III Service Bulletin JA~ III

DATE: APRIL 19921992 PAGE: 11 of 4 REF: JD 03/92

Owing toto revisedrevised informationinformation receivedreceived fromfrom Engineering, pages 1111 of Service Bulletin JD 01/92,3/401/92, 3/4 and 9/10911 0 of Service Bulletin JD 02/92 are being re-issuedre-issued and are pro­pro- vided at thethe end of thisthis Bulletin, marked"marked " *Issue 2*2' ".

Existing pages oftheof the above shouldshoutd be removedremoved and discarded toto be replacedreplaced with thethe revisedrevised version.

XJ6 3.2 & 4.0 ITEM:ITEM: 2020

0303 ADDITIONAL REPAIRREPAIR OPERATIONOPERATION TIMETIME

TheThe followingfollowing RepairRepair OperationOperation limesTimes areare nownow available:available:

12.29.1612.29.16 -- CylinderCylinder HeadHead GasketGasket RearRear BlankingBlanking PlatePlate -- RenewRenew -- 1.401.40 HrsHrs GasketGasket 12.29.1712.29.17 -- CylinderCylinder HeadHead RearRear BlankingBlanking PlatePlate -- RenewRenew -- 1.401.40 HrsHrs

PleasePlease amendamend youryour RepairRepair OperationOperation TimeTime ScheduleSchedule accordingly.accordingly.

NoNo otherother RepairRepair Timesnmes areare affected.affected.

XJ6/XJ6 / XJS ITEM:ITEM: 2121

1010 BRAKEBRAKE SYSTEMSYSTEM SERVICESERVICE RECOMMENDATIONSRECOMMENDATIONS

WithWith thethe introductionintroduction ofof newnew brakebrake componentscomponents onon thethe aboveabove models,models, thethe brakebrake servicingservicing recommendationsrecommendations havehave changed.changed.

NoNo routineroutine replacementreplacement ofof systemsystem sealsseals isis necessary necessary asas thethe sealsseals areare designeddesigned toto lastlast forfor thethe lifetife ofof thethe vehicle.vehicle.

TheThe brakingbraking systemsystem mustmust stillstill bebe inspectedinspected forfor satisfactorysatisfactory operationoperation andand conditioncondition atat thethe regularregular serviceservice intervals.intervals.

BrakeBrake fluidfluid toto bebe renewedrenewed atat 22 yearsyears oror 3030 000000 milesmiles (48000(48 000 km)km) intervals, intervals, whicheverwhichever isis thethe sooner.sooner. ForFor NorthNorth AmericaAmerica only,only, 1818 monthsmonths oror 3030 000000 milesmiles (48(48 000 000 km).km).

N.2:te..;N9te; ServiceService ManualsManuals willwill bebe up-datedup-dated atat thethe nextnext reprint.reprint.

Jaguar Limited Jaguar CarsCars Limited Jaguar Cars Limited 2005 % JDJD 03/9203 / 92 JA~JAGUAR

ALL AJ~ENGINEDAJGENGINED VEHICLES ITEM:ITEM: 2222

2626 WATER PUMPSPUMPS

AA revisedrevised water water pumppump assemblyassembly hashas beenbeen introducedintroduced onon AJ6AJ6 engines.engines. TheThe assemblyassembly nownow hashas aa gasketgasket betweenbetween thethe twotwo halves,halves, insteadinstead ofof RTVRTV sealantsealant asas previouslypreviously used.used. TheThe revisedrevised assemblyassembly isis fittedRtted fromfrom thethe followingfollowing engineengine numbers:numbers: 3.2 : 107696 4.0: 157275 TheThe partpart numbernumber ofof thethe newnew assemblyassembly isis ESCEBC 85508550 andand replacesreplaces EBCEBC 4437. TheThe partpart numbernumber ofof thethe gasketgasket isis ESCEBC 9220.9220.

Note:Note: THETHE GASKETGASKET CANNOTCANNOT BEBE RETRO-FITTEDRETRO-FITTED TOTO RTV-SEALEDRTV-SEALED WATER PUMPS.PUMPS. IFIF A LEAKLEAK BETWEENBETWEEN THETHE TWOTWO HALVESHALVES ISIS APPARENT, THETHE OLDOLD STYLESTYLE PUMPPUMP ASSEMBLY MUSTMUST BEBE REPLACEDREPLACED BYBY EBCEBC 8550.8550. When ESCEBC 85508550 hashas beenbeen fittedfitted toto anan engine,engine, thethe boltsbolts securingsecuring thethe twotwo halveshalves to­to- gethergether mustmust bebe re-torquedre-torqued toto 21.521.5 NmNm -- 28.528.5 Nm,Nm, toto overcomeovercome thethe possibilitypossibility ofof gasketgasket relaxation.relaxation.

XJ6 / XJ-S I/ 5.111S.III ITEM:ITEM: 23

8080 AIR CONDITIONING/HEATERCONDITIONING/!-IEATER MICROPROCESSORMICROPROCESSOR 8282 Refe[Refer toto ServiceService BulletinBulletin JDJD 09/91,09/91, ItemItem 62.62. ToTo improveimprove thethe retentionretention ofof thethe airair conditioning/heaterconditioning/heater servoservo drivedrive motormotor lesICs (inte­(inte- grated circuits) secured to·to'the the microprocessor unitunit heatsink, thethe supplier has now changed thethe process toto "Rivscrews"."Rivscrews". This modification commenced during mid-Novembermid-Novem ber 19911991 and .raplacedreplaced thethe previ­previ- ous bolt-type fixings.fixings. Air conditioning/heater units fittedfitted with revisedrevised microprocessors were progressively introducedintroduced fromfrom VINs:

XJ6 - 659029

XJS - 183501 S.l1IS.III - 486299

XJ6 ITEM:ITEM: 24

84 WINDSCREEN WIPER ARM AND BLADE

From VINVlN 657725, all XJ6vehiciesXJ6 vehicles have been fittedfitted with a revisedrevised wiper arm and blade assembly. These new parts are interchangeableinterchangeable with cars built prior to this VIN.VIN, when changed as an assembly only. Dimensional changes prevent the fitmentfitrnent of a mixed condition of arm and blades.

Dealers are reminded that wiper blade replacement remains a part of the 7500 mile (12000 km) service schedule for all vehicles.

2 Jaguar Cars Limited 2005 JDJD03 03/92 / 92 JA~JAGUAR%

XJSXJS ITEM:ITEM: 2525

8686 STOPSTOP LIGHTLIGHT FAILUREFAILURE SENSORSENSOR MODULEMODULE -- LOCATIONLOCATlON

FromFrom VIN VlN 179737179737 (92MY(92MY Facelift Facelift XJS).XJS), the the stopstop lightlight failure failure sensorsensor modulemodule isis locatedlocated inin the the bootboot oftheof the vehicle, vehicle, attachedattached to to thethe insideinside of of thethe bootboot side side reinforcementreinforcement panel panel (drainage(drainage channel)channel) L.H.L.H. (Fig.(Fig. 1).1).

FIG.FIG. 11

PriorPrior toto VIN VIN 179737179737 (90MY(90MY XJSJ, XJS), thethe modulemodule isis locatedlocated beneathbeneath thethe centrecentre consoleconsole veneerveneer finisher,finisher, aattachedttached toto aa bracketbracket inin frontfront ofof thethe stowastowagege compartmentcompartment (Fig.(Fig. 2). 2).

FIG.FIG. 22

3 Jaguar Cars Limited 2005 =h+ JD 03/9203 192 - JA~JAGUAR

XJ6 ITEM:ITEM: 26

88 EXTERNAL SPEED SENSOR BRACKETS - IDENTIFICATION1DENTlFlCATlON

TwoTwoexternal extern a I speed sensor bracketsbracketsareavailablefor are avai lable for use on XJ6 models.models, To avoid any confusion, they are identifiedidentified as follows:fojlows:

Bracket Description Of Use Part No CAC 9884 For all Drive Units prior toto thethe introductionintroduction of EBC 9750 and ESCEBC 9751 (no(no colour identification).identification). EBC 9820 For all Drive Units from the introductionintroduction of EBC 9750 and ESCEBC 9751 (identified by a "spot" of blue paint).

