1994 JAGUAR XJ6 ESP

Electrical cl
.
SECTION CONTENTS
Subsection Title SRO Page
i ................ PreliminaryPages .................................................................... i
15.1 ............. Supplemental Restraint System (SRS) .................................................... 1
15.1.1 ............ SRS. General Description .............................................................. 1
15.1.2 ............ SRS. Handling Undeployed Modules .................................................... 2
15.1.3 ............ SRS. Emergency First Aid Procedures .................................................... 3
15.1.4
............ SRS. Safety Procedures. Handling Deployed Modules ...................................... 3
15.1.5 ............ SRS. Safety Procedures. Handling Undeployed Damaged Modules ........................... 3
15.1.6. ........... SRS. Fire Hazard Information .......................................................... 4
15.1.7.
........... SRS. Ventilation ...................................................................... 4
15.1.8 ............ SRS. RespiratoryPrecautions ........................................................... 4
15.1.9.
........... SRS. Eye Protection ................................................................... 4
15.1.10
.......... SRS. Protective Clothing ............................................................... 4
15.1.11 ........... SRS. Handling & Storage Precautions .................................................... 4
15.1.12 .......... SRS. Modules. Assembly/ Removal/Setvice Instructions ................................... 4
15.1.13 .......... SRS. Spillage & Leakage ............................................................... 5
15.1.14 .......... SRS. Scrapping Vehicles With Live Airbags ............................................... 5
15.1.15 .......... SRS. Scrapping Vehicles With Deployed Airbags .......................................... 6
15.1.16 .......... SRS. Disposal of Live Airbag Modules ................................................... 6
15.1.17 .......... SRS. Disposal of Deployed Airbag Modules .............................................. 7
15.2 ............. Instruments ........................................................................\
. 8
15.2.1
............ Instruments. General Description ....................................................... 8
15.2.2 ............ Instruments. Analog Display ........................................................... 8
15.2.3
............ Instruments. Indicator Lamps ........................................................... 8
15.2.4.
........... Instruments. Liquid Crystal Display ..................................................... 8
15.2.5.
........... Instruments. Transducers .............................................................. 8
15.2.6. ........... Instruments. Panel. General ........................................................... 8
15.2.7.
........... Instruments. Gauges .................................................................. 9
15.2.8. ........... Instruments. Odometer ............................................................... 10
15.2.9
............ Instruments. Trip Computer ........................................................... 10
15.2.10 .......... Instruments. Driver Information Messages ............................................... 10
15.2.11 ........... Instruments. Illumination ............................................................. 10
15.2.12 .......... Instruments. General Repair Notes ..................................................... 10
15.3 ............. Speed Control ...................................................................... 11
15.4 ............. Driver Ergonomics .................................................................. 12
15.5
............. Battery& ChargingSystem ........................................................... 13
15.5.1 ............ Battery, General .................................................................... 13
15.5.2 ............ Battery, ReserveCapaci ty ............................................................. 13
15.5.3.
........... Battery. Cranking Performance ........................................................ 13
15.5.4 ............ Battery. Electrical Data ............................................................... 13
15.5.5
............ Battery. State of Charge .............................................................. 13
15.5.6 ............ Battery, Rate of Charge ............................................................... 13
15.5.7 ............ Battery. LoadTest ................................................................... 13
15.5.8 ............ Battey. Specific Gravity Test .......................................................... 14
15.5.9 ............ Battery. Electrolyte Temperature Correction .............................................. 14
15.5.10 .......... Battery. Health & Safety Precautions ................................................... 14
15.5.11. .......... Battery. Remove & Refit ......................................... 86.15.01 ............ 15
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rl Electrical
15.1.6 Fire Hazard Infonnath
Thermal decomposition or combustion may produce dense smoke and other dangerous fumes which in fire situations
form
a highly toxic explosive.
In the event of fire the surrounding area must be evacuated and
all personnel kept well upwind of the area.
