Multiple Procedural Updates (SECTION 04, NO. 12)

Publication date: 1993-11-01
Reference number: SECTION 04, NO. 12

MULTIPLE PROCEDURAL UPDATES

TECHNICAL SERVICE BULLETIN

Reference Number(s): SECTION 04, NO. 12

ENHANCEMENT PROGRAM - SERVICE ACTIONS & PROCEDURES

Model(s): 1993 Jaguar XJ6

Section: 4 - Maintenance & PDI Schedule

Bulletin No.: 04-12

Date: 11/93

SERVICE INFORMATION

The workshop procedures described in this enhancement package resolve the following potential service problems:

PREMATURE BULB FAILURE

Premature bulb failure is caused by excessive voltage at the bulbs. Production vehicles now have voltage dropping diodes fitted at each bulb failure module and a resistance link lead in each harness for the headlights. Long life bulbs are now fitted in the tail lights.

Bulb failure modifications introduced: VIN 685l97

RADIO RE-CODING/POOR AM RECEPTION

The radio intermittently requiring re-coding and/or having poor AM reception is caused by the retaining nut at the antenna coax cable connection being loose, giving a poor radio chassis ground.

Antenna coax cable nut tightness assured from VIN 685497

WATER INGRESS INTO THE EMS ECM AND LOWER "A" POST CONNECTORS

The cause of water ingress is poor drainage of the plenum chamber. On production vehicles this has been resolved by installing an extended drain tube. Damage to electrical components due to water ingress has also been avoided by introducing a shroud for the EMS ECM, foam seals for the lower "A" post connectors and applying water-proof grease to the connectors.

Extended plenum drain tube introduced: VIN 681967

EMS ECU and lower "A" post sealing introduced: VIN 683199

A/C TRINARY SWITCH FAILURE

Failure of the Trinary Switch is caused by mechanical vibration being applied to the Trinary switch by the Slow Fan Pressure Switch when it operates. The vibration oscillates the contacts of the Trinary Switch causing arcing and deposition on the contacts and eventually, an open circuit condition. The Slow Fan| Pressure Switch is now mounted on a rubber extension hose to eliminate the vibration.

A/C Slow Fan Pressure Switch relocation introduced: VIN 1 687220

ERRATIC ENGINE LOAD SIGNAL - SECURE AIR MASS METER

Erratic engine load signal can be caused by the degradation of the mass air flow sensor connection.

INTERMITTENT FLAGGING OF FF 12

Engine management diagnostic trouble code (DTC) 12 can be flagged if the ignition is switched off when the engine speed is above 1500 RPM.

A capacitor within the EMS ECM maintains power to the ECM momentarily after the ignition has been switched off. The crank sensor still detects that the engine is running but the air mass flow meter is off. The OBD system assumes that a fault exists with the air mass flow meter and reads FF 12.

A link harness and revised main fuel injection relay have been introduced to rapidly discharge the capacitor when the ignition is switched off.

Link harness and new fuel injection relay introduced: VIN 677925

MOMENTARY ILLUMINATION OF INSTRUMENT PACK

This can occur when the front wheels pass over large metal objects, i.e. a manhole cover or R/R tracks, due to discharge of static electricity build-up. The front hubs are now grounded to the chassis of the vehicle.

Front hub ground straps introduced: VIN 685240

NOTE: The parts required for each VIN group are identified in the following table. Refer to the warranty information for a breakdown of the VIN groups.

REPAIR PROCEDURES - SECTION A

PREMATURE BULB FAILURE MODIFICATION

Open the hood and fit fender covers.
Note the customer's preset AM/FM memory stations. Open the trunk, remove the battery cover and disconnect the battery ground cable.
Remove the spare wheel trim cover, spare wheel, wheel changing tools, trunk floor carpet, front liner trim panel and both side liner trim panels.

