1994 JAGUAR XJ6 service

1. SERVICE TOOLS & EQUIPMENT
Illustration Jaguar Number Description Notes
not illustrated JD 188 Underscuttle pad securing SRO 76.46.1 1/90 and
not illustrated JD
202 Fascia center vent removal SRO 76.46.06
clip removal tool SRO 76.46.15190
tool
11. TORO U€ TIGHTEN1 NG SPEC1 FlCA TlONS
Fixing Tightening Torque (Nm) 1
Fascia I I
Instrument pack to support panel I 1.8 I
Fascia to support bracket
Fascia to console
3
Tunnel bracket to body
22 - 28
22
- 28
Bolster to tunnel bracket 1.5
Instrument pack to fascia
3.0
Strut to fascia 2.0
Fascia support strut to body 7 - 10
CPU bracket to fascia 5
-7
Fascia demister bracket to fascia
1.5
1 .o
1 .o
5-7
5
-7
Fascia
and air con. location to body
Air dist. box duct to air dist. box
Airbag carrier mounting bracket to fascia
Instrument pack support bracket to fascia
Airbag bracket to fascia
2.0
Air dist. box to fascia 2.0
Inst. pack support bracket to fascia 5-7
22 - 28 Fascia assembly to body
Airbag door brackets to fascia 5-7
4.0
4.0
Airbag door bracket to fascia and strut
Airbag door bracket to door frame assembly
Hood
Hood lock to body
Hood buffer assembly 7
-10
Gas strut - ball pin to weld nut
7 - 10
7
- 10
Hood lever 5
-7
Clamp
- hood adjust cable 6-8
Interior
Sun Visor fixings 1.8
Sunblind to parcel shelf
Sunblind bezel assembly
1 .o
Coat hook 3.0
Tighten to prevailing torque

Body Components & Trim -
Fixing
Seat belts
Front tear loop belt buckle to bracket fixing
Front belt buckle to bracket fixing
Tightening Torque (Nm)
30 - 40
30
- 40
Front belt reel bracket to body fixing
Front belt anchor fixing 30 - 40
30 - 40
7
-10
23
- 27
30
- 40
30 - 40
30
- 40
30 - 40
30
- 40
Front belt upper guide fixing
[Height adjuster to 'B' post screws
Height adjuster to seat belt anchor retaining
nut
Rear inertia belt anchor fixing
Rear inertia belt bracket to body fixing
Rear inertia belt reel securing bracket to body fixing
Rear inertia
/ static belt buckle bracket to body fixing ~
Rear
static belt / inertia buckle bracket to body fixing
: Sunroof ~
Sunroof frame
to roof
30 - 40
4
-5
111. SERVICE MATERIALS
Sunroof to frame 4-5
'Trunk
Compact disc autochanger bracket to body
I Battery clamp to tray
I Warning triangle lower bracket to trunk lid inner panel
9- 11
7
-10
1.5
X300 VSM V Issue 1 August 1994
I trunk lock barrel to lid
j Trunk latch actuator to bracket
Trunk latch actuator mounting to
lid
j Electrical carrier box to body
Load floor support block to body
Trunk seal retainer to body
trunk latch to lid and striker to body
4-5
7
-10
7
-10
7
-10
5
-7
9- 11
9- 11
Description Uses
'Fibrefresh' Carpet Shampoo
'1001' Foam Shampoo
'Novatreat' Cleaning
of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Notes
'Genklene' (Trichloroethane)
'Spot Remover' Cleaning
of grease or oil based
stains from carpets
Cleaning of grease or oil based
stains from
caroets

