1994 JAGUAR XJ6 lock

(amps)
F1 Light Blue 15
F3 Light Blue 15
F4 Light Blue 15
F5 Tan 5
F6 F7 Light Green 30
- -
F8 Red 10
F9 Clear 25
FIO Tan 5
F11 Yellow 20 0
Light Green
Light Blue
F18 Light Blue
0'
I
Circuit
Central door locking
Deadlocking (where fitted)
Transmission interlock relay
Key
-switch solenoid relay
Center console switch pack
Interior lighting switch
Seat motors
- left-hand side
Seat motors
- left-hand side
Automatic transmission control module
(TCM)
Not used
Anti
-lock braking system / traction control control module (ABS /
TC CM)
Interior lamps
Luggage compartment lamps
Seat heaters (where fitted)
Data link connector
Fuel pump relay coil
Air conditioning blower motor
- right-hand
Air conditioning
Seat control modules
(SCMs)
Mirror heaters relay
Power assisted steering
Not used
Mirrors, Heated rear window, Cigar lighter
Rear lighting control module
High mounted stop lamp (where fitted)
Window lift (front and rear)
-left-hand side
Windshield wiper system Front screen heaters
Front lighting control module
- left-hand
Water pump relay
Headlamp levelling (where fitted)
Clock
Airbag
Sunroof (where fitted)
Issue 1 August 1994 AI-95MY 17 X300 VSM

General Fitting Instructions
SECTION CONTENTS
Subsection Title SRO Page
i ................ PreliminaryPage ..................................................................... i
A3.1 ............. Safety Precautions ................................................................... 1
A3.1.1 ........... Safety Precautions. Used Engine Oils ................................................... 1
A3.1.2 ........... Safety Precautions. Health Protection Precautions ........................................ 1
A3.1.3 ........... Safety Precautions. Environmental Protection Precautions .................................. 1
A3.2 ............. General Fitting Instructions ............................................................ 2
A3.2.1
........... General Fitting Instructions. Precautions Against Damage To The Vehicle ..................... 2
A3.2.2
........... General Fitting Instructions. Preparation ................................................. 2
A3.2.3
........... General Fitting Instructions. Dismantling ................................................ 2
A3.2.4
........... General Fitting Instructions. Inspection .................................................. 2
A3.2.5
........... General Fitting Instructions. Ball And Roller Bearings ...................................... 3
A3.2.6
........... General Fitting Instructions. Oil Seals ................................................... 3
A3.2.7
........... General Fitting Instructions. Joints And Joint Faces ......................................... 4
A3.2.8
........... General Fitting instructions. Hydraulic Flexible Pipes And Hoses ............................ 4
A3.2.9
........... General Fitting Instructions. Metric Bolt identification ...................................... 4
A3.2.10
.......... General Fitting instructions. Metric Nut Identification ...................................... 4
A3.2.11
.......... General Fitting Instructions. Hydraulic Fittings -Metrification ............................... 5
A3.2.12
.......... General Fitting Instructions. Keys And Keyways ........................................... 6
A3.2.13
.......... General Fitting Instructions. Split Pins ................................................... 6
A3.2.14
.......... General Fitting instructions. Tab Washers ................................................ 6
A3.2.15
.......... General Fitting instructions. Special Fixings .............................................. 6
A3.2.16
.......... General Fitting Instructions. Nuts ....................................................... 7
A3.2.17 .......... General Fitting Instructions. Locking Wire ................................................ 7
A3.2.18 .......... General Fitting Instructions. Screw Threads ............................................... 7
A3.2.19 .......... General Fitting Instructions. Unified Thread Identification - Bolts ............................ 7
A3.2.20 .......... General Fitting Instructions. Unified Thread Identification - Nuts ............................ 7
A3.2.21 .......... General Fitting Instructions. Unified Thread Identification - Studs. Brake Rods. etc .............. 7
A3.3 ............. Taper Roller Bearings - Fault Diagnosis .................................................. 8
X300 VSM i Issue 1 August 1994