LEFT HAND FRONT LIGHTING SYSTEM

At the LH front of the vehicle, within the engine compartment, release the air cleaner cover clips and remove the cover and element.
Detach the White multi-plug for the bulb failure module from its mounting bracket and disconnect it from the module.
Remove and retain the Yellow plastic insert from the multi-plug.
Locate the Brown wire with Green tracer at the back of the multi- plug, release and extract its spade terminal
NOTE: Use a small jeweler's screwdriver to hold back the anti- backout lug of the terminal during extraction. The same technique is used to remove all the terminals identified in this procedure.
Bend back the extracted wire (Brown with Green tracer) and connector away from the White multi-plug.
Remove the plug from a Diode Assembly (Part No. LSJ 3998AA). Insert the spade terminal, previously extracted from the multi- plug, into the plug. Refit the diode to the plug.
Insert the spade terminal, of the Brown wire leading from the diode/plug assembly, to the vacant port of the multi-plug. (The port previously occupied by the connector of the Brown with Green tracer wire.)
Refit the Yellow plastic insert to the multi-plug, ensuring that it is fully seated.
Fold the wires of the diode assembly and secure to the multi-plug harness with a ratchet strap (Part No. C 46294. Cut off the protruding tail of the ratchet strap.
Reconnect the White multi-plug to the bulb failure module and fit the multi-plug into its mounting bracket.
Release the Black multi-plug from its mounting bracket and disconnect it from the bulb failure module.
Remove and retain the Yellow plastic insert from the Black multi-plug.
Extract from the multi-plug the two spade terminals connected to Black wires. (Ground connections.)
Cut off the spade terminals from both Black wires.
Form the new Headlamp Ground Lead Part No. LSJ 3998CA) into a coil of approximately 50mm diameter, with ends protruding according to the dimensions indicated in Fig. Fig 1 . Use adhesive tape to secure the wire in a coil, as shown.
NOTE: Markers are fitted on each end of the wire. The 100mm. dimensions in Fig. Fig 1 are measured from the centers of these markers.

Fig 1: New Headlamp Ground Lead
Courtesy of JAGUAR CARS, INC.
Release the air cleaner intake grommet at its top edge. Carefully peel it away from its aperture, to give access to the cavity behind.
Insert the coiled ground lead into the cavity. Position the coil forward of the grommet aperture, so that it can be secured to the side harness using a ratchet strap (Part No. C 46294). See Fig 17 .

Fig 2: Positioning Headlamp Ground Lead Coil
Courtesy of JAGUAR CARS, INC.
Cut off the protruding tail of the ratchet strap.
Draw the end leads of the ground wire coil through the same opening in the air cleaner intake grommet, through which the side harness passes. See Fig 2 . The ends of the leads must be positioned BELOW the side harness, with the two markers aligned to the position of the intake grommet when refitted to its aperture.
Refit the air cleaner intake grommet in the fender aperture. Ensure that the ground lead ends will clear the air intake trumpet when it is installed later.
Remove the nut and washer from the ground stud, located in front of the wheel arch contour. Onto this stud, install the eyelet of the wire leading from the coiled headlamp ground lead. Refit the washer. See Item 1 Fig. 3. Then refit and fully tighten the nut on the ground stud. The wire should be routed to follow the contour of the inner fender, as shown in Fig. Fig 3 .

Fig 3: Installing Headlamp Ground Lead to Ground Stud
Courtesy of JAGUAR CARS, INC.
Route the Black wires, with twin spade terminals, along the side harness. Connect the spade terminals to the vacant ports in the Black multi-plug (from which the Black wires and their terminals were previously extracted). The polarity of these terminals is not important, as both are connected to chassis ground via the coiled lead. Refit the Yellow insert to the multi-plug.
Tape the new ground wire to the side harness, together with the cut ends of the original two Black ground wires (the spade terminals were cut off previously).
Refit the Black multi-plug to the bulb failure module and fit the multi-plug to its mounting bracket.
Refit the air cleaner element and cover. Secure the cover with the over center retaining clips.

