1994 JAGUAR XJ6 service

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Page 409 of 521

JAGUAR XJ6 1994 2.G Workshop Manual Routine Maintenance
Service intervals
Check power steering system for leaks and hydraulic
pipes
/ unions for chafing /corrosion
Check Cooling
/ heating system for leaks / security
Check

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JAGUAR XJ6 1994 2.G Workshop Manual used.
WARNING: FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G.
TRICHLOROETHANE, WHITE SPIRIT, SBPB, METHYLENE CHLORIDE, PERCHLORETHYLENE.
DO NOT SMOKE IN THE VI

used.
WARNING: FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G.
TRICHLOROETHANE, WHITE SPIRIT, SBPB, METHYLENE CHLORIDE, PERCHLORETHYLENE.
DO NOT SMOKE IN THE VICINITY OF VOLATILE DEGREASING AGENTS.
Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from
naked flames and other sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as
causing damage to protective coatings, there is
a risk of damage from stray heat to electronic equipment and brake
lines. Do not leave tools, equipment, spilt oil etc. around or on work
area. Wear protective overalls and use barrier
cream when necessary.
0 A3.1.1 Used Engine Oils
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dry- ness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause
skin cancer. Washing facilities and adequate means of skin protection should be provided.
A3.1.2 Health Protection Precautions
0 Avoid prolonged and repeated contact with oil; particularly used engine oils.
o Wear protective clothing, including impervious gloves where practicable
0 Do not put oily rags in pockets.
0 Avoid contaminating clothes, particularly underwear, with oil.
0 Overalls must be cleaned regularly. Discard unwashable clothing and footwear which is oil impregnated.
o First Aid treatment should be obtained immediately for open cuts or wounds.
0 Use barrier creams, applying before each work period, to enable easier removal of dirty oil / grease from the
skin.
0 Wash with soap and water to ensure that all oil is removed (skin cleaner and a nail brush will help). The use of
preparations containing lanolin will help to replace the natural skin oils which have been removed.
o Do not use petrol, kerosene, gas oil, thinners or solvents for washing skin.
0 If skin disorders develop, obtain medical advice immediately.
0 Where practicable, degrease components prior to handling.
0 Where there is a risk of fluids coming into contact with the eyes, eye protection should be worn, for example,
goggles or a face shield. An eye wash facility should be provided.
A3.1.3 Environmental Protection Precautions
A3.1 SAFETY PRECAUTIONS
Whenever possible, use a ramp or pit whilst working beneath a car, in preference to jacking. Position chocks at the
wheels as well as applying the handbrake. Never rely on a jack alone to support a car. Use axle stands, or blocks care- fully placed at the jacking points, to provide a rigid location. Checkthat any lifting equipment used has adequate capac- ity and is fully serviceable. Ensure that a suitable form of fire extinguisher is conveniently located.
When using
electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed. Disconnect
the earth (grounded) terminal of the car battery. Do not disconnect any pipes of the air conditioning refrigeration sys-
tem unless you are trained and instructed to do so. A refrigerant is used which can cause blindness if allowed to come
into contact with the eyes. Ensure that adequate ventilation is provided when volatile degreasing agents are being
It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses. The burning of used engine
oil in small space heaters or boilers is not recommended unless emission control equipment is fitted. Dispose of used
oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation trade.
If in doubt, contact the Local Authority for advice on disposal facilities.
X300 VSM 1 Issue 1 August 1994

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JAGUAR XJ6 1994 2.G Workshop Manual General Fitting Instructions
A3.2 GENERAL FITTING INSTRUCTIONS
A3.2.1
Always fit covers to protect the wings before commencing work in the engine compartment. Cover the seats and
carpets,

