1997 JAGUAR XJ6 air condition

being drawn back into the master cylinder.
Wait several seconds for brake fluid to be
drawn from the reservoir into the piston bore,
then depress the piston again, removing your
finger as brake fluid is expelled. Be sure to put
your finger back over the hole each time
before releasing the piston, and when the
bleeding procedure is complete for that outlet,
renew the plug and snug it up before going on
to the other port.
Refitting
16Refit the master cylinder over the studs on
the brake servo and tighten the mounting nuts
only finger tight at this time.
17Thread the brake line fittings into the
master cylinder. Since the master cylinder is
still a bit loose, it can be moved slightly to
allow the fitting threads to start easily. Do not
strip the threads as the fittings are tightened.
18Tighten the brake fittings securely and the
mounting nuts to the torque listed in this
Chapter’s Specifications.
19Fill the master cylinder reservoir with fluid,
then bleed the master cylinder and the brake
system (see Section 9).
20To bleed the master cylinder on the
vehicle, have an assistant pump the brake
pedal several times and then hold the pedal to
the floor. Loosen the fitting nut to allow air and
fluid to escape, then tighten the nut. Repeat
this procedure on both fittings until the fluid is
clear of air bubbles. Test the operation of the
brake system carefully before placing the
vehicle into service.
7 Brake servo-
general information,
removal and refitting
2
General information
1A hydraulic brake servo system assists
braking when the brake pedal is depressed.
The booster unit, located between the brake
pedal box and the master cylinder, is operated
by hydraulic pressure generated by an engine-
driven pump (on early models) or by an electric
pump (on later models). When the engine isrunning, the pump supplies hydraulic pressure
to an accumulator. The accumulator stores and
regulates the pressure to the hydraulic brake
servo. When you depress the brake pedal, the
pressure in the booster helps actuate the
master cylinder, reducing pedal effort.
2The hydraulic brake servo isn’t rebuildable;
if it fails, it must be replaced. Basic operation
can be checked (see Chapter 1, Section 15),
but in-depth testing of the system requires
special tools, so diagnosis is beyond the
scope of the home mechanic. If the system
fails, take it to a dealer service department or
other qualified repair workshop for repairs.
However, if the unit must be replaced, you
can do it yourself as follows.
Removal and refitting
3With the engine off, discharge the hydraulic
accumulator by depressing the brake pedal
several times until it feels hard to depress.
4Remove the master cylinder (see Section 6).
5Clean the area around the return and
supply tube nuts, then disconnect them with a
flare-nut spanner (see illustration). Plug the
lines to prevent dirt from entering the system.
Caution: Even a particle of dirt can damage
the servo system, so be extremely careful
to prevent dirt from entering the system
while the lines are disconnected.
6To disconnect the brake servo pushrod
from the brake pedal, remove the access
plugs from both sides of the pedal box (see
illustration), remove the clevis pin retaining
clip and drive out the clevis pin.
7Remove the four mounting nuts and
remove the brake servo (see illustration).
8Refitting is the reverse of removal. Tighten
the hydraulic line fittings securely.
9When you’re done, adjust the brake light
switch (see Section 13).
8 Brake hoses and lines-
inspection and renewal
4
Inspection
1About every six months, with the vehicleraised and placed securely on axle stands, the
flexible hoses which connect the steel brake
lines with the front and rear brake assemblies
should be inspected for cracks, chafing of the
outer cover, leaks, blisters and other damage.
These are important and vulnerable parts of
the brake system and inspection should be
complete. A light and mirror will prove helpful
for a thorough check. If a hose exhibits any of
the above conditions, renew it with a new one.
Flexible hose renewal
2Clean all dirt away from the ends of the
hose.
3To disconnect the hose at the frame end,
use a second spanner on the hex-shaped
fitting on the end of the flexible hose and
loosen the nut on the metal brake line (see
illustrations). If the nut is stuck, soak it with
penetrating oil. After the hose is disconnected
from the metal line, remove the nut right
above the bracket and detach the hose from
the bracket.
4To detach the flexible hose from the caliper,
simply unscrew it.
5Refitting is the reverse of the removal
procedure. Make sure the brackets are in
good condition and the locknuts are tightened
securely.