RIGHT HAND FRONT LIGHTING SYSTEM

Repeat all of the operations for the LH front lighting system, described above, on the RH front lighting system.

NOTE: On XJ6 vehicles, as no air cleaner or associated components are fitted on the RH side of the vehicle, references to these components in the procedure for the LH side should be ignored.

LEFT HAND REAR LIGHTING SYSTEM

Detach the White multi-plug, for the LH bulb failure module, from its mounting bracket and disconnect it from the module.
At the rear of the White multi-plug, release the latch.
Locate the Brown wire with Green tracer, release and extract its spade terminal.
Bend back the extracted wire and terminal away from the multi-plug.
Remove the socket from a Diode Assembly (Part No. LSJ 3998BA). After opening the latch on the rear of the socket, insert the spade terminal of the Brown with Green tracer wire, fully into the socket. Close the latch.
Refit the diode to the socket.
Insert the spade terminal of the Brown wire leading from the diode/socket assembly, into the vacant port of the multi-plug (previously occupied by the Brown with Green tracer wire).
Close the latch at the rear of the multi-plug.
Fold the wires of the diode assembly and secure to the multi- plug harness with a ratchet strap (Part No. C 46294). Cut off the protruding tail of the ratchet strap.
Reconnect the White multi-plug to the bulb failure module and fit the multi-plug to its mounting bracket.
NOTE: In the following operations, reference is made to "LONG LIFE" lamp bulbs.

"LONG LIFE" lamp bulbs are identified as follows:

On the metal cap of the bulb, the word "Motorcraft" AND the letter "L" is embossed. This is in addition to identification of the bulb voltage and wattage. Also, in some Long Life bulbs, the ceramic bead which locates the lead-in wires within the bulb is BLUE in color.
Remove the two hand wheels from the rear of the LH lamp unit and withdraw the bulb mounting board.

Remove and inspect each bulb, to determine whether or not it is of "Long Life" specification (see note above).

If YES: Refit the bulb.

If NO: Replace the bulb with a "Long Life" bulb as follows:

LONG-LIFE BULB PARTS INFORMATION

BULB-LONG LIFE	PART NO.	QTY./VEHICLE
Tail lamp Stop lamp, Reverse	D8C 11711	As required
or Direction Indicator	DBC 11382	As required

Refit the rear lamp bulb mounting board, install and tighten the hand wheels.

RIGHT HAND REAR LIGHTING SYSTEM

Repeat the operations for the LH lighting system, described above, on the RH system.

REPAIR PROCEDURES - SECTION B

RADIO GOING TO CODE/POOR AM RECEPTION

At the RH side of the trunk, check and if necessary fully tighten, by hand only, the fluted ring-nut which retains the antenna coax cable to the connection at the base of the antenna mast.
Refit both side liner trim panels, the front liner trim panel and the trunk floor carpet.

Refit the wheel changing tools, spare wheel and its trim cover.

REPAIR PROCEDURES - SECTION C

CAUTION: Certain of the following operations specify the application of a Spray Grease (Part No. JLM 11472). This product is contained in a pump-type dispensing container. The basic grease is already mixed with a volatile solvent to promote mobility of the grease over the surfaces onto which it may be sprayed.

While the product is non-toxic, prolonged contact between the spray grease and the skin should be avoided. It is strongly recommended that PVC or Nitrile Rubber gloves are worn when using this product. It is also prudent to perform ALL operations involving the use of products containing solvents in a well ventilated work area. Ensure that spray grease does not contaminate carpets, plastic trim or upholstery. Where necessary, shield the surrounding area in which the spray grease is being applied.

PROPERTIES OF SPRAY GREASE

The spray grease has the properties of dispelling moisture from electrical contacts and providing a protective film guarding against corrosion.