4 Jaguar Cars Limited 2005 IIIII =Q% Service Bulletin ~AGUA~ . , . Service Bulletin JA~ III

DATE:DATE: OCTOBEROCTOBER 19921992 PAGE:PAGE: 11 ofSof 8 REF:REF: JDJD 16/9216/92

ERRATAERRATA

OwingOwing toto revisedrevised information,information, thethe torquetorque figurefigure farfor thethe coolantcooiant temperaturetemperature trans­trans- mittermitter toto engine,engine, XJSXJS models,models, isis 14,514,5 toto 19,519,5 Nm.Nm.

TheThe torquetorque figurefigure givengiven inin ServiceService BulletinBulletin JDJD 10/9210192 andand SectionSection 8888 ofof XJSXJS ServiceService Manual,Manual, JJMJJM 100406/20,10 04 06/20, shouldshould bebe ignoredignored andand onlyonly thethe revisedrevised figurefigure used.used.

ServiceService ManualsManuals will will bebe amendedamended atat thethe nextnext reprint.reprint.

XJ6XJ6 9393 MYMY (FROM(FROM VINVIN 667829)667829) ITEM:ITEM: 4444

BATIERYBA-TTERY TRANSITTRANSIT RELAYRELAY -- REMOVALREMOVAL

OwingOwing toto thethe relocationrelocation ofof thethe batterybattery intointo thethe bootboot atat 9393 MY,MY, aa revisedrevised batterybattery transit transit relayrelay hashas beenbeen introduced,introduced, (see{see FigFig 1).1).

FIGFIG 11

TheThe procedureprocedure forfor thethe removalremoval ofof thisthis newnew relayrelay isis asas follows:follows:

WITHWITH THETHE IGNITIONIGNITION OFF:OFF: 1.1. OpenOpen thethe bootboot andand removeremove thethe batterybattery cover,cover, (see(see FigFig 2).2). 2.2. RemoveRemove thethe negativenegative leadlead fromfrom thethe battery.battery. 3.3. DisconnectDisconnect thethe transittransit relayrelay fromfrom thethe battery.battery. Jaguar Cars Limited 2005 4.4. RemoveRemove thethe whitewhite I/yellow yellow (W/Y)(WN) ignition ignition wirewire fromfrom thethe transittransit relay.relay. JD 16/92 JA~JAGUAR

FIG 2 5. Remove thethe positive leadlead fromfrom thethe transittransit relayrelay terminalterminal post, (A,(A, Fig 3). 6. Reverse thethe positive leadlead clamp and refitrefit thethe clamp toto thethe positive leadlead (B,(6, Fig 3).

=-=-===' ====-::~

J'S117t!ol

FIGFIG 33 7.7. DisplaceDisplace thethe battery.battery. 8.8. TieTie backback andand securesecure thethe white I/yellow yellow (W/Y)(WH) ignition ignition wire, (see(see FigFig 4).

Jaguar Cars Limited 2005 FIG 4

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 16/9216 192 JA~JAGUAR-

9. Refit the battery. 10. RefitRefit: and secu.resecu,re the positive and then negative leadlead of the battery. 11.1 1. Replace thethe battery cover.

NOTE: ALL UKUKOEALERS DEALERS MUSTMUSTCONTINUETORETURNTHE CONTINUE TO RETURN THE DISPLACED DISPLACEDTRANSlT TRANSIT RELAYS.

REMOVAL OF THE TRANSIT RELAY SHOULD BE CARRIED OUT NO LONGER THAN 24 HOURS BEFORE THE VEHICLE ISIS HANDED OVEROVERTOTHE TO THE CUSTOMER.

THE RADIO AND TIME CLOCK MUST BE RESET AFTER THE RELAY IS1s RE·RE- MOVED.

IMPORTANT:IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD THE RELAY BE USED OR RE·RE- TAINED AS AN ISOLATIONISOLATION DEVICE FOR ROAD USE.

XJS ITEM: 45

03 REPAIR OPERATION TIMES

Air ConditioningConditioning BlowerBlower MotorMotor Assembly

TheThe repairrepair operationoperation timestimes forfor renewingrenewing thethe airair conditioningconditioning blowerblower motormotor assem·assern- bliesblies havehave beenbeen re-studiedre-studied onon 19921992 MYMY vehicles.vehicles.

TheThe newnew operationoperation timestimes forfor vehicles fromfrom VIN 179737179737 areare asas follows:follows:

Right-handRight-hand drivedrive vehiclesvehicles

82-25-1382-25-13 BlowerBlower Assembly -left-Hand- Left-Hand -- RenewRenew 0.950.95 HrsHrs 82-25-13/0982-25-1 3/09 As 82-25-1382-25-1 3 (Less(Less JDSJDS Allowance) 0.600.60 HrsHrs

82-25-1482-25-14 BlowerBlowerAssembly-Right-Hand-Renew Assembly - Right-Hand - Renew 1.601-60Hrs Hrs 82-25-14/0982-25-1 4/09 As 82-25-1482-25-1 4 (Less(Less JDSJDS Allowance) 1.251.25 HrsH rs

Left-handLeft-hand drivedrive vehiclesvehicles

82-25-1382-25-1 3 BlowerBlower Assembly -- Left-HandLeft-Hand -- RenewRenew 1.601.60 HrsHrs 82-25--13/0982-25-1 3/09 As 82-25-1382-25-13 (less(Less JDSJDS Allowance) 1.251.25 HrsHrs

82-25-1482-25-1 4 BlowerBlower AssemblyAssembly -- Right-HandRight-Hand -- RenewRenew 0.950.95 HrsHrs 82-25-14/0982-25-24/09 AsAs 82-25-1482-25-14 (Less(Less JDSJDS Allowance)Allowance) 0.600.60 HrsHrs

PleasePlease amendamend youryour repairrepair timestimes accordingly.accordingly.

NoNo otherother repairrepair timestimes areare affected.affected.

Jaguar Cars Limited 2005 =+b JOJD 16116/92 92 JAGUARJA~

XJ6XJ6/ 1 XJSXJS ITEM:ITEM: 4646

10 BRAKE SYSTEMSYSTEM SERVICESERVICE RECOMMENDAT1ONSRECOMMENDATIONS

Note: ThisThis bulletin supersedessupersedes ItemItem 2121 ofof ServiceService Bulletin JDJD 03/92.03/92.

With thethe introductionintroduction of thethe ABS brake system, fromfrom thethe followingfollowing VINs, thethe brake servicing recommendations have changed:

1. XJ6 fromfrom VIN 594576.

2. XJS (5.3 convertible) from VIN 147269.

3. XJS (5.3coupe)(5.3 coupe) from VIN 148782.

4. XJS (3.6 coupe) from VINV1N 148945.

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 the regular service intervals.

Because of its hygroscopic nature, brake fluid must be renewed at 2 year or 30 000 mile I48(48 000 km) intervals, whichever is sooner.

XJ6 ALL MODELS ITEM: 47

18 LAMBDA SENSOR SPLASH-SHIELD

Following reports of the intermittent display of "Fuel Failurefailure 44" on the instrument pack, it was found that this symptom could be caused bywaterby water penetrating the lamb­lamb- da sensor.

A lambdalambda sensor splash-shield has been introducedintroduced from VINV1N 664941, which can be fitted retrospectively and should be installedinstalled whenever a lambdalambda sensor isis changed. This will reduce the possibility of water ingress.ingress.

/~

Jaguar Cars Limited 2005 % JD16/92JD 16 192 JAGUARJA~

The six-inch silver heat-proof sleeve is fitted by sliding it over the sensor, prior to its replacement. After the sensor has been fined,fitted, Dealers should ensure thatthethat the sleeve is pushed fully back down to cover the whole sensensor- SOL

ALL MODELS ITEM: 48

18 IGNITION SPARK PLUGS

Spark plugs have been returned under warranty with a yellow I/ brown stain visible on the insulator housing. Dealers have incorrectly interpreted this as leakage of com­corn- bustion gases between the insulator and metal housing and the cause for spark plug misfire. ThefollowingThe following is an explanation forthefor the staining and the more likely cause for spark plug misfire.

During mostatmosphericmost atmospheric conditions a form of staticstaticdischarge, discharge, common to high volt­volt- age conductors, can occur.occur, which ISis commonly known as "Corona discharge".

Ignition systems are particularly pronetoprone to this effect during wet weather, when the air space surrounding the spark plugs becomes charged with a gas composed of elec­elec- trons, ions and air particles, forming a state of general ionization. Too much ioniz­ioniz- ation counteracts the spark plug insulation and causes a partial discharge, which in turn gives out a blue light.

