1994 JAGUAR XJ6 air suspension

10.4.3 Diagnostic chart 2
0 Trouble
'lay at steering wheel
ieavy when stationary
Excessively heavy when
hiving, stationary effort
3K
Too easy when driving,
itationary effort OK
fffort not equal side to
;ide from center
dariation from heavy to
?asy when driving
:yclic load variation at steering wheel - 2 per
.evolution
:losely spaced cyclic
oad variation at steering
Nheel
Cause
Rack damper loose
Pinion bearing loose
Worn intermediate shaft joint
Worn suspension joint
Loose lower column 'pinch' bolt
Transducer not closed
Transducer not closed
- ground short
Transducer not closed
- no feed voltage
Transducer not closed
- defective cable
SCM defective
Delivery pressure or flow too low
Internal rack leakage
tire pressures low
Transducer open too early
Transducer open too early, incorrect SCM
h/Pe
Transducer open too early, incorrect
speedometer signal
Rack 'reaction limitation valve' CLOSED
or setting incorrect
Transducer not open (no oil flow)
Transducer not open, SCM faulty
Transducer not open, incorrect speedom
-
eter signal
Rack 'reaction limiting valve' OPEN or
setting incorrect
Low pressure pipe 'flattened' or re
-
stricted
Blocked reservoir filter
tire pressure high
Rack check valve leak
Rotary valve blockage Incorrect lower column assembly, see
'Cyclic load variations'
Incorrect speedometer signal
Transducer cable
/ connection faulty or
grounded
Lower column universal joint fitting error
Rack damper too tight
Remedy
Renew rack
Renew rack
Renew joint
Renew joint
Tighten to specification
Inspect and check for debris
Renew transducer*
Investigate and repair
Renew cable
Renew module*
Renew pump
Renew rack
Set to specification
Renew transducer*
Renew
SCM*
Renew speedometer transmitter*
Renew rack
Inspect and check for debris
Renew
SCM*
Renew speedometer transmitter*
Renew rack
Renew pipe
Renew filter
Set to specification
Renew rack
Renew rack
Rectify as required
Renew speedometer transmitter*
Investigate and repair
Verify that the lower column assembly is
correct for that drive.
RH and LH assem- blies MUST NOT be interchanged due to
joint phase differences
Renew rack
W: Items marked * should be validated using EDM test procedures.
X300 VSM 7 Issue 1 August 1994

Suspension Systems
11.4.3 Front End Inspection
Do not check and adjust front wheel alignment without carrying out the following inspection for front end damage and
wear:
. Check for specified air pressure in all four tires.
Raise front of vehicle off the floor; grasping upper and lower surface of the tire, shake each front wheel to check for
. Check front suspension lower arm ball joint and mounts for looseness, wear and damage.
Check steering gear mountings and all steering linkages for looseness.
. Renew parts if necessary.
. Grasp upper and lower surface of tire and shake each wheel to check wheel bearing end play.
. Check the action of the front dampers and the condition of their attachments, as sticking or binding front dampers
worn
bearings.
Check brake caliper mountings.
may not allow the vehicle to settle in to a normal level position, possibly affecting the front-wheel alignment.
m: Front wheel bearings are adjustable (0.001 to 0.003 in. endfloat).
11.4.4
. Check the wheel bearings.
. Inspect the front suspension upper joint and renew front suspension lower wishbone if needed.
Raise vehicle and position floor jacks beneath the front suspension lower wishbone.
Grasp the lower edge of the tire and move the wheel in and out.
While moving the wheel, observe the upper and lower wishbone.
. Movement between the vertical links and the wishbones indicates abnormal ball joint wear.
. Renew ball joints.
. Check the front wheel bearings.
. Check for excessive play and wear.
Upper / Lower Ball Joint Inspection
11.4.5 Damper Inspection
m: The gas-pressurized hydraulic front dampers are not serviceable, adjustable or refillable.
Verify that all attachments of the suspension components and the front dampers are tight. Renew any front damper
. Check front dampers for external damage.
. Check for oil leakage and vehicle sag.
that
has a damaged integral lower mounting bushing.
0 Oil Leak
Leakage is the condition in which the entire damper body is covered with oil and from where
it will drip on to
the pavement. Due to correct damper lubrication a light film of oil (weepage) can usually be seen on the upper
portion of the damper.
Should there be any leakage, ensure that the fluid does not originate from sources other than the front damper.
Renew worn or damaged dampers.
0 Vehicle Sag
Renewing front dampers will not correct the problem of vehicle sag, as basically this is controlled by the spring
units.
issue 1 August 1994 4 X300 VSM