Braking system 9•9
9
7.5 Use a flare-nut spanner to loosen the
fittings, then pull the lines back from the
brake servo and plug them to prevent
contamination7.6 Pry off the two rubber caps from the
pedal box7.7 To detach the brake servo from the
pedal box, remove these four nuts
(arrowed) (lower right nut not visible
in this photo)
8.3a To remove a front flexible brake hose
from a metal brake line, use one spanner
to hold the hose fitting just below the
bracket (lower spanner), then break loose
the nut on the metal line (upper spanner);
to disconnect the flex hose from the
bracket, remove the centre nut (arrowed)
just above the bracket
3261 Jaguar XJ6

3261 Jaguar XJ6
11
Chapter 11
Bodywork and fittings
Body - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Body repair - major damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Body repair - minor damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . 10
Bonnet and boot lid support struts - removal and refitting . . . . . . . . 9
Bonnet release latch and cable - removal and refitting . . . . . . . . . . . 11
Boot lid - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . 16
Boot lid latch and lock cylinder - removal and refitting . . . . . . . . . . . 17
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 24
Cowl cover - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dashboard trim panels - removal and refitting . . . . . . . . . . . . . . . . . 26
Door - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . 19
Door latch, lock cylinder and handles - removal and refitting . . . . . . 20
Door trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 18Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . . 22
Door window glass regulator - removal and refitting . . . . . . . . . . . . . 21
Front spoiler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front wing - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hinges and locks - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instrument cluster housing - removal and refitting . . . . . . . . . . . . . . 25
Outside mirrors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 23
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Seats - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Steering column cover - removal and refitting . . . . . . . . . . . . . . . . . 27
Upholstery and carpets - maintenance . . . . . . . . . . . . . . . . . . . . . . . 4
Vinyl trim - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windscreen and fixed glass - replacement . . . . . . . . . . . . . . . . . . . . 8
11•1
Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
1 General information
These models feature a “unibody”
construction, using a floor pan with front and
rear frame side rails which support the body
components, front and rear suspension
systems and other mechanical components.
Certain components are particularly vulnerable
to accident damage and can be unbolted and
repaired or replaced. Among these parts are
the body mouldings, bumpers, front wings,
bonnet and boot lids and all glass.
Only general body maintenance practices
and body panel repair procedures within the
scope of the do-it-yourselfer are included in
this Chapter.
2 Body- maintenance
1
1The condition of your vehicle’s body is very
important, because the resale value depends
a great deal on it. It’s much more difficult to
repair a neglected or damaged body than it is
to repair mechanical components. The hidden
areas of the body, such as the wheel wells,
the frame and the engine compartment, areequally important, although they don’t require
as frequent attention as the rest of the body.
2Once a year, or every 12,000 miles, it’s a
good idea to have the underside of the body
steam cleaned. All traces of dirt and oil will be
removed and the area can then be inspected
carefully for rust, damaged brake lines, frayed
electrical wires, damaged cables and other
problems. The front suspension components
should be greased after completion of this job.
3At the same time, clean the engine and the
engine compartment with a steam cleaner or
water soluble degreaser.
4The wheel wells should be given close
attention, since undercoating can peel away
and stones and dirt thrown up by the tyres
can cause the paint to chip and flake, allowing
rust to set in. If rust is found, clean down to
the bare metal and apply an anti-rust paint.
5The body should be washed about once a
week. Wet the vehicle thoroughly to soften the
dirt, then wash it down with a soft sponge and
plenty of clean soapy water. If the surplus dirt
is not washed off very carefully, it can wear
down the paint.
6Spots of tar or asphalt thrown up from the
road should be removed with a cloth soaked
in solvent.
7Once every six months, wax the body and
chrome trim. If a chrome cleaner is used to
remove rust from any of the vehicle’s plated
parts, remember that the cleaner also removes
part of the chrome, so use it sparingly.
3 Vinyl trim- maintenance
1
Don’t clean vinyl trim with detergents,
caustic soap or petroleum-based cleaners.
Plain soap and water works just fine, with a
soft brush to clean dirt that may be ingrained.
Wash the vinyl as frequently as the rest of the
vehicle.
After cleaning, application of a high quality
rubber and vinyl protectant will help prevent
oxidation and cracks. The protectant can also
be applied to weather-stripping, vacuum lines
and rubber hoses (which often fail as a result
of chemical degradation) and to the tyres.