Under normal circumstances this will in no way affect the running oftheof the car, provid­provid- ing the spark plug insulatorsirlsulators are kept clean.

RunniRunning n9 problems would normally onlyonlyoccur occur iftheif the spark plug insulators were coated in a film of dirt, which would allow high voltage tracking, known as "flashover","Rashover", be­be- tween the spark plug terminal stud and earth, thus causing a misfire.

However, protection is provided against this eventuality by the inclusion of "ribs" along the insulator body. To identify whether or notthenot the spark plugs have been sub­sub- jected to Corona discharge.discharge, plugs should be examined in daylight for the presence of a yellow I/ brown stain at the base of the insulator, next to the metal housing.

The actual stain is caused by oil-contaminated particles, in suspension around the spark plug insulator, receiving the electrostatic charge of ionization and fusing them­them- selves to the plug. The stain is quite harmless and can usually be wiped off easily.

Corona discharge will cause no deterioration in service or malfunction of the spark plug. Moisture or dirt may cause "flashover" but Corona discharge does not. Cleanliness is vital, therefore, spark plug insulators should be kept clean and dry at all times.

Note: Spark plugs returned under warranty may be rejected as "no fault found" for the reasons given above.

XJ6 ALL MODELS ITEM~ 49

64 REAR SHOCK ABSORBERS Jaguar Cars Limited 2005 From VIN 667829.667829, a new rear shock absorber is fitted to all non-ride-Ievellingnon-ride-levelling ve­ve- hicles. This new part is fully interchangeable with all previous components when '==-% JD 16/9216 / 92 JAGUARJA~

This new part, number CCC 6923, should be used in all cases where rear shock ab­ab- sorbers are replaced, with immediate effect.

Under no circumstances should this new part be mixed with old condition parts on a vehicle axle.

When failures are identified in service, single shock absorbers only need to be changed if the parts have less than 25,000 miles (40,OOOkm}(40,000km) service use.

The new units, which have a black finish, can be easily distinguished from the previ­previ- ous parts by a new sealed gaiter, which will reduce dirt ingress.

XJS 6CYl/GCYL I V12 AND SERIES III111 V12 ITEM: 50

82 RECEIVER DRIER BOTTLE

When replacing the receiver drier bottle, Part Number CAeCAC 1881, it is essential that the receiver drier bottle is mounted with the sight glassglassvertical. vertical. This is to ensure that the pick-up tube inside the drier bottle is always immersed in liquid refrigerant. IftheIf the receiver drier bottle is mounted at angles in excess of +j~+1-20 20 degreesdegreesfrom from the vertical, there is a risk, under certain conditions, that vapour rather than liquid may enter the pick-up tube. Should this occur.occur, erratic air conditioning performance may result.

XJS 4.0l4.01 I/ V12 ITEM: 51

86 LOW COOLANT WARNING LIGHT FAULT DIAGNOSIS

Dealer investigations into low coolant warning light concerns have resulted in a high number of low coolant probes and control units being rep/acedreplaced unnecessarily, as most probes and control units tested by the supplier reveal no faults. In order to re-re~ duce this unnecessary replacement.replacement, the following electrical checks should be carried out by Dealers before condemning or replacing components where the cause is found to be loweoolantlow coolant level. The checkschecksshould should include inspection oftheof the coolant sys­sys- temtern for leaks.leaks, which is best achieved by pressure testing the coolant system to locate the source of the leak.

Coolant leaks may be caused by: loose hose clip connections, worn or damaged pres­pres- sure cap seals, or damaged hoses. Lack of coolant recovery from the atmospheric recovery bottle may be a further reason for lowtow coolant level in the header tank.

Transfer of coolant from the atmospheric recovery bottle relies on the presence of a vacuum, as the coolant contracts when the engine is turned off. Checks should be made to ensure that the recovery bottle and its connections through to the header tank are leak-free and unrestricted. In addition, the vacuum valve in the header tank should be checked to ensure that it operates correctly and does not stick.

ELECTRICAL CHECK PROCEDURE

CIRCUIT I SYSTEMSYSfEM DETAILS Jaguar Cars Limited 2005 The system operates by measuring the resistance of the coolant. With resistance below 5,000 Ohm, the warning light is off. The light will illuminate with the resistance % JDJD 16/9216/92 JA~JAGUAR

, ___.;..:w'--_-----, W/R

II 1--_--..:8=------, w/u

6 2

COMPONENTCOMPONENT I/ CIRCUITCIRCUIT CODE CODE WIRINGWIRING CODECODE 11 -Ignition- Ignition (lGN)(IGN) supply supply WW -- WhiteWhite 22 -low- Law coolantcoolant control control unitunit W/RW/R -- WhiteWhite I/ RedRed 33 - -WarningWarning lightlight (Will(W/L) W/UW/U -- WhiteWhite I/ BlueBlue 44 --Header Header tank tank BB -- BlackBlack 55 --low Low coolantcoolant probeprobe 66 --Header Header tanktank earthearth viavia fixingfixing boltsbolts

FAULTFAU LT CAUSECAUSE ACTIONACT1 0N W/lWfL doesdoes notnot illuminateilluminate at at BlownBlown W/l W/L oror openopen circuitcircuit CheckCheck byby shortingshorting whitewhite fI any time.time. (Bulb(Bulb checkcheck onon W/LW/L wirewire blueblue (W/U)(W/U) wire wire toto earth-earth - doesdoes notnot occur occur Le. i.e. @@ 11 sec sec W/lW/L shouldshould comecome on.on. onon followingfollowing ign)ign) EarthEarth wire wire atat unit unit open open cir- cir- CheckCheck resistanceresistance toto goodgood cuitcuit cchassishassis groundground -less -less thanthan 22 Ohm.Ohm. Ignlgn supply supply to to unit unit open opencir- cir- CheckCheck supplysupply atat unit,unit, cuitcuit shouldshould bebe battery battery voltage.voltage.

IftheIf the aboveabove checkschecks areare satisfactorysarisfactorv replacereplace faultyfaultv lowlow coolantcoolant unit.unit.

W/lW/L onon allall thethe timetime withwith LowLow coolant coolant 'CheckCheck andand toptop upup asas re­re- tgnign quiredquired IfIf the the coola coolant nt level level isis satisfactory, satisfactory, the the followi following ng checkcheck wi will II determdetermine i ne wh which ich partpart of of the the circuitcircuit isis atat fault.fault. DisconnectDisconnect the the probe probe wirewire atat the the tanktank andand shortshort toto ground. ground. IfIf the the W/L W/L goesgoes out,out, pro­pro- ceedceed toto (A).(A). IfIf thethe W/LW/L staysstays on,on, gogo toto (B).(B).

(A) PoorPoor connection,connection, tanktank CheckCheck resistanceresistance ofof tanktank bodybody toto earthearth bodybody toto goodgood chassischassis earthearth -should-should bebe less less than than 20hm.2 Ohm. PoorPoor connectionconnection onon LucarLucar VisualVisual checkcheck -- clean,clean, re-re- connectorconnector RedRed I/ WhiteWhite placeplace asas required.required. wirewire.. LucarLucar rivetrivet looseloose onon lowlow coolantcoolant probeprobe lowLow coolantcoolant probeprobe // plat-plat- RemoveRemove probe probe from from tank-tank- inging contaminatedcontaminated cleanclean withwithJaguar wirewire Cars woolwool Limited -- 2005ifif probeprobe LucarLucar isis damageddamaged : oror loosenedloosened durinadurina re-re- JD 16/9216 192 JAGUARJA~-

(B)I B Short to earth in W/L wire Unplug low coolant unitunit. If or W/L bulb-holder pack the W/L goes off, circuit OK-IfW/LremainsOK-If WjL remains illumi- nated-locate short circuit. Short to earth on probe With unit and probe dis- wire White I/ Red (W/R) connected, check the White I/ Red wire resis- tance to good chassis earth - should be above 20,000 Ohm.0 hrn.

If all of the above checks are satisfactory,satisfactorv, replaceredace faultyfaultv low coolant unit.