APPLYING SPRAY GREASE

Nozzle should be 1/4" from face of connector.
Wait 15 seconds before reconnecting assembly.
1. Open the front passenger side door for access.
2. From the "A" post extract the front end of the corrugated cable gaiter, which encloses the cable harness between the "A" post and interior of the front door.
3. Carefully pull on the harness at the "A" post until the two harness interface connectors can be extracted through the opening in the "A" post. (Connectors LB 082, LB 083 - 20 way Black, 6 way White). See Fig 4 .
  
  Fig 4: Location of "A" Post Harness
  Courtesy of JAGUAR CARS, INC.
4. Disconnect each connector. Apply spray grease to both mating faces of each connector (see note at start of the procedure). Allow 15 seconds for solvent to evaporate before reconnecting each connector.
5. Apply a generous amount of spray grease to the REAR faces (the "harness entry" faces) of both connectors.
6. Carefully pass the two connectors forwards into the "A" post opening, toward their original locations.
7. Use cleaning solvent to remove all traces of grease from the groove at the forward end of the corrugated gaiter and from the aperture in the "A" post into which it fits.
8. Allow the solvent to evaporate, then apply a bead of Mastic sealer (JLM 11548) to the full circumference of the forward groove of the corrugated gaiter to completely fill the groove with sealer. Twist the gaiter in each direction to obtain the required access. See Fig. 5.
  
  Fig 5: Applying Mastic Sealer to Corrugated Gaitor
  Courtesy of JAGUAR CARS, INC.
9. Refit the corrugated gaiter to the "A" post. Twist the gaiter in each direction as the groove engages with the opening in the "A" post, spreading the sealer, to ensure that it forces a continuous seal between the gaiter and the body metalwork. Wipe off any excess sealer to restore a good cosmetic appearance.
10. At the passenger side front footwell, remove the dash liner/ armature for access.
11. Cut and discard the ratchet strap retaining the harness to the blown aspirator and disconnect from the aspirator.
12. Displace the heater duct outlet.
13. Carefully un-clip the passenger door aperture flange finisher from the area of the "A" post fuse box trim pad.
14. Remove the screw which secures the fuse box trim pad and remove the trim pad. l5. Remove the passenger side front floor carpet.
15. Remove the screws which secure the fuse box to the body.
  NOTE: Retrieve the spacer washer fitted at this point.
16. Release the fuse box from its front retaining clip, allowing the fuse box to be moved aside as required for further access.
17. Disconnect the Blue and Yellow connectors, FE 41 and FE 42 of the Engine Control Module (ECM), remove the 4 securing screws and remove the ECM.
18. Release connector assembly LB/RB 09 (White, 12 way) from its clip on the LH sill.
19. Remove the lower foam block (Item 3, Fig. 6) from the "A" post cavity. Inspect/check the foam block, by squeezing it ;. If the block is dry, refit it. If the block is wet, replace it by a new block.
20. Displace and remove the "A" post upper foam pad. Item 1, Fig 21 . to give access to the upper foam block. Item 2, Fig. 6. Similarly inspect/check the upper foam block. If dry, refit the block. If wet, replace the block by a new one. Refit the upper foam pad.
  
  Fig 6: Removing Lower Foam Block From "A" Post Cavity
  Courtesy of JAGUAR CARS, INC.
21. Extract the LH side harness grommet from the "A" post. Use the cleaning solvent to remove all traces of grease from the groove of the grommet and from the aperture in the "A" post into which it fits.
22. Allow the cleaning solvent to evaporate, then apply a bead of Mastic sealer to the full circumference of the groove of the grommet. See Fig 7 .
  
  Fig 7: Applying Mastic Sealer to "A" Post Grommet
  Courtesy of JAGUAR CARS, INC.
23. Refit the grommet into the "A" post. Twist the grommet in each direction as the flange engages with the opening in the "A" post, spreading the sealer to ensure that it forms a continuous seal between the gaiter and the body metalwork. Wipe off any excess sealer.
24. Disconnect the mating portions of the LB/RB 09 connector assembly, previously released from its mounting clip .
25. Treat both mating faces with spray grease, allow 15 seconds for the solvent to evaporate, then reconnect.
26. Apply spray grease to the rear faces of both connectors.
27. Raise the connector assembly and secure it with a ratchet strap (Part No. C 46294), to the side harness in a position as high as the harness leads will permit. See Item 1, Fig. 8. Cut off the protruding tail of the ratchet strap.
  