General Fitting Instructions
A3.2 GENERAL FITTING INSTRUCTIONS
A3.2.1
Always fit covers to protect the wings before commencing work in the engine compartment. Cover the seats and
carpets, wear clean overalls and wash hands or wear gloves before working inside the car. Avoid spilling hydraulic
fluid, anti
-freeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use poly- thene sheets in the boot to protect carpets. Always use the recommended service tool, or a satisfactory equivalent,
where specified. Protect temporarily exposed screw threads by replacing nuts or fitting caps.
Precautions Against Damage To The Vehicle
A3.2.2 Preparation
Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed,
blank off any exposed openings using greaseproof paper and masking tape. Immediately seal fuel, oil and hydraulic
lines when separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends
of oilways, exposed by component removal, with tapered hardwood plugs or readily visible plastic plugs. Immediately
a component is removed, place
it in a suitable container; use a separate container for each component and its asso- ciated parts. Before dismantling a component, clean it thoroughly with a recommended cleaning agent: check that the
agent will not damage any of the materials within the component. Clean the bench and obtain marking materials, la-
bels, containers and locking wire before dismantling a component.
A3.2.3 Dismantling
Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic
system are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems. Clean all tapped holes, crevices, oilways and fluid passages with compressed air.
WRNIFLG: DO NOT PERMIT COMPRESSED AIR TO ENTER AN OPEN WOUND. ALWAYS USE EVE PROTECTION
WHEN USING COMPRESSED AIR.
Ensure that any 'O'-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure
that they are replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of caus- ing distortion or the initiation of cracks, which could occur if a center punch or scriber were used. Wire together mating
parts where necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to
be renewed and to parts requiring further inspection before being passed for reassembly.
Place labelled parts and other parts for rebuild
in separate containers.
Do not discard a part which is due for renewal until it has been compared with the new part, to ensure that the correct
part has been obtained.
A3.2.4 Inspection
Before inspecting a component for wear or performing a dimensional check, ensure that it is absolutely clean; a slight
smear of grease can conceal an incipient failure. When a component is to be checked dimensionally against figures
quoted for
it, use the correct equipment (surface plates, micrometers, dial gauges etc.) in serviceable condition. The
use of makeshift equipment can be dangerous. Reject a component if its dimensions are outside the limits quoted,
or if damage is apparent. A part may be refitted if its critical dimension is exactly to the limit size and it is otherwise
satisfactory. Use Plastigauge 12 Type PG-1 for checking bearing surface clearance e.g. big end bearing shell to crank
journal. Instructions for the use of Plastigauge and a scale giving bearing clearances in steps of
0,0025 mm (0.0001
in) are supplied with the package.
0
0
0
X300 VSM Issue 1 August 1994 2

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JAGUAR XJ6 1994 2.G Workshop Manual in these areas indicates the onset of wear.
Hold the inner race between the fingers and thumb of one hand, spin the outer race and checkthat
it revolves absolutely
smoothly. Rotate the o

in these areas indicates the onset of wear.
Hold the inner race between the fingers and thumb of one hand, spin the outer race and checkthat
it revolves absolutely
smoothly. Rotate the outer ring with a reciprocating motion, while holding the inner ring; feel for any obstruction to
rotation and reject the bearing if the action is not perfectly smooth. Lubricate the bearing generously with lubricant
appropriate to the installation. Inspect the shaft and bearing housing for discolouration or other marking which may
suggest that movement has taken place between the bearing and bearing seat.
If markings are found, use Loctite when
installing the replacement bearing.
Ensure that the shaft and housing
are clean and free from
burrs before fitting the bearing. If one bearing of a pair
shows an imperfection, it is generally advisable to renew
both bearings: an exception could be made only if the bear- ings had covered a low mileage and it could be established
that damage was confined to the one bearing.
- In the case of bearings which are lubricated with grease (e.g.
hub bearings) the space between the bearings should be
smeared with a recommended grade of grease, and the
bearings and seal should be re
-packed. When fitting the
bearing to the shaft, apply force only to the inner ring of
bearing (Fig.
1A). When fitting the bearing to the housing,
apply force only to outer ring (Fig. 1B).
Always mark components of separable bearings (e.g taper
roller bearings) when dismantling, to ensure correct
reassembly. Never
fit a new inner roller assembly to a used
outer track.
A3.2.6 Oil Seals
Always fit new oil seals when rebuilding an assembly.
Examine the seal before fitting to ensure that it is clean and
undamaged. Smear sealing lips with clean grease, pack
dust excluder seals with grease and pack grease into the
cavity between the sealing lips of duplex seals. Ensure that
the seal spring,
if provided, is correctly fitted.
Place the lip
of the seal towards the fluid to be sealed and
slide it into position on the shaft, using a fitting sleeve (Fig. 2) when possible to protect the sealing lip from damage by
threads, splines or sharp edges on the end of the shaft. If a fitting sleeve is not available, use plastic tube or adhesive
tape to prevent damage to the sealing lip.
Grease the outside diameter of the seal, place it square to the
housing recess and press it into position, using great care
and, where available, a seal installer (Fig. 3) to ensure that
the seal does not tilt. In some cases it may be preferable to
fit the seal to the housing before fitting it to the shaft. Never
let the weight of an unsupported shaft rest in a seal. If the
correct service tool is not available, use a piece of tube which
is approximately 0,4 mm (0.015 in) smaller than the outside
diameter of the seal. Use a press to install the seal or use a
hammer VERY GENTLY on the tubular drift if a press is un-
suitable or not available.
,107 001 A B
I Fig. 1
A3.2.5 Ball And Roller Bearings
CAUTION: Never replace a ball or roller bearing without first ensuring that it is in as-new condition.
Remove
all traces of lubricant from the bearing by washing it in petrol or a suitable degreaser. Maintain absolute
cleanliness throughout the operations. Inspect visually for markings of any form on rolling elements, bearing tracks,
outer surface of outer rings or inner surface of inner rings. Reject any bearings found to be marked, since any markings
Fig.
2
307 002
i
Fig. 3
Issue 1 August 1994 3 X300 VSM