W/LWIL flashes on, then goes Low coolant level Check - top up as re- off quiquired. red. InterrnittentIntermittent 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 specspecification ificatio n earth-shouldearth -should be less than unit, cause a fault 2 Ohm. Poor connection on Lucar Visual check - clean re- connector Red I/ White (RIIR/ plplaceace as required. , W) wire. Lucar rivet loose on low coolant probe Low coolacoolant Dt - probe I/ plat- Remove probe from tank, ing contaminated clean with wire wool - if probe Lucar is damaged or loosened during re- moval replace probe.

Jaguar Cars Limited 2005 -- - -. ------... 1 - - 1 I -~AGUAR~~ I Service Bulletin I1 Service Bulletin --

DATE:DATE: MARCH MARCH 1993 1993 PAGE:PAGE: 11 of of 99

REF~REF: JDJD 05/9305/93

ERRATAERRATA

WITHWITH REFERENCEREFERENCE TO TO SERVICESERVICE BULLETINBULLETIN JDJD 17/92,17192, PLEASEPLEASE NOTENOTE THAT THATTHE THE WAR­WAR- RANTYRANP COMPLAINTCOMPLAINT CODE CODE SHOWN SHOWN ONON PAGE PAGE 2 2AS AS 1 I LBKLBK ISIS INCORRECT. INCORRECT. THISTHIS CODECODE SHOULDSHOULD READREAD 1'I LKBLKB

V12V12 ANDAND AJ6AJ6 ENGINESENGINES ITEM:ITEM: 0101

1212 INTRODUCTIONINTRODUCTION OFOF GRADEDGRADED CRANKSHAFTCRANKSHAFT BEARINGSBEARINGS

AsAs partpart ofof Jaguar'sJaguar's on-goingon-going commitmentcommitment toto improvingimproving quality,quality, threethree gradesgrades (sizes)(sizes) ofof crank crank pinpin and and journal journal bearingsbearings havehave been been introduced introduced onon allall productionproduction V12and V12and AJ6AJ6 engines.engines. ThisThis willwill improveimprove engineengine andand vehiclevehicle refinementrefinement byby reducingreducing the the maximummaximum crankcrank runningrunning clearancesclearances byby appro)(imatelyapproximately 20%.20%.

GradedGraded bearingsbearings werewere introducedintroduced onon productionproduction from from thethe following following engineengine numbers:numbers:

V12V12 XJS:XJS: 8S8s 8681786817 V121112 SeriesSeries Ill:Ill: 7P7P 769127691 2

6.06.0 JaguarSport:Jaguarsport: TBATBA ** 3.2: 98 111574

4.0: 9E/9W 164637

..* 6.06.0 litrelitre JaguarSportJaguarsport enginesengines willwill useuse thethe gradinggrading systemsystem whenwhen aa commoncommon crankcrank shaftshaft isis usedused forfor bothboth JaguarSportJaguarsport andand JaguarJaguar 6.06.0 litrelitre engines.engines.

TheThe threethree differentdifferent gradegrade diametersdiameters ofof thethe journalsjournals andand pinspins areare representedrepresented by aa letterletter which correspondscorresponds toto aa colour.colour, ii.e..e. "P""P" equalsequals Pink,Pink, "R""R" equalsequals Red,Red, etc.etc. TheThe gradegrade ofof eacheach individualindividual journal andand pinpin onon eacheach crankshaftcrankshaft isis identifiedidentified byby havinghaving thethe grading diameter colour stamped on thethe No 11 balance weight, indicatingindicating thethe grade of shell toto be fitted. as follows:follows:

Jaguar Cars Limited Jaguar Cars Limited 2005 JD 05193 JA~

V12 AJ6

A: F Indicateslndicates front A: F Indicates front B:8: Journals 1 to 7 B: Journals 1 to 7 C: Pins 1 to 6 C: Pins 1 to 6

The bearing sheil is identified by having the colour on one of its edges.

The grade lenerletter and colour for each diameter are as follows:

V12

JOURNALS GRADE LETTLElTERER GRADE COLOUR GRADE DIAMETER Pp PINK 3.0005 INS (76.212MM) 3.0008 INS1 NS (76.220M M)M 1 W WHITE 3.0009 INS (76.222MM) 3.0012 INS (76.230MMI(76.230MM) G GREEN 3.0013 INS (76.233MMI(78.233MM) 3.001SINS3.001 6 INS (76.240MM)I76.240MM)

PINS GRADE LETTERLElTER GRADE COLOUR GRADE DIAMETER R RED 2.2993 INS (58.402MM) 2.2996 INS (58.409MM) yY YELLOW 2.2997 INS (58.412MMII58.412MM) 1 2.3000 INS (58.420MM) B6 BLUE 2.3001 INS (58.422MM) 2.3004 INS (58.430MM)

2 Jaguar Cars Limited 2005 JDJD 05/9305 / 93 JA~JAGUAR%

AJ6

JOURNALSJOURNALS GRADEGRADE LETIERLElTER GRADEGRADE COLOURCOLOUR GRADEGRADE DIAMDIAMETER ETER pP PINKPINK 3.00023.0002 INSINS (76.207MM)(76.207MM) 3.00063.0006 INSINS (76.216MM)(76.216MM) WW WHITEWHITE 3.00063.0006 INSINS (76.217MM)I76.217MM) 3.00103.00t0 INSINS (76.226MM)I76.226MM) GG GREENGREEN 3.00103.0010 INSINS (76.227MM)176.227MM) 3.00143.0014 INSINS (76.236MM)(76.236MM)

PINSPINS GRADEGRADE LETTERLETER GRADEGRADE COLOURCOLOUR GRADEGRADE DIAMDIAMETER ETER RA REDRED 2.08522.0852 INSINS (52.966MM~(52.966MM) 2.08562.0856 INSINS (52.975MM}(52.975MM) VY YELLOW 2.08562.0856 INSINS (52.976MM}(52.976MM) 2.0860 INSINS (52.985MM)I52.985MM) B BLUE 2.0860 INSINS (52.986MM}(52.986MM) 2.0864 INSINS (52.99SMM)(52.995MM)

NewNew PartPart NumbersNumbers forfor thethe gradedgraded bearingbearing shellsshells areare asas follows:follows:

V12 GRADEDGRADED BEARINGBEARING SHELLSSHELLS (S.3(5.3 && 6.06.0 LITRE)LITRE)

PARTPART NUMBERSNUMBERS

PARTPARTNO NO NONOPER PER COLOUR REPLACESREPLACES ENGINE CODE CONN ROD BEARING SIZESIZE1 1 JLM 11138/0111138/01 RED SIZESIZE2 2 JLM 11138/0211138102 1212 YELLOW CC38933 38933 SIZESIZE3 3 JLM 11138/0311138103 BLUE MAINMA1 N BEARING-BEAR IN G - SIZESIZE1 1 JLMJLM11139/01 11139/01 PINK FROFRONT/INTERMEDIATE NT(INTER MEDIATE SIZE 2 JLM 11139/021 1'I39102 5 WHITE C 29313/12931311 SIZESIZE3 3 JLM 11139/0311139103 GREEN MAIN BEARING - CENTRE SIZESIZE^ 1 JLM 11140/0111140/01 PINK SIZESIZE2 2 JJLM LM 11140/0211140102 1 WHITE C 29314/12931 4/1 SIZESIZE3 3 JLM 11140/03 GREEN MAIN BEARING - REAR SIZESIZE1 1 JLMJLM11141101 11141/01 PINK SIZE 2 JLM 111411021 11 41 102 1 WHITE EAC 3973 SIZESlZE 3 JLM 11141/0311141/03 GREEN CRANKSHAFT 55.3L.3L EBC 1096110961 CRANKSHAFT 6.0L6.OL EBC 10992'10992

3 Jaguar Cars Limited 2005 JD 05/93 JA~

AJ6 GRADEDGRADED BEARINGBEARING SHELLSSHELLS (3.213.2 && 4.0 LITRE)LITRE)