  Fig 8: Securing Connector Assembly to Side Harness
  Courtesy of JAGUAR CARS, INC.
28. Re-engage the fuse box to the retaining clip at the forward end, refit and tighten the screws which secure the fuse box.

NOTE: Refit the spacer washer before refitting the upper screw.

NOTE: SECTION C PROCEDURES

continue at step 34.

REPAIR PROCEDURES - SECTION D

EMS ECM CONNECTORS - APPLY GREASE

Inspect the connecting faces of both connectors FE 41 and FE 42 which mate to the ECM. If not previously greased, treat both front and rear faces of both connectors with spray grease.
Inspect the terminal headers of the ECM. If these have not been previously greased, apply spray grease to them.

REPAIR PROCEDURE - SECTION E

EMS ECM CONNECTOR - FIT SHIELD

Reconnect connectors FE 41 and FE 42 to the ECM.
Re-align the ECM to its mounting bracket, interposing the drip shield (Part No. LMB 1720AA) between the module and bracket, positioned as in Fig 9 .

Fig 9: Fitting Drip Shield to ECM
Courtesy of JAGUAR CARS, INC.
Fit and tighten the screws securing the ECM.

REPAIR PROCEDURES - SECTION C (CONTINUED)

Refit the passenger side floor carpet, fuse box trim pad assembly and securing screw. Locate the flange of the fuse box trim pad to the door aperture and refit the flange finisher, ensuring that the flange finisher is correctly seated.
Refit the heater duct assembly to the outlet pipe, ensure it is correctly aligned.
Reconnect the connector to the blown aspirator, secure the harness to the aspirator using a ratchet strap (Part No. C 46294). Cut off the protruding tail of the strap.
Refit the passenger side dash liner/armature.
Close the passenger side front door.
Open the driver's front door for access.
From the "A" post extract the front end of the corrugated cable gaiter.
Carefully pull on the harness at the "A" post until the three harness interface connectors can be extracted through the opening. (Connectors LB 014, LB 002, LB 012 - 20-way Green, 20-way Black, 6-way White).
Treat the three connectors with spray grease, on both mating and rear faces of both portions; degrease and apply Mastic sealer to the groove of the corrugated gaiter. Return the harness connectors to their original locations; refit the front end of the corrugated gaiter, as described above for the passenger side gaiter.
At the driver's side front footwell, remove the dash liner/ armature for access.
Carefully unclip the driver's door aperture flange finisher from the area of the "A" post fuse box trim pad.
Remove the screw which secures the fuse box trim pad and remove the trim pad.
Remove the driver's side front floor carpet.
Remove the screws which secure the fuse box to the body.
NOTE: Retrieve the spacer washer fitted at this point.
Release the fuse box from its front retaining clip, allowing the fuse box to be moved aside as required for access.
Remove the lower foam block from the "A" post cavity. Inspect/ check the foam block, by squeezing it. If the block is dry, refit it. If the block is wet, replace it by a new block.
Displace and remove the "A" post upper foam pad, to give access to the upper foam block. Inspect/check the upper foam block. If dry, refit the block. If wet, replace the block by a new one. Refit the upper foam pad.
Extract the connector RS 73 of the catalyst switch module from within the RH side harness grommet. Remove the grommet from the "A" post.
Use the cleaning solvent to remove all traces of grease from the flange of the grommet and from the aperture in the "A" post into which it fits
Allow the solvent to evaporate, then apply a bead of Mastic sealer to the full circumference of the flange of the grommet.
Refit the grommet into the "A" post. Ensure that the sealer forms a continuous seal between the gaiter and the body metalwork. Wipe off any excess sealer.
Disconnect the mating portions of the RS 73 connector assembly from the catalyst switch module. Treat both mating faces with spray grease, allow 15 seconds for the solvent to evaporate, then reconnect.
Apply spray grease to the rear faces of both portions of the connector assembly. Refit the connector assembly into the side harness grommet.
Re-engage the fuse box to the retaining clip at the forward end, refit and tighten the screws which secure the fuse box.
NOTE: Re-locate the fixing lug of connector LB/RB 111 between the mounting stud and the fuse box upper securing lug, before refitting the upper screw.
Refit the floor carpet, fuse box trim pad assembly and securing screw. Locate the flange of the fuse box trim pad at the door aperture and refit the door aperture flange finisher. Ensure that the flange finisher is correctly seated.
Refit the dash liner/armature.