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

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

General Fitting Instructions
Pressordrifttheseal in tothefull depthofthe housing ifthe housing is shouldered,orflush withthefaceofthe housing
where no shoulder is provided.
Note: Careless fitting of oil seals, which can result in damage to the seal and sealing surfaces, accounts for most
cases of failure of seals. Care in fitting is essential
if good results are to be obtained.
A3.2.7 joints And joint Faces
Remove all traces of old jointing materials prior to reassembly. Inspect joint faces for scratches or burrs and remove
with a fine file or oilstone; do not allow swarf or dirt to enter tapped holes or enclosed parts. Blow out any pipes, chan- nels or crevices with compressed air, refitting or renewing any 0-rings or seals which have been displaced by the com- pressed air.
Always use the specified gaskets. Use jointing compound only when recommended, otherwise fit joints dry. When
jointing compound is used, apply in
a thin film to metal surfaces; take great care to prevent it from entering oilways, pipes or blind tapped holes.
A3.2.8
Before removing a hose from the brake or power steering systems, thoroughly clean the end fittings and the area sur- rounding them. Obtain blanking caps beforedetaching hosefittings,sothat portscan becovered to excludedirt. Clean
the hose externally and blow through with compressed air. Examine the hose carefully for cracks, separation of plies,
security of end fittings and external damage. Reject any hose found to be faulty. When refitting the hose, ensure that
no unnecessary bends are introduced and that the hose is not twisted before or during tightening of union nuts.
Do not store hydraulic fluid in an unsealed container because it will absorb water. Fluid in this condition would be dan- gerous to use due to a lowering of its boiling point. Do not allow hydraulic fluid to be contaminated with mineral oil,
or use a container which has previously contained mineral oil.
Do not re-use fluid bled from the system. Always use clean brake fluid, or a recommended alternative, to clean the
hydraulic components. Fit a blanking cap to the hydraulic union and
a plug to its mating socket, after removal from
the vehicle, to prevent ingress of dirt. Absolute cleanliness must be observed with hydraulic components at all times.
After any work has been performed on hydraulicsystems, inspect carefully for leaks underneath the car while a second
operator applies maximum pressure to the brakes (with the engine running) and operates the steering.
Hydraulic Flexible Pipes And Hoses
A3.2.9 Metric
Bolt Identification
An IS0 metric bolt or screw, made of steel and larger than
6mm in diameter can be identified by the symbols ISOM or M embossed on top of the head (Fig. 1 ). In addition to marks
to identify the manufacturer, the head is also marked with
symbols to indicate the strength grade eg
8.8, 10.9, 12.9 or 14.9. The first figure gives the minimum strength of the bolt
material in tens of kgf / mm2. Zinc plated IS0 metric bolts
and nuts are chromate passivated and coloured greenish- khaki to gold-bronze.
A3.2.10 Metric Nut Identification
A nut with an IS0 metricthread is marked on one face (1 Fig. 2) or on one of the flats (2 Fig. 2) of the hexagon with the
strength grade symbol 8, 12 or 14. Some nuts with a
strength 4,5 or 6 are also marked and some have the metric
symbol M on the flat which is opposite to the strength grade
marking.
Aclockfacesystem is used as an alternative method of indi
- cating the strength grade (3 Fig. 2). The external chamfers
or a face of the nut is marked in a position relative to the ap-
propriate hour mark on a clock face to indicate the strength
grade. A dot is used to locate the 12 o’clock position and a dash to indicate the strength grade. If the grade is above 12,
two dots identify the 12 o’clock position. Fig.
1
I I
Fig. 2
X300 VSM Issue 1 August 1994 4