PARTPART NUMBERSNUMBERS

PARTPART NONO NONO PERPER COLOURCOLOUR REPLACESREPLACES ENGINEENGINE CODeCODE CONNCONN RODROD BEARINGBEARING SIZE'SIZE1 JLMJLM 11135/0111135101 REDRED SIZE2SIZE2 JLMJLM 11135/0211135102 66 YELLOWYELLOW EACEAC2502 2502 SIZESIZE3 3 JLMJLM 11135/0311135103 BLUEBLUE MAINMAIN BEARINGBEARING -- SIZESIZE1 1 JLMJLM 11136/0111136101 PINKPINK FRONT/INTERMEDIATE/AEARFRONT/INTERMEDIATE/REAR SIZE2SIZE 2 JLMJLM 11136/021 1 136102 66 WHITE EACEAC7957Iredl 7957 (red) SIZE3SEE3 JLMJLM 11136/0311136/03 GREENGREEN EACEAC7958(blue) 7958 (blue) MAINMAIN BEARINGBEARING -- CENTRECENTRE SIZESIZE 11 JLMJLM 11137/01I1137101 PINKPINK SIZE2SIZE 2 JLM11137/02JLM 11 137102 11 WHITE EACEAC7961Ired) 7961 ~red) SIZESIZE 33 JLMJLM 11137/031 1137103 GREENGREEN EACEAC 79627962 (blue)(blue1 CRANCRANKSHAFT KSHAFT 3.2L3.2 L ESCEBC 1091610916 CRANCRANKSHAn KSHAFT 4.0L ESCEBC 1091510915

IfIf a crankshaft or bearing problem isis encountered on engines built prior toto thethe intro­intro- duction of graded bearings.bearings, the following applies:

IfIf thethe bearingbearing shellsshells onlyonly havehave toto bebe replaced,reptaced, setssets oftheof the oldold conditioncondition shellsshells will stillstill bebe availableavailable andand shouldshould bebe orderedordered asas before.before.

IfIf thethe crankshaftcrankshaft needsneeds toto be changed,changed, aa gradedgraded bearingbearing crankshaftcrankshaft will bebe suppliedsupplied fromfrom PartsParts OperationsOperations andand thethe relevantrelevant gradedgraded bearingsbearings will needneed toto bebe fitted.fitted,

rfIf a crankshaft or bearing problem isis encountered on engines with the graded bear­bear- ings,ings, the following applies:

IfIf thethe bearing shells only have toto be replaced,replaced, thethe relevantrelevant shells, as noted on thethe No.1 balance weight (see(see abovel,above), should be ordered.

IfIf thethe crankshaft needs toto be replaced,replaced, a graded bearing crankshaft willwit1 be supplied by Parts Operations and thethe relevantrelevant graded bearings should be ordered separately.

ALL MODELS ITEM:ITEM: 02

17 EVAPORATIVE EMISSION CONTROL SYSTEM

InIn order toto meet stricter world-wide emission regulations, an Evaporative Emission Control System isis now fitted to allal4 Jaguar vehicles.

IntroductionIntroduction VIN's areare::

XJS - 184907 SERIES III111 - 486831 XJ6 - 664941

Evaporative Emission Control Systems are designed to prevent fuel vapour, which consists mainly of hydro-carbons, escaping intointo the atmosphere.

The following isis a resume of major components of the system and the way inin which the system functions:

4 Jaguar Cars Limited 2005 JD 05/93 JA~

MAJOR COMPONENTS:

/.------8 K

jSI-la~a

1. Fuel Tank 2. Evaporative loss flange 3. PressureNacuum relief valve with vacuum operated by-pass valve 4. Purge control valve 5. Purge air port (onIon charcoal canister) 6. Charcoal canister 7. Purge port (onIon induction manifold) 8. Electrical connection to ECU 9. Induction manifold

5 Jaguar Cars Limited 2005 JD 05/93 JA~

THETHE SYSTEMSYSTEM FUNCTIONSFUNCTIONS ININ THETHE FOLLOWINGFOLLOWING WAY:WAY

FuelFuel vapour, generatedgenerated inin thethe fuelfuel tank,tank, isis passedpassed inin a a controlledcontrolled mannertomanner to aa storagestorage device,device, locatedlocated atat thethe frontfront left-handleft-hand sideside ofof thethe vehicle, inin frontfront ofof thethe roadroad wheel. TheThe storagestorage devicedevice isis aa plasticplasticcanisterfilled canister filled withwith charcoal,charcoal, (6,(6, FigFig 1).1). The The charcoalcharcoal ab­ab- sorbssorbs thethe vapour,vapour, enhancingenhancing thethe storagestorage capacitycapacity ofof thethe canister.canister.

WhenWhen aa vehiclevehicle isis atat restrest withwith thethe engineengine turnedturned off,off, thethe flowflow ofof vapourvapour isis controlledcontrolled byby aa pressure/vacuumpressure/vacuurn reliefrelief valvevalve (3.(3, Fig Fig 1),I), soso thatthat aa lowlow positivepositive pressurepressure isis main­main- tainedtained inthefuelin the fuel tank.lfthistank. Ifthis pressurepressure exceedsexceeds approximatelyapproximately 1.51.5 psi.psi, thethe pressure/va­pressure/va- cuumcuum relIefrelief valve opens.opens, toto allowallow thethe excessexcess pressurepressure andand fuelfuel vapour toto bleedbleed intointo thethe charcoalcharcoal canister,canister, thusthus maintainingmaintaining thethe lowlow positivepositive pressure.pressure.

ShouldShould therethere bebe anyany blockageblockage ofof thethe lineline betweenbetween thethe fuelfuel tanktank andand thethe charcoalcharcoal can­cen- ister,ister, therethere areare furtherfurther pressurepressure reliefrelief valves, inin bothboth thethe evaporativeevaporative lossloss flangeflange andand thethe fuelfuel fillerfiller cap,cap, toto preventprevent anyany excessexcess tanktank pressure.pressure.

When thethe engineengine isis running,running, thethe pressure{vacuumpressure/vacuum reliefrelief valvevalve isis heldheld open open byby engineengine vacuum,vacuum, allowingallowing anan uncheckedunchecked flow Row ofof vapourfrom thethe fuelfuel tanktank toto thethe canistercanister andand "zero""zero" pressure inin thethe fuelfuel tanktank (i.e.(i.e. atmospheric pressure.)

The charcoal canister is connected to to the the vehicle's inductioninduction manifoldmanifoldviaa via a purge con­con- troltrol valve (Fig(Fig 1,1, itemitem 4), thethe operation of which isis controlled by an electrical signal fromfrom thethe engineengine managementmanagement ECU,ECU, accordingaccording toto aa pre-determinedpredetermined map.map.

TheThe canistercanister isis purgedpurged bydrawingby drawing thethe vapour intointo the the inductioninduction manifold,manifold, thethe volumevolume ofof vapourvapour beingbeing controlledcontrolled byby thethe purgepurge valve via thethe ECU.ECU. TheThe vapour isis thenthen dis­dis- posedposed ofof duringduring thethe combustioncombustion process.process.

ALL 4.0L4.OL AUTO MMODELSODELS ITEM:ITEM: 03

1818 TRANSMISSION CONTROL UNIT (TCU)(TCU)

Should an automatic transmission failurefailure warning be accompanied by faultfault codes 1717 and 08 (torque(torque control and select - possible open circuit), technicianstechnicians may assume thatthat thethe transmissiontransmission control unit (TCU)(TCU) isis faultyfaulty and erroneously loggingbogging thethe faultfault codes.codes, particularly ifif no faultfault isis immediatelyimmediately evident with thethe wiring. However, itit isis unlikely thatthat the TCU isis at fault, as the most likelylikely cause of thethe fault isis inin the wiring to the engine management ECU.

The "pull-up" resistors for the torque control and select tines are locatedlocated inin the en­en- gine management ECU. tftheIf the supplytothissupply to this ECU isis faulty.faulty, therethere will be no pull-up and thethe voltage on thethe select and control lineslines will drop. The TCU will diagnose thisthis as an open circuit failure.failure. Therefore, when faultfault codes 1717 and 08 are seen together,together, thethe supply toto thethe engine management ECU should be checked.

ItIt isis also possible thatthat thisthis faultfault may be caused by any non- approved security/alarm systems, which immobiliseirnmobi lise the engine management system by cutting itsits power sup­sup- ply.

6 Jaguar Cars Limited 2005 JD 05/93 JA~

ALL MODELS ITEM: 04

26 DELETION OF BARRS LEAK

When draining and refilling the cooling system during vehicle maintenance, it is no longer necessary to add 'Barrs Leak' radiator leak sealer.

Process improvements and improved component quality now render the continued use of 'Barrs Leak' unnecessary.

Note: On vehicles prior to the following VIN'sVINJs'Barrs 'Barrs Leak' radiator leak sealer should still be used.