REPAIR PROCEDURES - SECTION F

INSTALLATION OF EXTENDED PLENUM DRAIN TUBE

At the rear of the engine compartment, locate and cut away the ratchet strap retaining the drain tube of the plenum chamber. Remove and discard the existing "short" drain tube. Note that the tip of the drain tube is positioned "across" th1 vehicle.
Replace the drain tube with an "Extended" length drain tube (Part No. LMB 7000BA). Position the tip of the drain tube "in line" with the vehicle; the slit in one face of the rubber tube should face the right hand inner fender of the vehicle. See Fig 10 .
Secure the drain, using a ratchet strap (Part No. C46294). Cut off the protruding tail of the strap.

Fig 10: Fitting the Extended Drain Tube

Courtesy of JAGUAR CARS, INC.

REPAIR PROCEDURES - SECTION G

MASS AIR FLOW SENSOR CONNECTOR

(If the vehicle is in group 8, open hood and fit fender covers)

Disconnect and reconnect the mass air flow sensor plug 3 times.
Route the air flow sensor harness lead forward from the connector plug to the air cleaner housing clip at the left side of the mass air flow sensor.
Strap the lead to the air cleaner clip using tie strap AGU 1058/J.

REPAIR PROCEDURES - SECTION H

TRINARY SWITCH - CHECK/RENEW & INSTALL EXTENSION 10SE

Use a calibrated digital multi-meter set to read DC voltage (Mv range).
Reconnect the battery ground cable if vehicle is not in group 8.
Turn the ignition switch to the auxiliary position. Select low fan speed. Select A/C and MAX on the A/C control panel. Ensure that the compressor clutch has engaged, then proceed as follows.
Locate the compressor clutch relay (FE 47), on the passenger side bulkhead. Connect the red probe of the DVOM to the compressor clutch relay terminal 85 carrying the Blue/Black (U/B) cable, and connect the black probe to a good earth stud connection and note the measurement.
If the voltage measurement is 60 Mv DC or less, no further action is required with the trinary switch. If the voltage measurement is GREATER than 60 Mv DC, the trinary switch will require replacement using the following procedure.
If the vehicle is in group 8, note the customers preset radio stations and remove the battery cover. Disconnect the battery ground cable.
Recover the refrigerant from the system. Ensure that it is COMPLETELY discharged. Follow the procedures defined in the XJ6 Service Manual number 4; section 82 and the instructions provided with your R134A refrigerant recovery equipment.
If the voltage measurement taken previously was greater than 60 Mv DC then change the trinary switch at this time. Ensure that the system is completely discharged. Disconnect the harness multi-plug (FE 16) on the trinary switch fly lead. Install a new trinary switch (Part No. LMB 7657AA). Item A, Fig 2 . Use the appropriate hand tools.

