty. '!he The prcduct product is assessed as r 'equivalent to or similar materials' of catalysed polyester type, and shares with m tendency to prcxiuce mce micro-blistering around interface between repair and original materials, particularly in high humidity conditions. Hence, on Jaguar and Daimler DaimLer vehicles its use must J:e be confined confhd to repairs W'hich which do not carry Warranty

32 AIL KDELS Fl'lTED WTIH AIR a::tidrrictflng ITEM: B~G BIANKING PUX;S PLIKS FOR MR REFRIGERATION CIRCUITS Attention ~ttention is is drawn dram to to neoo need for connections on on Refrigeration ~efrigeration Circuit components conpnents to to l::e b blanked off, whenever circuit is is disturbed for servicing or or component replacement, in in order to to prevent contamination of of circuit by by ingress of of rroisture mistwe and I 'foreign' I material. As As well as as l::eing king necessary for on-vehicle components ampnents, I this also applies to to components being returned Wlder under Warranty, since sutsequent suk;sequent investigation of of se components is is often compromised cdmprclmis& by by contamination c o n ~ t i oof of n ir interior before receipt at at Jaguar. Components being returned to to Jaguar should l::e k blanked off using blanks installed on on replacement replamt part. Components Compnmts on on vehicle should be be blanked blank& off using suitable internal line plugs and and external line caps. A set of of plugs and and caps found suitable for for most mst of of corrqxlj1ents components in in Refrigeration Circuit is is Vacuum and and Fuel Line Plug Set, available from Snap-on Tools, Tmls, under ir Part No. No. THX THX It It is is recommended recmmwxled that Dealers should obtain sets of of se, or or ir equivalent, from ir lcx2l 1-1 distributors. In In addition, certain connections can be k blanked off using a a Bonnet stop, Stop, Part No. BD BD 10224, available via Jaguar Parts Operations. Oprations. It It is is important to to note that plugs and caps kept for repetitive use on on Refrigeration ~efrigeration Circuits circuits should be be kept segregated segreqatd from those used for or purposes, such as as blanking off off fuel or or hydraulic components. wmponenb. I'lDI: ITEM: RECEIVER RElXIER DRIER ASSEMBLY OJrrent Current instructions require rquire that Receiver Drier Assembly be be replaced replacd whenever Refrigeration circuit is is opened, opend, even though re may my 00 be no no reasons to to suspect serviceability of of Drier. This Service Bulletin revises that requirement and permits Drier to to remain ramin in in service provided:- blanks are are installed on on component copnent and and refrigerant line connections immediately after disconnection. blanks are are only removed rmvd from conponent compnent and and refrigerant 1 line connections immediately Wiately prior to to reconnection Refer to to Item al:ove above of of this service Service Bulletin for details of of blanking plugs and caps required. rquired