XJ6 Models - VIN. 670522 XJS Models - VIN. 186210

XJ692 MY ITEM: 05

51 FINAL DRIVE UNIT

VIN range 665838 to 667716

A number of vehicles within the above VIN range have been fitted with an alternative final drive unit,unit. The current and alternative units can be distinguished by the number of bolts in the output shaft seal housing, five in the current final drive unit and three in the alternative. The alternative final drive will not be supported with spare parts until mid-1993, therefore, should there be any service concerns, Jaguar Parts Oper­Oper- ations will only supply the current final drive units. To complete the repair it will be necessary to fit the appropriate speed sensor bracket.

ForfinalFor final drive unit part numbers EBC 10910/1/2/3 and ESCEBC 10911/1/2/3,10911/1/2/3, fit speed sen­sen- sor bracket EBEBCC 9820 (identified by a blue paint spot). FoForr aallll other final drive unit part numbers, fit speed sensor bracket CAeCAC 9884. ::n.. ,.,. 11:2.. Lt.-"- ,-NCf'/ (J h .. ote:::: JI...-r"'f'_ll'-.4-/- l LC{c... XJ6 1991 MY - 1993 MY ITEM: 06

86 BATIERYBATTERY QUIESCENT DRAIN INFORMATION

To enable Jaguar Dealers and their technicians to keep abreast of both past and pres­pres- ent quiescent drain specifications, the following information covers thethevehicle vehicle range over the last three years.

METHOD OF MEASUREMENT

In order to correctly measure quiescent current, technicians MUST adhere to the fol­fol- lowing procedure:

- Disconnect the battery negative lead.

- Connect ammeter between the battery negative post and negative lead.

- Select high meter range (ie:Iie: equal to or more than 10 amps)

- Switch the ignition "on" then ""off", off", then remove the key. (Do notcranktheengine)not crank theengine)

- Observe and record the measurements obtained overtheover the time scales identified in this Bulletin.

7 Jaguar Cars Limited 2005 JD05/93 JA~

Note: Whilst testing is being carried out. no vehicle systems must be activated. For this reason, on 1993 Model Year vehicles, the boot light should be dis­ abled and its lock latched shut.

QUIESCENT DRAIN FIGURES (Approximate values in milliamps)

COMPONENT VEHICLE MODEL YEARS iUMY azMY :llMY XJ6 XJ6 XJ6 Air con/heater 0.5 Ride level 1.0 0.6 0.6 Transmission control 1.3 2.0 2.0 Central processor 3.3 8.0 8.0 Instrument pack 2.5 2.5 2.5 Alternator 0.5 3.0 3.0 Radio head unit 2.6 2.6 2.6 CD Autochanger 2.5 3.5 3.5 Clock 0.3 0.7 0.7 Air bag module 0.3 Engine ECU 3.5 3.7 3.7 Infra-red locking 1.0 1.5 1.5 Seat memory modules 7.0 Gearshift interlock control module I 1.0 Passive ECU 1.0 1.0 Door lock EeU 1.0 1.5 1.5 Facia switch panel 1.0 1.0 Wipe logic 1.0 1.0 F/R/H Bulb fail unit 0.6 0.6 0.6 F/R/H Bulb fail unit (UK) 1.5 1.5 1.5 F/LJH Bulb fail unit 0.6 0.6 0.6 F/LJH Bulb fail unit (UK) 1.5 1.5 1.5 R/ RtH Bulb fail unit 0.4 0.4 0.4 R/l/H Bulb fail unit 0.4 0.4 0.4

TYPICAL QUIESCENT CURRENT LOADS FOB 1993 MY

XJ63.2 XJ64.0 SOV 3.2 SOV 4.0 DAIM 4.0 SPECIFICATION TOTAL 20.0 28.6 27.3 28.6 28.6 (NOMINAL VALUEI BASE RF ALARM 10 10 10 10 10 (DISARMED) TOTAL DRAIN CURRENT 30.0 38.6 37.3 38.6 38.6 VEHICLE STANOING TIME 53.3 42.4 43.8 42.4 42.4 IN DAYS (INC ALARM)

8 Jaguar Cars Limited 2005 =+% JD 05/9305 193 JAGUARJA~

Note: - These figures were calculated for a new battery.battery, discharging from 80% charged to 20% charged. - The base quiescent drain figures will vary between markets. - Accessory parts will reduce the vehicle stand time. - Non-approved accessories are likely to reduce considerably the vehicle stand time.

IMPORTANT: - Vehicle drain figures should be calculated according to their indi­indi- vidual specifications.

This information must be passed on to the appropriate workshop technicians_technicians-

STAGES OF QUIESCENT DRAINDFIAlN

IMPORTANT:IMPORTANT - The current figures used here are only examples_examples. The time scales shown are, however, accurate.

VEHICLE QUIESCENT DRAIN FIGURES

0-5 minutes 500 milliamps (example) 6-21 minutes 75 milliamps (example) 22 minutes onward 25 milliampsrnilliamps (example)

The above example highlights the significant drop in current demand.demand, which can be measured after the vehicle has been left for a few minutes.

Note: - The current drain will not drop to this final value if the keys are left in the ignition, even if the ignition is not switched on.

ALARM QUIESCENT ORAlDRAIN N FIGURES (R F Alarm with ultra-sonic intrusion sensors).

1-3 days 16 milliampsmilliarnps 4-28 days 10 milliampsmilliarnps 29 days onward 6 milliampsmilliarnps

Note: The current drain will only drop to this final value if the alarm is armed. IftheIf the alarm is left disarmed, then there will be a constant drain of 10 milliampsmilliarnps for as long as the vehicle is left.

For general current measurement and battery charging procedures, pleaseptease refer to the Battery Care Manual.

9 Jaguar Cars Limited 2005 rr;::::F~~~~r -. - -- ·· - ·---~=== ·· ~===. -~-~--~. ~ . ~ i Service Bulletin JAGUAR

l . L. _==-~~__ - ...-._~- .. _- . ------~ey-,

WIE:IWI'E: R:T\7EJo1BER 1993

Pm:PAGE: 1 of 3

REF: JD.JD 38/93

00 EmAmlMERRA'ruM

PLEASE NOTE TEETHE FOLlDWlNGFOLI..OWING ERRATUM IN SEEWICESERVICE BuUEITNBUI.LEI'IN JD 26/93

JD 26/93 dateddated. Sept-September 1993, IbnItem 27,27 f Page 3,3 f Line 2:

This'!his line should read:

NHBNEB 6740AA Intermediate Pipe All mrketsmarkets

XJl.2 6.0 1993 .25 MY VIN 673299 CIMARIE I'I'EM: 36

03 REPAIR OPERATION TIMES - AMENCMENTS

'Ihe following Repa.ir Operation Times are amended, following the intrOOUction of heat shields for the front engine mountings.- Please arne.rrlamend your Repair Operation-ation Time ScheduleSch&ule accordingly.accog-ly.

12-45-01 Front engine mountingmaunting I1-IIH - Renew G.aL 0.60 hrs

12-45-03 Front engine mounting RH - Renew G.OL 0.65 hrs

12-45-08 Enginekgine mountingsmtings - front set - Rene.wRenew G.OL6.OL 1.00 hrs

12-45-13 Enginewine mountingsmwntings - engine set --MewRenew G.OL6.0L 2.402.40hrs hrs

12-45-14 EngineI3qine mountingmtirq bracket IRLH - Rene.wRenew G.OL6.0L L201.20 hrs

12-45-15 Enginewine mounting bracket RH --RenewRenew G.OL6,OL 1.201.2Ohrs hrs

Jaguar Cars LimitedLimited Jaguar Cars Limited 2005 XJl.2 6.0 1993.25 MY VIN 673299

0303 REPAIRREP= OPERATIONOPERATION TmFSTIMES -- ADDITIONAL

'!heThe followingfollcrwjng RepairRepair OperationOperation Times~hez areare nCMnm available;available; pleaseplease amerrlamend youryaur RepairRepir OperationOperation TimeTim? SCheduleSchedule accordi.nc:Jly.accordhqly-

30-10-62 HeatHeat shield,shield, frontfront engineengine - Renew 600L 0.20 hrs lWUlltingmwntiq IRIH

30-10-63 Heat&t shield,shield, frontfront engineengine -- RenewRenew 600L6.0L 0.20 hrs IIDUJ1tingrru;nmt* RHRH

30-10-64 HeatHeat shield,shield, frontfront engineengine -- RenewRenew 600L6.0L 0.30 hrs nxrunting,mamtirq, vehicle setset

XJ6 AND XJl2 1994 M'l VlN 687219 <:HiARDS ITEM: 38

03 REPAIR OPERATION TIMESTlMES - ADDITIONAL

'!heThe followingfollcrwing RepairRepair operationoperation TimesTimes areare nO\tlnow available;available; please arnerrlammd your RepairRepair OperationBperation Time he ScheduleSchedule accordi.ngly.accordhqly. 76-10-56 Auto-dim interiorinterior mirror -- RenewRenew 0.500.50 hrshrs

76-10-56/0976-10-56109 As 76-10-5676-10-56 (less(less JDSJDS Allowance) 0.15 hrs

ITEM: 39

VIN RAH:;E 629286 'lU 688826

19 FUEL FILLERFlLLEFi CKPCAP BREAKAGE

At VIN 629286 a changeqe in material specification was introduced to produceprduce a matt-black finish for the fuel filler cap. '!hisThis cha.rBechange proved to have adversely affectedaf fed& the strengthseength of the filler cap, which has beenbm prone to breakage on removal.rmval.