Fig 11: Installing New Trinary Switch & Adapter
Courtesy of JAGUAR CARS, INC.
Disconnect the harness multi-plug on the slow fan pressure switch. Using the appropriate hand tools, loosen and remove the slow fan pressure switch. Item B, Fig 2 . Remove and discard the pressure switch "O" ring.
Lubricate the new "O" ring (Part No. KSG 108116) supplied in the kit and carefully fit the "O" ring to the adaptor (Part No. MMB 7375AA). Item D, Fig. 11
NOTE: Use only approved oil.
Fit and tighten the adaptor into the refrigerant hose manifold. (Item C, Fig 2 . DO NOT EXCEED THE RECOMMENDED TORQUE SPECIFICATION. Refer to the Torque Chart.
NOTE: Use extreme caution when installing the adaptor due to the fragile nature of the adaptor threads.
Install and tighten the extension hose (Part No. MMB 7374AA), to the adaptor. Items D & E, Fig 2 . DO NOT EXCEED THE RECOMMENDED TORQUE SPECIFICATION. Refer to the Torque Chart.
NOTE: Use extreme caution when installing the extension hose to the adaptor due to the fragile nature of the adaptor threads. When tightening the hose to the adaptor, an open ended wrench MUST be used to prevent the adaptor from turning. Refer to Fig 12 .

Fig 12: Tightening Extension Hose to Adapter
Courtesy of JAGUAR CARS, INC.
Lubricate the new "O" ring (Part No. KSG 108116) supplied and carefully fit the "O" ring to the slow fan pressure switch, see Item B, Fig 2 . Use only approved oil.
Fit and tighten the slow fan pressure switch (Item B, Fig 2 ) to the extension hose (Item E, Fig 2 ). DO NOT EXCEED THE RECOMMENDED TORQUE SPECIFICATION. Refer to the Torque Chart.
Position the extension hose/slow fan pressure switch against the corrugated harness tubing at the bulkhead. Secure the pressure switch to the tubing as shown. Use the tie strap provided (Part No. ADU 9028). See Item F, Fig 2 .
Route the slow fan pressure switch fly lead (part of engine harness) as shown. See Item G, Fig 2 .
Release the engine harness bulkhead securing clip, see Item H, Fig 2 . Route the slow fan pressure switch harness through the clip and close the clip.
Reconnect the slow fan pressure switch multi-plug (FE 7). Position the harness against the corrugated tubing and secure using the tie straps provided (Part No. ADU 9028). See Item J, in Fig 11 .
Evacuate and recharge the A/C system. Leak check the system to ensure that all refrigerant hose connections are correctly sealed.
Reconnect the battery ground cable. Install the battery cover.
Test the A/C system to confirm correct operation of the compressor and engine cooling fans.
NOTE: If vehicle is within VIN range 667829 - 677924 proceed to Section I.
Reset the clock, re-code the radio and reset the customers pre-set radio stations.
Remove the fender covers and close hood.

TORQUE SPECIFICATION DATA

COMPONENT	NEWTON METERS	INCH POUNDS (FOOT POUNDS)
ADAPTOR TO REFRIGERANT HOSE	6 NM	53 INCH/LBS (4.4 FT/LBS)
EXTENSION HOSE TO ADAPTOR	12 NM	106 INCH/LBS (8.8 FT/LBS)
SLOW FAN PRESSURE SWITCH TO EXTENSION HOSE	12 NM	106 INCH/LBS (8.8 FT/LBS)
TRINARY SWITCH TO REFRIGERANT HOSE	12 NM	106 INCH/LBS (8.8 FT/LBS)

REPAIR PROCEDURES - SECTION I

INSTALL LINK LEAD AND NEW FUEL INJECTION RELAY

Remove the PI main relay (FE 38) from its base (black).
Remove the anti-backout clips from the relay base.
Remove the following wires from the relay base:
Brown/Yellow from pin 30

White/Brown from pin 87
Install the Brown/Yellow wire into pin 87 of the relay base.
Remove the black wire from pin 85 of the relay base.
Connect the appropriate end of the new link harness (LMB 3998AA) to the connector of the Black wire removed from pin 85 of the relay base.
NOTE: Only one end of the link harness will mate with the connector of the Black wire.
Install the other end of the link harness (Black wire with White marker) to pin 87A of the relay base.
Install the remaining Black wire of the link harness to pin 85 of the relay base.
Refit the anti-backout clips.
Use suitable adhesive electrical insulation tape to secure the link harness to the relay harness.
NOTE: Ensure that the exposed connection is properly insulated.
Refit the relay base to the mounting bracket.
Fit the new relay (DAC 7687) into the relay base.