13.2.18 Fuel Filler Flap, Description
The fuel filler flap comprises a hinged flap attached to the body decking panel by two M5 nuts; the flap incorporates
a rubber buffer, snap
-in striker, hinge spring and the fuel cap stowage magnet. The rubber fuel bowl moulding is at- tached via a steel armature to the body reinforcement panel by five M5 nuts and is retained at the filler neck by a clip.
The mating drain tube is fitted with an internal filter.
The fuel filler flap latch mechanism attached
tothe fuel bowl armature bytwo M5 nuts, includes a locking pin and actua- tor which are both serviceable items. The latch actuator operates independently from the central locking system; it is
driven directly
by the security and locking control module. Locking of the fuel filler flap is achieved only by operation
of the key or by the remote rf transmitter.
13.2.19 Filler Flap and Hinge, Renew
. Disconnect vehicle battery ground lead.
With filler cap open, remove hinge securing screws, fuel
. To refit, carry out reversal of the above procedure.
filler cap
and remove flap and hinge assembly.
13.2.20 Filler Cap Retention Magnet, Renew
. With filler flap open, use a blunt flat bladed implement and
CAUTION: Take care not to damage paintwork.
. To refit, carry out reversal of the above procedure.
Disconnect
vehicle battery ground lead.
remove the magnet assembly.
13.2.21 Filler Flap latching Assembly, Renew
. Disconnect vehicle battery ground lead.
. Depress the latching assembly retaining nut and remove
CAUTION: Take care not to damage paintwork.
. To refit, carry out reversal of the above procedure.
the
assembly.
1. Hingedflap 2. Striker 3. Hinge spring 4. Stowage magnet 5. Fuelbowl
Fig. 1 Fuel Filler Flap
X300 VSM Issue 1 August 1994 8
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13.4 TRUNK
13.4.1 Trunk, Description
The trunk houses the spare wheel, the battery, an electrical carrier containing electrical fuses, relays and modules and
a compact disc auto-changer attached to body bracketry. The trunk is fitted with push-fit, velour finish, liners (1 Fig. 1) to the sides and front inner panel; the trunk floor is covered with carpet attached to a removable floor board (2 Fig. 1) and a battery cover (3 Fig. I), one covering the spare wheel and wheel changing equipment, the other covering the
battery and electrical carrier.
The floor board rests on the spare wheel, the front and rear edges
of the floor board locating in blocks on the fuel tank
backboard and on the rear of the body. The blocks accommodate the two possible height settings caused by the differ- ence in thickness between the space saver and full sized spare wheels.
A tread plate (4 Fig. 1) is attached to the trunk sill and a liner is fitted to the rear of the trunk below the sill. Interior trim finisher panels are fitted to the rear lamp units accessed from the trunk opening.
The trunk lid
(5 Fig. 1) is fitted with a removable moulded liner and two trunk illumination lights; the lid is supported by two gas struts, attached through press-on fittings between the inner wheel arch and trunk hinge (6 Fig. 1). A warning
triangle is attached by a bracket to the trunk lid and retained in the open position by a rubber block (Europe inc UK only).
Trunk locking is based on a central latch and striker, operated electrically through the central locking system
by an ad- jacent actuator or by key in a barrel lock located behind the trunk lid badge.
For details on renewal
of trunk front and side liners, trunk carpet, trunk seal retainer and battery cover, see relevant
Service Repair Operations.
2 4 3 J76-1056
1. Trunk Liners 2. Removable floor board 3. Battery cover
4. Treadplate 5. Trunk lid 6. Hinge
Fig.
1 Trunk Components and Trim
Issue 1 August 1994 X300 VSM 38