Suspension Systems
1 1.4.8 Diagnostic Procedure
Condition
Hard steering
Shimmy
I----
Bump steer (unequal
side-to-side)
Sawtooth pattern or
t excessive tire wear
Uneven tire wear
(outer or inner
shoulder)
Fronvrear
suspension noises
Possible Cause
Side-to-side difference in caster.
Tire pressure Steering gear or linkage worn or defective.
Tire
conicity
Power steering gear or linkage worn,
damaged, or incorrect adjusted.
Wear of front suspension
lower/upper
wishbone ball joints.
Unequal tire pressure.
Brake system
fault(s)
Wheel/tire imbalance or runout.
Damaged tires, unbalanced or damaged
wheels.
Incorrect wheel alignment.
Steering system malfunction
Front damper malfunction.
Loose front damper mounting.
Damaged front suspension upper
or lower
ball joints.
Damaged or worn sub
-frame to body
mounting. Damaged or worn stabilizer bar insulators.
Damaged or worn stabilizer bar link.
Damaaed or worn wheel bearina.
Rear suspension damage.
Worn steering gear mounting bracket
housing insulators.
Excessive toe
-in (high edges inboard) or
toe-out (high edges outboard).
Incorrect tire pressure.
Excessive toe.
Excessive positive or negative camber.
Loose/missing front dampers and front
damper bolt to front suspension lower
wish bone.
Action
Check the alignment and if incorrect,
adjust the caster
if needed. Inspect
components for wear or damage.
Check for abnormal loading.
Check steering system
Inspect tire for excessive wear.
Check and adjust the tire air pressure.
Note: Excessively worn or uneven tires can
cause
pull/drift.
Check steering system.
Renew ball joints.
Inflate the tires to correct and uniform
pressure.
Check the brakes.
Check wheels and tires.
Check the tires and renew
if necessary.
Balance the wheels
if necessary.
Adjust wheel alignment.
Check steering system.
Renew front damper
if necessary.
Tighten front damper mounting.
-
Renew upper and lower ball joint.
Renew rear suspension bushing.
Renew insulators.
Renew link.
Renew/adjust wheel bearing.
If the caster is uniform, check and compare
the wheelbase at the right and left sides.
If
different, inspect the suspension
components for wear and damage.
Renew bracket housing insulators.
Check and adjust toe
-in.
Correct tire pressure.
Check toe and adjust
if needed.
Check the camber and
if incorrect inspect
the related components for wear or
damage.
Tighten/renew damper bolts.
Inspect wheel hubs.
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lssue 1 August 1994 6 X300 VSM

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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
-
Issue 1 August 1994 1 X300 VSM

Body Systems & Body Repair
Location
Centre line of the front crossmember rear mounting, at the
main floor
RH longitudinal
A4.2.2.1 Datum location, Example
The FRONT MASTER DATUM (front crossmember rear mounting at the inner face ofthe main floor RH longitudi- nal) is nominally 359,5mm to the right-hand side of the body center line. The LH side front datum is measured 717,0/ 721,Omm from the RH. Please refer to the illustration on the following page.
Expressed as
a true position in three planes, the front master datum is:
Position
X 300,O
Y 359.5 Z -50.0
0
Datum
Front Master Datum
Plan
A4.2.2.2 Key, Plan View
Please refer to the illustration on the opposite page.
Key Location
1
2
3
4
5 Driveshaft centre bearing fixings
6
7
8
9
10 Front
face body
- bumper strut / mounting point
Rearmost hole, Vee
-mount to crush tube
Front Master Datum Plan, centre line
of the front crossmember rear mounting at the main floor RH longi-
tudinal
Rearmost hole, transmission mounting
at the main floor RH longitudinal
Rear Master Datum Plan, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear suspension differential strut mounting
Rear face body
- bumper strut / mounting point
X300 VSM Issue 1 August 1994 10

E 12
Rear face bodv - bumDer strut / mountina Doint
Body Systems
I
& Body
side vww
the illustration on the opposite page.
Repair
Location
Front face body - bumper strut / mounting point
Front Master Datum Vertical. centre line of the front crossmember rear mountina
Front
face body - bumper strut / mounting point
Front Master Datum Vertical, centre line of the front crossmember rear mounting
Transmission mountings
at the main floor longitudinal
Driveshaft centre bearing fixings
Rear Master Datum
Vertical, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear suspension differential strut mounting
Rear face body
- bumper strut / mounting point
Transmission
mountings
at the main floor longitudinal
Driveshaft centre bearing fixings
Rear Master Datum
Vertical, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear
susoension differential strut mounting
Wheel centre to
bummr cover face I
Wheel base I
Wheel centre to bumper cover face
Body Systems & Body Repair
A4.2.2.3 Key, Side Vww
Please refer to the illustration on the opposite page.
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X300 VSM Issue 1 August 1994 12

Body Systems & Body Repair
A4.2.4 PANELS - ASSOCIATED, RENEW
SRO 77.10.02
w: Where other components must be removed to gain access, please referto the relevant manual section for guid- ance. This is critically important with regard to steering, braking, suspension, electrical and safety systems.
. Expose the resistance spot welds, for those spot welds which are not obviously visible, use a rotary wire brush fitted to an air drill or a hand held wire brush (A Fig. 1).
WARM: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
. Cut out the spot welds using a Zipcutter or Roto-Bor (B Fig. 1).
Jhh: On some panels, before removing the bulk of panel with the pneumatic saw, brazed areas and MIG welded
seams should be removed.
= Separate the spot welded joints and remove the panel remnants.
At
this point
it may be necessary to cut out the bulk of the panel using a pneumatic saw (C Fig. 1).
A
C
Fia. 1
B
II I
II I
15 Issue 1 August 1994 X300 VSM