REPAIR PROCEDURES - SECTION J

MOMENTARY ILLUMINATION OF INSTRUMENT PACK WARNING LIGHTS

To install ground straps on vehicles from VIN 667829 to 685239, use the following procedure:

Raise the vehicle on a lift.
Remove both front wheels.
Use tin-snips to cut a 10mm (3/8") section from the large eyelet end of both ground straps (LMB 3744AA) to form a spade end connection. See Fig 13 .

Fig 13: Modifying Ground Strap
Courtesy of JAGUAR CARS, INC.
Remove the bolt retaining the L/H ABS speed sensor. See Fig 14 A.

Fig 14: Location of ABS Speed Sensor Retaining Bolt
Courtesy of JAGUAR CARS, INC.
Align the small eyelet end of the ground strap to the ABS speed sensor bolt hole.
NOTE: Position the ground strap to point upwards.
Refit and tighten the bolt retaining the L/H ABS speed sensor to secure the ground strap, Fig 5 , item B.
Clean any underseal material from around the nut (Fig 15 C) which retains the brake hose to its bracket. Loosen the nut until the shake-proof washer (Fig. Fig 15 ) is loose.
Slide the spade end of the ground strap under the shake-proof washer. The ground strap must face towards the rear of the vehicle, (Fig 15 ). Re-tighten the nut to clamp the ground strap between the shake-proof washer and the brake hose mounting bracket.

Fig 15: Fitting Ground Strap to Brake Hose Support Bracket
Courtesy of JAGUAR CARS, INC.
Note the location of the ratchet strap retaining the brake pad sensor harness to the brake hose, (Fig 15 E). Cut and discard the ratchet strap.
Install a NEW ratchet strap (C 46294) at the same position around the brake hose, brake pad sensor harness and ground strap. Tighten the ratchet strap only enough to ensure it stays in place.
NOTE: DO NOT pull the strap fully tight.
Cut off the protruding tail of the ratchet strap.
Fit the second ground strap on the R/H front hub, using the same procedure.
NOTE: There is no brake pad wear sensor wire at the R/H brake hose. The ratchet strap fitted around the brake hose retains only the ground strap to the brake hose. Locate the ratchet strap at the lowest point of the brake hose.
Refit the front wheel assemblies.
Lower the vehicle from the lift.

1993 MY XJ6 ENHANCEMENT PROGRAM - WARRANTY INFORMATION

For 1993 MY XJ6 ENHANCEMENT PROGRAM - WARRANTY INFORMATION, see Fig 16 - Fig 23 . For 1994 MY XJ6 ENHANCEMENT PROGRAM - PARTS INFORMATION TABLE, see Fig 24 .

Fig 16: GROUP 1 WARRANTY INFORMATION TABLE

Fig 17: GROUP 2 WARRANTY INFORMATION TABLE

Fig 18: GROUP 3 WARRANTY INFORMATION TABLE

Fig 19: GROUP 4 WARRANTY INFORMATION TABLE

Fig 20: GROUP 5 WARRANTY INFORMATION TABLE

Fig 21: GROUP 6 WARRANTY INFORMATION TABLE

Fig 22: GROUP 7 WARRANTY INFORMATION TABLE

Fig 23: GROUP 8 WARRANTY INFORMATION TABLE

Fig 24: 1994 MY XJ6 ENHANCEMENT PROGRAM - PARTS INFORMATION TABLE