Full fire fighting protective gear and
a self contained breathing apparatus operating in the positive pressure mode must
be worn for combating fire. Material near fires must be cooled with water spray to prevent ignition.
Fires should be allowed to burn themselves
out if not threatening to life or property. If fire is threatening to life or prop- erty use copious quantities of water to extinguish.
15.1.7 Ventilath
Local exhaust ventilation designed by a professional engineer should be provided if vapours, fumes, or dusts are gen- erated whilst working with airbag module.
The latest issue of the manual for recommended practices on 'Industrial Ventilation' is available from the
ACGIH Com- mittee on Industrial Ventilation, PO Box 16153, Lansing, MI 48910, USA.
The need for local exhaust ventilation should be evaluated by a professional industrial hygienist.
15.1.8 Respiratory Precauth
To prevent the inhalation of dangerous fumes and dusts, an approved mask should be worn.
15.1.9 Eye Protection
Chemical protective goggles are recommended where there is a possibility of eye contact with the propellant.
Safety glasses with side shields are recommended for
all other operations.
15.1. I0 Protective Clothing
Approved protective gloves, overalls and shoes / boots should be worn.
15.1.1 1 Handling and Storage Precautions
Do not store airbag module near live electrical equipment or circuitry. Store in a dry environment at ambient tempera-
tures.
Good housekeeping and engineering practices should be employed to prevent the generation and accumulation of
dusts. Store in compliance with
all local state and federal regulations.
15.1.12 Driver And Passenger Airbag Modules Assembly / Removal / Service Instructions
Before starting work, ensure ignition switch is in 'IocK position, key is removed and negative terminal cable
is disconnected from the battery.
As the airbag is equipped with a back up power source and due to the risk of airbag being inadvertently
deployed, wait one minute or longer before starting work.
0 Disconnecting the battery cancels the memory for clock, radio, seats, mirrors, steering column and any other
components using battery power. Reset memory after work is completed.
0 Never use airbags from other vehicles, always use new parts.
0 After work is completed, reconnect battery and perform warning light check see diagnostic manual.
0 Never use electrical probes to check voltage or electrical resistance.
0 Disconnect the airbag before carrying out any work on, or in the vicinity of module, or when using electric weld- ing equipment.
0 Always ensure that battery negative has been disconnected for one minute or longer before commencing any
removal procedure.
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Issue 1 August 1994 4 X300 VSM

Electrical
(continued from previous page)
. The vehicle is now to be scrapped in normal manner with module installed.
Fig.
1
. In the event of any problems or queries, contact Jaguar Cars Ltd. or the importer.
15.1.15 Scrapping Vehicles With Deployed Airbag@
0 Verify that all installed airbags have been deployed or removed.
0 In the event of one airbag being deployed and one not deployed, it must be assumed that the undeployed airbag
is still live, therefore it must first be deployed.
0 The vehicle is now to be scrapped in a normal manner.
15.1.16 Disposal of live Airbag Modules
W
€AUTIQN: Never use a customer's vehicle to deploy airbags.
Equipment required: Deployment Cage,
IDC link harness (see 15.1.14 for details of components required), Battery,
Safety Goggles to BS 2092 grade 2 or equivalent, Rubber Gloves to PREN 374 class 2 or equivalent, Ear Protectors to BS EN 24869 or equivalent, Particulate Respirator to EN 149 grade FFP 25 or equivalent.
The deployment procedure should be performed outdoors away from other personnel.
Remove any loose debris from around airbag and ensure no flammable liquids are present.
Assemble the disposal cabinet
as shown in Fig.1 in line with the following procedures:
. Remove mesh guard from rig frame.
Attach guard to frame by bolting hinges to the frame.
(continued next page)
Modules
removedlrenewed by
Jaguar Service are to be returned to the importer for deployment and disposal.