Body Components & Trim
la 'Fi brefresh'
Ib '1001 Foam Shampoo'
Ic 'Novatreat'
13.7.5 Carpet Cleaning and Stain Removal Materials
The carpet cleaning and stain removal materials listed in the table below must be used according to manufacturer's
instructions.
Servicemaster
308
Melton Road, Leicester LE4 7SL
(Tel. 0533 6107610)
P C Products
Swinton, Manchester
(Tel. 061 792 61
11)
British Nova Works
57
/ 61 Lea Road, Southall, Middx
(Tel. 081 574 6531)
Trichloroethane - 'Genklene'
'Spot Remover' ~
ICI
R.P.M. Marketing
(Sussex)
11 Chaucer Industrial Estate
Dittons Road, Polegate, East Sussex BN26 6JF
(Tel. 0424 21 1427)
13.7.6 Repair of Damaged Carpet
The most common cause of accidental damage to carpets is cigarette burns (especially to polypropylene carpet).
These can be repaired easily on new carpets by cutting out the face material in the affected area and replacing with new face material with a latex locking coat of approximately 100g/m2 dry then incorporating a P.S.A.B. (pressure sensi- tive adhesive backing) which would be applied to roll carpet in the form of a laminate film at Firth Furnishings subsidi- ary Textile Bonding, Higham Ferrers, Northampton, UK.
The
film has a peelable release paper, which means that the new material would simply be cut to size, the release paper
removed and then the new carpet pressed into position.
The problem
in replacing areas in old or soiled carpets is that the replacement of damaged areas with new carpet would
create a visual difference, ie un-worn pile, clean appearance, which would then cause the repaired area to stand out
from the rest of the carpet. The only answer would be to abrade the rest of the new carpet to the same degree as the
old carpet.
3a
UK
3b Continental Europe
3c UK
3d Continental Europe
X300 VSM 47 Issue 1 August 1994
SEBO (UK) Ltd.
Baker Street, High Wycombe,
HPll 2RX
(Tel. 0494 534801)
Stain
& Co. GmbH
Wulfrather Strasse 49 - 49,
D
-5620 Velbert
Germany
HOST
(UK)
Unit 1, Ranch House,
Normanton Lane, Bottesford, Nottingham NG 13
OEL (Tel. 0949 43372)
Mr Alex de Roeper
Sanfresh BV
Dotterbloemstraat 1,
3053 JV Rotterdam, Holland
(Tel. 31
10 422 5455)

Climate Control Systems
Description U-
HFC 134A - ICI Klea or
equivalent
Polyalkyleneglycol (PAG) Compressor lubricant
Refrigerant
111.
Notes
Recyclable. NOT
compatible
with CFC 12
Absorbs water readily. NOT
compatible with mineral based
oils
SERVICE MATERIALS
Standard for Recovery I Recycle 1 Recharge Equipment.
Recovery rate
Cleaning capability
Oil separator
.Moisture indicator
Vacuum pump
Filter Replaceable with moisture indicator
Charge Hoses
Feature Requirement
0,014 - 0,062 m3 / min. (1,36 kg in 20 minutes)
15 parts per million (ppm) moisture; 4000 ppm oil; 330 ppm non condensable gases
in air
With hermetic compressor and automatic oil return
Sight glass type, sensitive to 15 ppm minimum
2 stage 0,07 - 0,127 m3 I min.
Selectable charge weight and automatic delivery
Dedicated HFC 134A port connections.
Iv. SERVICE DATA
Application
Charae weight
Lubricant capacity
Compressor pressure relief valve
Drive belt 12 cylinder
Drive belt tension
All figures apply to a cold belt
Special note
Drive belt tension measuring point
Drive belt 6 cyclinder
Drive belt tension
All figures apply to a cold belt
Drive belt tension measuring point
Specification
160 - 200 ml
Opening point 34 Bar. Closing point 27,6 Bar.
Maximum leakage rate of 113 liters 1 minute @ 41 Bar
7 rib Poly
-vee; 1450 mm long
Burroughs method
- New belt 790 N; If tension falls
below 270 N reset at 630 N
Clavis method
- New belt 114 to 120 Hz; If tension falls
below 70 Hz reset at 87 to 93 Hz
For new belt; rotate engine 3 revolutions minimum and
retension
Mid-way between crankshaft and compressor pulley ~
4
rib Poly-vee X 1010 mm long
Burroughs method
- New belt 556 to 578 N; If tension
falls below 245 N reset at 378 to 400
N
Clavis method - New belt 167 to 173 Hz; If tension falls
below 85 Hz reset at 127 to 133 Hz
Mid
-way between crankshaft and compressor pulley on
the upper run
1 Charge pressure I Heating element to increase pressure
Issue 1 August 1994 X300 VSM iii