- A3.2.19 Unified Thread Identification - Bolts
A circular recess is stamped in the upper surface of the bolt
head (1 Fig. 1).
A3.2.20 Unified Thread Identification - Nuts
A continuous line of circles is stamped on one of the flats of
the hexagon, parallel to the axis of the nut (2 Fig. 1).
A3.2.2 1 Unified Thread Identification - Studs, Brake
Rods, etc.
The component is reduced to the core diameter for a short
length at its extremity (3 Fig. 1).
A3.2.16 Nuts
When tightening a slotted or castellated nut, never slacken it in order to insert the split pin or locking wire, but tighten
it to align the next slot. The exception is in those recommended cases where slackening the nut forms part of an adjust- ment e.g. bearing endfloat or preload adjustment. If difficulty is experienced, alternative washers or nuts should be
selected, or a washer of a different thickness used. Where self-locking nuts have been removed, replace them with
new ones.
A3.2.17 Locking Wire
Fit new locking wire of the correct type to the assemblies incorporating it. Arrange the wire so that its tension tends
to tighten the bolt heads, or nuts, to which it is fitted.
A3.2.18 Screw Threads
Metricthreads to IS0 standards and UNF threads are used. See below forthread identification. Fixings with damaged
threads must always be discarded. Cleaning the threads with a die or tap impairs the strength and closeness of fit and
is not recommended. Always ensure that replacement bolts are of equal strength to those removed. Do not allow oil,
grease or jointing compound to enter blind threaded holes because the hydraulic action which would be generated
when screwing in the bolt or stud could split the housing. Oil the thread lightly before tightening to ensure
a free run- ning thread, except in the case of self locking nuts. Always tighten a nut or bolt to the recommended torque figure.
Damaged or corroded threads will affect the torque reading. To check or retighten a bolt or screw to a specified torque
figure, first slacken by a quarter of a turn, then retighten to the correct figure.
I
7
-3
‘2 507 011
Fig. 1
X300 VSM 7 Issue 1 August 1994

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 system, or cover, be renewed but should
not be necessary if the cover is removed for service reasons.
The front mountings must initially be set for 'cross car' pitch and center within the clearances around thestrut to body
. In orderthat the bumpertop face, headlamp surrounds and grille lower have the correct relationship the strut height
. Set the guide blocksto thespecified dimensionto achievethecorrect bumpertofender gap, BEFOREfittingthecover
. With all fixing points set, the bumper cover may be fitted and adjusted as necessary to achieve the specified gap
fixings.
adjusters must be finally
set AFTER the cover is fitted.
because adjustments can only be made with the cover
off.
Fig. 1 Front bumper setting dimensions
Issue 1 August 1994 37 X300 VSM

Body Systems & Body Repair
A4.6.1.5 Fitted Condition (Rear)
The following procedures may apply should any part of the bumper mounting system, or cover, be renewed but should
not be necessary if the cover is removed for service reasons.
. The rear mountings must initially be set for 'cross car' pitch and center within the clearances around the strut to body
. To initially achieve the relationship between the bumpertop face and the rear panel, the strut height adjustersshould
9 Settheguide blockstothespecified dimensiontoachievethecorrect bumpertofender gap,BEFOREfittingthecover,
fixings.
be set to the dimension shown (Fig.
1) BEFORE the cover is fitted.
because adiustments can onlv be made with the cover
off.
. With all fixing points set, the bumper cover may be fitted and adjusted as necessary to achieve the specified gap
- Note:
conditions.
Access to the beam height adjusters may be made with the cover fitted by removing the tailpipe trims.
. With the bumper correctly adjusted to the body and all fixings tightened to specification, it is important that the ex-
haust tailpipes are then centered within the bumper cover cut-outs. This may be achieved by slackening the rear
section clamp and rotating the rear exhaust assembly. Please note that this may only be achieved before the tailpipe
trims are fitted; these must also be correctly aligned for good appearance.
J76-1019
Fig. 1 Rear bumper setting dimensions
X300 VSM Issue 1 August 1994 38