X#w) VSM Issue 1 August 1994 6

rl Electrical
15.12 RELAYS
15.12.1 €@ne Compartment Relays, General Description
05
04
03
02
Fig. 1 Engine Compartment Relays
In order to locate individual relays,
Fig.1, showing all relay locations within the engine compartment, is to be read in
conjunction with the following table. The numbers indicating the relays on the illustration correspond to the numbers
in the right
-hand column. To remove and refit individual relays, open the bonnet, locate the faulty relay, unplug and
renew.
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Body Systems Body Repair
A4.1 BODY REPAIR
Introduction
This section contains information, specifications and procedures for body repair and rectification of the Jaguar sedan
range (with standard wheelbase).
All repairs, whether structural or cosmetic, must ensure the continuance of the Paint Surface and Corrosion warranty,
where applicable.
Following repair or rectification, the vehicle must be returned to the original manufactured condition with regard to
occupant safety, dimensional accuracy, finish and corrosion protection.
Similarly, repaired vehicles must be fully checked, and where appropriate reset, with regard to steering, suspension,
restraint and
braking systems.
A4.1.1 Health and Safety
(Please Read The
Fol/owing Notes Carethlly)
Where legislation governing working conditions and practises is applicable, you should observe it. Do not forget that
you have a duty, to yourself and those around you, to act in a responsible manner in the workplace.
In the United Kingdom the Health and Safety
at Work Act (1974) places a duty on employers and employees to ensure,
whenever possible, safe working conditions and practices. Wherever a potential hazard is notified to, or identified by
the operator, he must employ the correct safety procedures and equipment.
Should
a personal injury occur as a result of any workshop activity, seek medical help as soon as possible and do not
attempt self-treatment other than by the application of first aid.
With the constant introduction of new materials in the manufacture of vehicles,
it is important that potential risks are
identified and precautions made known.
WARNING: READ AND UNDERSTAND WORKING PRACTICES CLIMATE CONTROL SYSTEMS, SECTION 14, WITH SPECIAL REFERENCE TO
ERY
/ RECYCLE / RECHARGE EQUIPMENT.
WEAR SUITABLE EYE AND SKIN PROTECTION.
OBSERVE ALL APPLICABLE SAFETY REQUIREMENTS.
DO
NOT VENT REFRIGERANT DIRECTLY TO ATMOSPHERE, ALWAYS USE JAGUAR APPROVED RECOV
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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 or service pro
- cedures are detailed.
All symbols will conform to standard
ANSl 2535.3 (Ameri- can National Standards Institute).
0 The surround shape of the symbol will indicate the
basis of the message to be conveyed (see top three el-
ements of Fig. l)
0 The icon depicting the message will be within the sur- rounding shape.
0 Once nominated the icon will retain its meaning. Hazard
A
Information
0
Jn-136
Flammable
Explosion
Poison
Eye protection
A ,774s
m-l*
A
m I.
Ear protection
@
@
Respiratory protection
(a i r-f ed 1
Respiratory protection
(self contained)
Hand protection
Extinguisher
Fia.
1 Svmbols
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Systems Repair Body & Body -
A4.1.3. POTENTIAL RISKS I
A4.1.3. Paint
Organic solvents, found in paints, may cause damage or severe irritation to liver, kidneys, digestive tracts and respira- tory system if inhaled over long periods of time.
Prolonged exposure to isocyanates may cause lung sensitization. Asthma
-like symptoms may develop with subse-
quent exposure to very low concentrations of isocyanates.
Solvent inhalation can cause dizziness or loss of consciousness.
Splashes of solvents, paint activators and additives can cause damage to the eyes and may cause dermatitis. Peroxide
and acid catalysts may cause burns.
Inhalation of
spray dust and sanding debris may cause lung damage.
I
A4.1.3.2 Applied Heat (Welding)
There is considerable risk of damage to eyes and skin when welding or flame cutting.
Fire is a serious danger and many materials or fluids within the vehicle are highly flammable.