Climate Control Systems
14.1 WORKING PRACTICES
14.1.1 General
o Be aware of, and comply with all health and safety requirements, whether they be legislative or common sense.
This applies to conditions set both for the operator and workshop.
o Before commencing any repair or service procedure, disconnect the vehicle battery ground connection and
protect the vehicle where appropriate, from dirt or damage.
0 Work in a well ventilated, clean and tidy area (Fig. 1).
0 Keep all components and tools clean.
0 Recovery / Recycle and Recharge equipment must comply with, or exceed the standard detailed in the
preliminary pages.
Fig.
1
14.1.2 Handling Refrigerant
0 Wear eye protection at all times. Use gloves, keep skin that may come into contact with HFC 134A covered.
Should refrigerant come into contact with your eyes or skin; wash the affected area with cool water and seek
medical advice, do not attempt to treat yourself.
o Avoid breathing refrigerant vapour, it may cause ir- ritation to your respiratory system.
0 Never use high pressure compressed air to flush out
a system. Under certain circumstances HFC 134A +
compressed air + a source of combustion (welding
and brazing operations in the vicinity), may result in
an explosion and the release
of potentiallytoxiccom-
pounds.
0 HFC 134A and CFC 12 must never come into contact
with each other (Fig. 21, they will form an inseparable
mixture which can only be disposed of by inciner
-
ation.
0 Do not vent refrigerant directly to atmosphere, al- ways use Jaguar approved recovery equipment. Re-
member, HFC 134A is costly but recycleable.
continued
1 Issue 1 August 1994 X300 VSM

Climate Control Systems
lnsufficent Cooling
0 Sluggish blower motor(s).
0 Restricted blower inlet or outlet passage
0 Blocked or partially restricted condenser matrix or fins.
0 Blocked or partially restricted evaporator matrix.
0 Blocked or partially restricted filter in the receiver drier.
0 Blocked or partially restricted expansion valve.
0 Partially collapsed flexible pipe.
0 Expansion valve temperature sensor faulty (this sensor is integral with valve and is not serviceable).
0 Excessive moisture in the system.
0 Air in the system.
0 Low refrigerant charge - possible code 23.
0 Compressor clutch slipping.
0 Blower flaps or distribution vents closed or partially seized - possible codes 41 or 46.
0 Coolant flow valve not closed.
0 Evaporator sensor incorrectly positioned
m: Should a leakor low refrigerant be established as the cause of /NSUff/C/€NTCOOL/NG,followthe procedures
Recovery / Recycle / Recharge, this section, and observe all refrigerant and oil handling instructions.
lntermiffent Cooling
0 Is the electrical circuit to the compressor clutch consistent?
0 Is the electrical circuit to the blower motor(s) consistent?
0 Compressor clutch slipping?
0 Motorized in-car aspirator or evaporator temperature sensor faulty, causing temperature variations - possible
codes 11 or 13.
0 Blocked or partially restricted evaporator or condenser.
Noisy System
0 Loose or damaged compressor drive belt.
0 Loose or damaged compressor mountings.
0 Compressor oil level low, look for evidence of leakage.
0 Compressor damage caused by low oil level or internal debris.
0 Blower motor(s) noisy.
0 Excessive refrigerant charge, witnessed by vibration and 'thumping' in the high pressure line (may be indicated
by high HIGH & high LOW side pressures).
0 Low refrigerant charge causing 'hissing' at the expansion valve (may be indicated by low HIGH side pressure).
0 Excessive moisture in the system causing expansion valve noise.
0 Air-lock in water pump*.
lnsufficent Heating
0 Coolant flow valve stuck in the closed position.
0 Motorized in-car aspirator seized.
0 Cool air by-pass damper stuck or seized - possible code 43.
0 Blocked or restricted blower inlet or outlet.
0 Low coolant level.
0 Blower fan speed low.
0 Coolant thermostat faulty or seized open.
0 Water pump inoperative or blocked
0 Air-lock in matrix*.
m: * Please see Sections 4.1 and 4.2 for specific coolant fill / bleed procedures.
Electrical faults may be more rapidly traced using
(JDE), please refer to the (EDM).
Issue 1 August 1994 16 X300 VSM