In addition, the filler cap was liable to 'click'fclickl when reIOC:lvalremoval was attempted,attmpted, giving a false indicationindication that it was released arrland leading"leading the customer to exert excess effort.

FramFrom VINKDl 688827 the material specification has revertedrev- to that for earlier components,cumpnents, whilemile a spring of lOW"erlower rate has also been specifia:i;spzified; combined,Wined, these changes will overcome recentrmt concerns.

'nleThe latest type of fuel filler cap is available via Jaguar PartsPark operations,matims, under Partpart No.NO. NMB 5942AB.5942AB,

Warranty Code: 2DBL.

2

Jaguar Cars Limited 2005 ~ XJU 6.0 1993.25 MY AIL VARIAm'S ITEM: 40

26 8OI'I'CMEurrm RADIAroRRADIAMR HOSEHOSE -- FOULFWL ONON ANTIANTI-ROLL -ROLL BAR

COncernConcern hashas teenbeen reportedreported thatthat onon certaincertain ofof thethe aboveabove rncxielsmodels thethe bottombottoan radiatorradiator hoseha maymy rrakerrake contactcontad withwith thethe anti-rollanti-roll bar,hx, whenwhen thethe engineengine isis atat nonnalnorm1 runningrunning tenperature.tenprature.

Investigations~nvestigations havehave inclic.atedindicated that thethe contactmntact isis ofof aa minor&or nature, with no significantsignificant wear to the hose material. TheThe concernconcern arisesarises framfrm manufacturingmufacturing tolerances inin componentcmpnent dimensions.dimensions.

Shorteningshorn ofof the hose to provide clearanceclearance fromfrom thethe antianti-roll-roll l:::arbar may,my, inin somesome cases,cases, result inin the hose foulingfouling the airair purrppup drivedrive belt, hence this course(=Ours@ ofof actionaction shouldshould Jnt.mt ]:)ebe followed.follmed.

AlthoughAlthouqh DealersDealers maymy identifyidentify the aboveabove concern,concern, nom acticn& need bebe taken.taken.

~ XJ6 4.0 AND 3.2 LI'lRE .fIDoI VIN 691288 ~ XJS 4.0 r.r:mE F'IUoI V1N 1.90774 ITEM: 41

26 CDJIANrQX>LANT lDSSU3SS FROMFRMul AJ6M6 WATER PUMPPUMP SI'UBSTUB PIPES.PIPES.

Frommom thethe aroveWe VINs aa revisedrevisd manufacturing process forfor securingsecuring thethe thertlX)Statthenmstat by-passby-pass andand headerheader tanktank stubstub pipes to thethe water pumppunp l:xxiy has been intrcxiuced.intrdued.

'Ihi$TI-& should eeliminateliminate any recurrence of isolatisolateded instances of coolant loss at the joints between the stub pipespips and thea water pumppwrp 1:xx:ly.body,

XIS, XJ6 AND XJl.2 1994 MY AIL VARIANI'S ITEM: 42

76 FRONT FCXJIWELL CARPEl'S

On all 19941994 MY vehicles, a revised rrethcx:imthd of retainingretain- the rear edges of front footwellfmtwell carpetscarpts has been intrcd.ucedintrduced, I replacing the turn­turn- buckles previously employed.

'TheThe revised method includesincludes a J-section retainingretain- strip on the rear edge of each carpet, which engagesqages with a corresponding J-sectionJ-sxtion retaining strip on the front edge of the Seat Control McrluleMdle cover.

3

Jaguar Cars Limited 2005 rr;::::=~====~~~~~~--~-- . ... ~ . ~ Ir - -- - ServiceService BulletinBulletin JAGUAR ! I! I I

Pl!GB lOF 4

REF:REF: JDJD 29/9429/94

XJ6 & X112 1994 MY .AU... V1\R11\NlS J.i'I04 V1N 696459 rIDI: 28

03 REPAIR OPERATION TlME'S - AME:NEMENI'S

ToTo covercover allall SaloonSalm nroelsrdels franfm VINVlN 696459,696459, (the(a pointpint ofof intrcductianintrabctim ofof rearrcar suspensionfllspensicm incorporatingincarprat- castcast wishbones,widdxmes, with independentnt rcom.tingsrt-mntix~~ forfor thethe roadroad springsspr- amard shockshock absorbers/struts),absorbsrdstruts), the folla.-ringfollmiq RepairRepair ~tianmtim 'I'irresT5ms areare arrended.~EI&x~. PleasePlease arren:lamd yc:urycu RepairRepair OperationOperatim T:irreThe Schedul~S-e accordingly.accordingly.

51-25-1351-25-13 FinalFinal DriveDrive emitUnit -- RenewRenew 66.20 . 20 hours 51-25-1451-25-14 FinalFinal DriveDrive UnitIEit -- RenewRmew -- vehiclesVehicles fittedfittd with RideRide LeVellingLadling 6.6.75 75 hourshcrurs

64-20-01 Rear Road Spring - RenewRent% 1.251.25 hourshrxlrs 64-20-02 Rear Road SpringSpritlg - vehicleVehicle Set - RenewFienew 2.35 hourshcrurs

64-25-01/90 RearRBar SUspensionWicm unitUnit - Vehicles fitted with ShoCkShock - AbsorbersAb~a- - asa~ 64-25-01 - ~E&mm for access and refit 2.10 hourshclurs

64-25-11/9064-25-11190 RearRBar SUspensionSuspensicm Unit - Vehicl~sVehicles fitted with Ride LevellingI&~&ling - asa~ 64-25-11 - RaroveRmm~ for access and refit 2.70 hourshm~~

64-30-01 RearF?ear Shock AbsorberAhso- - Vehicle Set - Renew 2.35 hours 64-30-02 Rear ShockShmk AbsorberAhsorbr - Renew 1.25 hourshrxlrs

66-20-01 RearW StrutStKUt - Renew 1.55 hours 66-20-02 Rear Strut - VehicleVtzhf.de Set - RenewRen€w 2.70 hoJrs

66-20-03 RearRBar Road Spring - Renew 1.60 hours 66-20-04 RearRBar Road SpringSprhq - Vehicle Set - ReneWReTlew 2.75 ho.Jrs

Jaguar Cars Limited Jaguar Cars Limited 2005 .JD 29/94

XJl.2lWlZ&X;JSvu & XIS Vl2 AIL-AIL ~ I'1B4: 29

18~8 SPARK pm;PWZ I...E'ADLEAD SETS

Incidents of rcugh idling/engineidliq/e@ne misfiring,misf iring, which havehaw developedM~pd after awraxirratelyapphtely 20,20,000 000 miles (32,200 kIn)h) franfrun new, naymy be attri.b..ltableattrihtable to certaincartah spark plug leads havinglmmg cc:necaw into contactmtact with cylindercylm headkad retainingretainirg bolts, causing High Tensionmian ignitionignitim trackingtram to occur.

To overccrreovena~ this cancem,carncern, anr::lad also to irrproveinprove the ro.ltingrmtirg of sparkSpark plug leads eman V12 enginesaqhes, I !leW'new lead sets haveham l:::eenbeen prqressivelyprcgressivel y intrcx:iucedintrduced in prducticmprcx:iuction franfran the follcwi.ngfollcrwizlg engine IUlITbers:hrs:

8D 11717 XIS Vl2

8e 13693 XJl2

JSI-22S1

Fig. 1.