Toxic and dangerous fumes may be liberated when any of the following are subjected to heat:
0 Expanded foam
0 Corrosion protection
0 Trim and seat materials
0 Paints which contain isocyanates
0 Adhesive and sealing compounds
When heated to a temperature of 3OO0C, polyurethane based compounds may liberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products; these chemicals can contain
isocyanates, oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases are produced by welding, for example; zinc oxide with zinc coated
panels, and ozone gas from the MIG process.
A4.1.3.3 Metal Repair
There is considerable risk of damage to eyes, ears and skin when metal cutting, forming, or dressing is being carried
out.
Soldering may be hazardous because of heat generated fumes and skin contact with the materials.
A4.1.4. PRECAUTIONS
A4.1.4.1 Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. En- sure that there is efficient ventilation / extraction at all times. Paint spraying should be confined as far as possible to
spray booths. Personnel with a history of asthma should not be engaged in any process which involves the use of
isocyanates. Any operator working inside
a spray booth where isocyanate material is present must use air-fed breath- ing equipment. Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water,
and fumes. Operators involved in handling mixing or spraying should wear protective clothing - gloves and goggles,
to avoid skin and eye contact.
A particle mask or canister type respirator should be worn when sanding.
A4.1.4.2 Applied Heat
When welding, flame cutting, brazing etc, the operator should use as appropriate, goggles, mask/fume extractor and
flameproof protective clothing. It is especially important when working with polyurethane compounds to use air-fed
breathing equipment.
Ensure that
at all times the appropriate fire fighting equipment is available and that personnel are trained in its use.
A4.1.4.3 Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding.
Operators should wear
a face mask or air-fed visor when sanding or flatting either body solder or fillers.
When
a soldering operation has been completed, swarf must be removed from the work area and the operator must
wash his hands thoroughly.
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Body Systems & Body Repair
A4.1.5 GENERAL REPAIR NOTES
The following advice should be noted before ANY repair work is carried out.
0 Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take
note of the reconnection procedures as detailed in Section 15.
0 Where structural parts are straightened or renewed, a body alignment / straightening jig must be used.
0 Where appropriate, structural sections should be straightened by cold processes. Heat, especially excessive
heat, will reduce the strength of steels.
0 Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts
and Jaguar approved materials are used.
0 Tools, procedures and facilities must be right for the job. Do not compromise the quality of the work by using
inappropriate methods.
0 All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal / replacement; this is especially important where hollow sections may contain harnesses, tubes or
foam, see section
A4.3.5.
0 The welding and gas processes detailed in the following sections are the only ones recommended by Jaguar
Cars Ltd.
0 Ensure that you have read and understood the safety related procedures in this and other relevant sections.
WARNING: DO NOT WORK
IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. READ WORKING PRAC- TICES AIR BAG, SECTION 15. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED. PLEASE SEE SECTION
AGE LOCATIONS. 13 FOR IMPORTANT INFORMATION REGARDING 'TEAR LOOP' SEAT BELTS / BUCKLES AND ANCHOR-
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high vottages produced by this process will cause irreparable damage to the electrical control and microprocessor systems.
A4.1.5.1 Welding and Gas Processes Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated,
metal.
The flanges of panels which are to be welded together must be clean, corrosion free and treated as appropriate,
with either weld-through primer or inter-weld sealer; use only materials and processes in accordance with the 'Body Seal-
ing and Preservation Manual' and relevant application areas in section A4.3.1.1.
See 'Zinc Coated Panels' section A4.2.
Generally, the resistance spot welding equipment used in the motor vehicle repair industry does not produce a weld
of equivalent strength to that of the manufacturer. Therefore, the expression 'single row of resistance spot welds'
means that the spots should be spaced on a pitch of
19mm to 25mm. This will usually result in more spot welds than
found in the original factory joint.
To remove resistance spot welds, a resistance spot weld cutter should be used.
If the new joint is to be MIG plug welded, the old resistance spot welds should be cut from the panel which is to be
retained and those holes used for plug welding.
Suitable holes may also be drilled or punched;
8,O mm dia for sections up to 1,6 mm, and 10,O mm dia for thicker sec- tions.
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X300 VSM Issue 1 August 1994 4