Page 425 of 521

JAGUAR XJ6 1994 2.G Workshop Manual Body Systems & Body Repair
Sub-Section Title SRO Page
A4.4.4 ........... Underhood Labels. Location & Tvpe ................................................... 32
A4.4.5
........... Stonechip Prot

Body Systems & Body Repair
Sub-Section Title SRO Page
A4.4.4 ........... Underhood Labels. Location & Tvpe ................................................... 32
A4.4.5
........... Stonechip Protection Area ............................................................ 33
A4.5.1.1
.......... Glass And Body Preparation .......................................................... 34
A4.5.1.2
.......... Glazing Adhesive Application Temperature ............................................. 34
A4.5
............. Glazing ........................................................................\
... 34
A4.5.1
........... Glazing. Special Notes ............................................................... 34
A4.5.1.3
.......... Glazing Adhesive Application ......................................................... 34
A4.5.1.4
.......... Glazing Adhesive Curing ............................................................. 34
A4.6.1
........... Bumpers ........................................................................\
... 35
A4.6.1.2 .......... Bumpers. Features ................................................................... 35
A4.6.1.3
.......... BUmpeN. Service Procedures ......................................................... 37
A4.6.1.4 .......... Bumpers. Fitted Condition - Front ..................................................... 37
A4.6.2
........... BUmpeN. Cover Damage ............................................................. 39
A4.6.1.1
.......... Bumpers.
Major Components ......................................................... 35
A4.6.1.5 .......... Bumpers. Fitted Condition -Rear ...................................................... 38
A4.6.2.1
.......... Bumpers. Damage Assessment ........................................................ 39
A4.6.2.2
.......... Bumpers. Repair Materials ............................................................ 39
A4.6.3 ........... Bumpers. Refinishing ................................................................ 40
A4.6.3.1
.......... Bumpers. Refinishing - Original ....................................................... 40
A4.6.3.2
.......... Bumpers. Refinishing - New .......................................................... 40
A4.6.3.3
.......... Bumpers. Refinishing - All ............................................................ 40
A4.6.4
........... Bumpers. Replacement Covers ........................................................ 40
A4.6.5
........... Recycled Materials. General Note ..................................................... 40
A4.6.6.1
.......... Body-side Moulding, Introduction ..................................................... 41
A4.6.6.2
.......... Body-side Moulding. Fitted Condition - Illustration ....................................... 41
A4.6.6.3
.......... Body-side Moulding. Fitting Process ................................................... 41
A4.6.7
........... Finisher, Door Frame - Fitted Condition ................................................ 42
A4.6.8
........... Finisher, Roof Drip Rail - Fitted Condition .............................................. 42
A4.7.1
........... Body Exterior Clearances & Alignments ................................................. 43
A4.7.1.1
.......... Body Exterior Clearances & Alignments. Introduction ..................................... 43
A4.6.6
........... Body-side
Moulding ................................................................. 41
A4.7.1.2
.......... Body Exterior Clearances & Alignments. Criteria - Clearances ............................. 43
A4.7.1.3
.......... Body Exterior Clearances & Alignments. Criteria - Alignment .............................. 43
A4.7.1.4
.......... Body Exterior Clearances & Alignments. Criteria - Exterior Fitments ........................ 43
A4.7.1.5
.......... Body Exterior Clearances & Alignments. Illustrations (Specifications) ........................ 43
A4.7.2
........... DOON ........................................................................\
..... 47
A4.7.2.1
.......... DOON. Features ..................................................................... 47
A4.7.2.2
.......... DOON. Removal .................................................................... 47
A4.7.2.3
.......... DOON. Fitting ....................................................................... \
47
A4.7.2.4
.......... DOON. Alignment ................................................................... 47
A4.7.2.5
.......... Door Seals. Table ................................................................... 48
A4.7.2.6 .......... Door Seals - Typical Sections. Illustration ............................................... 48
0
0
0
0
Issue 1 August 1994 X300 VSM ii

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JAGUAR XJ6 1994 2.G Workshop Manual A4.1.2 Notification Of Hazards
Symbols, which convey important information, will be posi- tioned at the beginning of any specific operation or text.
Standard symbols will be used where repairs

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JAGUAR XJ6 1994 2.G Workshop Manual in the same location as the previous label, see location illustrations.
A protective mask is used to prevent the replacement part label from being damaged or obscured
during the refini

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JAGUAR XJ6 1994 2.G Workshop Manual conditions.
. Tighten all fixings to specification.
A4.6.1.3 SERVICE PROCEDURES
A4.6.1.4
Fitted Condition (Front)
The following procedures may apply should any part of the bumper mounting

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