'!heThe new'new spark plug leadl& sets are available via Jaguar Parts Operations.Operaticms. TheW Part NimbrsNurrDers listed q:positeapposite supersed.esupers& the previ~lu~previous Part No. DAC 7831.

WhenWha fitting the new patternpattem of spaIkspa& plug leads, correct rootingrouting of the leads as irrlicatedindicated in Fig. 1 is irrp::lrtant,inporLant, as is thet;he fittingfitthg of a clip, Part No. KDP l08080/J,108080/J, between plug leads 1A and lB,19, also sha.msham in Fig.Fig* 1.

- 2 -

Jaguar Cars Limited 2005 JD 29/94

PARIS AVAIIABILTIY IR"OITPl'IOI- HJEL- l¥\RT=- RJDm QIY/VEHIaBmm- SparkSpark plugplug leadlead setset XJSXJS Vl2Vl2 IRDLJD 1509AA1509AA 11

SparkSpark plugplug leadlead setset XJl2Xn2 1M:LMC 1509AA1509AA 11

ClipClip AllAll aOOveahme KDPKDP 108080/Jl0808O/J 11

TID1: 30

26 lNIRODUCTIrn OF SPRr.N; IDRM-ORIVE IDSE CLIPS

An ll'rprovedinpmved designdesi~ ofof wonTI-driveworn-drie hose clip,clip, incorp:>ratingincorporating aa l:x:lwlm~ spring,sp-, has beenW intro::iuce:::lint-ced atat certainmain hose-to-pipeme-to-pip joints inin thethe coolingcool- systemSystm ofof allall m:xiels.Ms. 'IbisThis typetype ofof hose clipclip isis illustratedillustrated below.helm.

, ...

\

J51-2249

- 3 -

Jaguar Cars Limited 2005 .m 29/94

The?he bowh springspring providesprwides aa continuousemtimcm self-carpensatingself-cmpmsatiq tensioningt:e~l~idng - effecteffect afterafter thethe clipclip isis firstfirst tightened,tight&, thusthus naintainingrmintahixg thethe clanpingclmping forceforce onan thethe hose-to-pipehose-to-pipe jOint.joint. InIn tUDl,turn, thisthis actionactim carpensatesccrrpensates forfor thethe los8loss ofof clanpingclartpirg effecteffst whichwhich wouldwould otherwiseotherwise occuroccur asas thethe clipclip settlessettles intointo thethe rubber hose.hose.

IbisThis typetyp ofof hosebse clipclip doesdoes Hlr requirerequire routinemutine re-tighteningre-tiqhta ofof thethe worm-driveWOLM-dri~. .

InIn thethe unlikelyunlWy eventevent ofof aa CCX)lantcoolant leak,leak, thethe wonn-driveworm-drive shouldshould bebe re-tightena:lre-tightened toto aa torquetorque settingsetthg ofof 2.52.5 -- 3.53.5 Nn.m. 'IbisThis torquetoque settingsetting alsoalso appliesapplies shalldad itit be be necessarynecessary toto renovemmve arrland refitrefit suchsuch aa clipclip inin thethe courseme ofof otherother servicingservickq operations.-ti-.

WhereWhere itit isis necessarynecessary toto fitfit aa replacanentrepla-t clip,clip, ensureensure thatthat thethe centrecentre ofof thethe l::x::Mbm springspring isis atat theth!= '5'5 o·olclockl clock' positionpsitian relativerelative toto thethe centrecentre ofof thethe wormworm drivedrim casing,casiq, asas inin thethe illustration,illustmtim, priorprior toto tighteningti@teniq thethe clip.clip.

r.o::::ATIOOSmTIm FORFOR SPRUl-l;sm WORM-DRIVEKRM-mIvE HOSEHxTI CLIPSCLIPS

TheThe locationslocations ofof thethe sprungsprung patternpattern ofof clipclip andad the the !X)intspints ofof theirtheir intrcductionintmctian areare tab.llatedMated bela,.,:Haw:

KJEL lRlB)mlm I..CXln".[CH;ImmIm - VlNvm

XJSXSS 119513795137 AJ6,AJ6, Vl2V12 RadiatorRadiator tottanbottcm hosehose -- oothboth endsends AJ6,AJ6, Vl2V12 RadiatorRadiator toptop hohosese -- tcthboth endsends AJ6AT6 onlymly Hose,Wse, waterwater- p.mp toto -- tcthboth endsends waterwater railrail

XJ6X36 706502706502 XJ6,XJl2KJ6,Xn2 RadiatorRadiatorbottanhose-eeHd bottan hose - eJgine end allyd~ XJ6,XJl.2XJ6,Xn2 RadiatorRadiatortcphme top hose --Maboth ends XJ1.2XJ12 XJ6XJ6 onlydy Hose, Hcs=, waterwater p..mppnrp toto -- bothbth ends waterwater railrail

ItIt isis anticipatedanticipated thatthat thethe introductionintrductim ofof thesethese hose-clipsWe-clips willwill considerablyccmsi-ly reducere&= incidentsincidents ofof coolantcoolant leakageldcage atat the al:xJveatxlve locations.lmtians.

- 4 -

Jaguar Cars Limited 2005 r.-.- -. -. -. -- . . I1 ServiceService BulletinBulletin JA~ i

AUGUSTAUGUST 1994 1994

PAGEPAGE 1 1 OF OF 1 1

REF:REF: JD JD 37/94 37194

ALLALL MODELSMODELS 19941994 MODEL MODEL YEAR YEAR ITEM:32ITEM :32 XJXJ SALOONS SALOONS FROMFROM VIN VIN 702919 70291 9 ONWARDS; ONWARDS; XJSXJS FROMFROM vaN VlN 19331319331 3 ONWARDS ONWARDS

2626 COOLANTCOOLANT SYSTEMSYSTEM ANTI-FREEZEANTI-FREEZE

FromFrom the the aboveabove VINsVINs,, thethe coolantcoolant systemsystem ofof allall vehicles vehicles containscontains aa differentdifferent specificationspecification ofof anti-freeze.anti-freeze. TheThe newnew anti-freeze,anti-freeze, which which isis blueblue inin colourcolour insteadinstead ofof green,green, givesgives improvedimproved corrosion corrosion protection,protection, enablingenabling thethe intervalinterval betweenbetween coolantcoolant changeschanges toto bebe extendedextended toto 44 years,years, oror 9696 000000 kilometreskilometres (60(60 000 000 miles).miles).

VehiclesVehicles priorprior toto thethe aboveabove VINVIN ranges ranges maymay continuecontinue toto havehave their their coolantcooiant systemsystem topped­topped- upup oror re-filledre-filled withwith thethe oldold specificationspecification ofof anti-freezeanti-freeze untiluntil existingexisting stocksstocks areare exhausted.exhausted. AfterAfter existingexisting stocksstocks areare exhausted, exhausted, theythey shouldshould havehave their their systemsystem filledfilled withwith thethe newnew anti­anti- freezefreeze at at thethe nextnext scheduledscheduled coolantcoolant change_change.

IfIf necessary,necessary, thethe newnew anti-freezeanti-freeze maymay bebe usedused toto top-uptop-up aa systemsystem filledfilled withwith thethe oldold specificationspecification ooff anti-freezeanti-freeze (the{the oldold specificationspecification ofof antianti-freeze-freeze mustmust notnot bebe addedadded toto aa systemsystem filledfilled withwith thethe newnew anti-freeze,anti-freeze, asas thisthis willwill reducereduce thethe anti-freezeanti-freeze andand corrosioncorrosion inhibitioninhibition propenies).properties).

TheThe newnew anti-freezeanti-freeze isIs availableavailablg inin differentdifferent sizessizes ofof container,container, fromfrom JaguarJaguar PartsParts Operations,Operations, underunder thethe followingfollowing PartPart Numbers:Numbers:

JLM 11979/011 1979/01 500 millilitres (0(0.53.53 US quart) JLMJtM 11 11979102 979/02 1 litrelitre (1(I. .0606 US quarts) JLM 11 1 979/03 5 litreslitres (1.32(1.32 US gallons) JLM 11979/041 1979t04 25 litres (6.61 US gallons) JLM 11979/051 1979105 205 litres (54.23 US gallons)

00000

JaguarJaguar CarsCars LimitedLimited Jaguar Cars Limited 2005