4 Upholstery and carpets-
maintenance
1
1Every three months remove the carpets or
mats and clean the interior of the vehicle
(more frequently if necessary). Vacuum the
upholstery and carpets to remove loose dirt
and dust.
2Leather upholstery requires special care.
Stains should be removed with warm water
and a very mild soap solution. Use a clean,
damp cloth to remove the soap, then wipe

again with a dry cloth. Never use alcohol,
petrol, nail polish remover or thinner to clean
leather upholstery.
3After cleaning, regularly treat leather
upholstery with a leather wax. Never use car
wax on leather upholstery.
4In areas where the interior of the vehicle is
subject to bright sunlight, cover leather seats
with a sheet if the vehicle is to be left out for
any length of time.
5 Body repair- minor damage
3
Repair of minor scratches
1If the scratch is superficial and does not
penetrate to the metal of the body, repair is
very simple. Lightly rub the scratched area
with a fine rubbing compound to remove
loose paint and built-up wax. Rinse the area
with clean water.
2Apply touch-up paint to the scratch, using a
small brush. Continue to apply thin layers of
paint until the surface of the paint in the
scratch is level with the surrounding paint.
Allow the new paint at least two weeks to
harden, then blend it into the surrounding
paint by rubbing with a very fine rubbing
compound. Finally, apply a coat of wax to the
scratch area.
3If the scratch has penetrated the paint and
exposed the metal of the body, causing the
metal to rust, a different repair technique is
required. Remove all loose rust from the
bottom of the scratch with a pocket knife,
then apply rust inhibiting paint to prevent the
formation of rust in the future. Using a rubber
or nylon applicator, coat the scratched area
with glaze-type filler. If required, the filler can
be mixed with thinner to provide a very thin
paste, which is ideal for filling narrow
scratches. Before the glaze filler in the scratch
hardens, wrap a piece of smooth cotton cloth
around the tip of a finger. Dip the cloth in
thinner and then quickly wipe it along the
surface of the scratch. This will ensure that
the surface of the filler is slightly hollow. The
scratch can now be painted over as described
earlier in this section.
Repair of dents
4When repairing dents, the first job is to pull
the dent out until the affected area is as close
as possible to its original shape. There is no
point in trying to restore the original shape
completely as the metal in the damaged area
will have stretched on impact and cannot be
restored to its original contours. It is better to
bring the level of the dent up to a point which
is about 1/8-inch below the level of the
surrounding metal. In cases where the dent is
very shallow, it is not worth trying to pull it out
at all.
5If the back side of the dent is accessible, it
can be hammered out gently from behindusing a soft-face hammer. While doing this,
hold a block of wood firmly against the
opposite side of the metal to absorb the
hammer blows and prevent the metal from
being stretched.
6If the dent is in a section of the body which
has double layers, or some other factor makes
it inaccessible from behind, a different
technique is required. Drill several small holes
through the metal inside the damaged area,
particularly in the deeper sections. Screw
long, self-tapping screws into the holes just
enough for them to get a good grip in the
metal. Now the dent can be pulled out by
pulling on the protruding heads of the screws
with locking pliers.
7The next stage of repair is the removal of
paint from the damaged area and from an
inch or so of the surrounding metal. This is
done with a wire brush or sanding disc in a
drill motor, although it can be done just as
effectively by hand with sandpaper. To
complete the preparation for filling, score the
surface of the bare metal with a screwdriver or
the tang of a file, or drill small holes in the
affected area. This will provide a good grip
for the filler material. To complete the repair,
see the subsection on filling and painting later
in this Section.
Repair of rust holes or gashes
8Remove all paint from the affected area and
from an inch or so of the surrounding metal
using a sanding disc or wire brush mounted in
a drill motor. If these are not available, a few
sheets of sandpaper will do the job just as
effectively.
9With the paint removed, you will be able to
determine the severity of the corrosion and
decide whether to replace the whole panel, if
possible, or repair the affected area. New
body panels are not as expensive as most
people think and it is often quicker to refit a
new panel than to repair large areas of rust.
10Remove all trim pieces from the affected
area except those which will act as a guide to
the original shape of the damaged body, such
as headlight shells, etc. Using metal snips or a
hacksaw blade, remove all loose metal and
any other metal that is badly affected by rust.
Hammer the edges of the hole in to create a
slight depression for the filler material.
11Wire brush the affected area to remove
the powdery rust from the surface of the
metal. If the back of the rusted area is
accessible, treat it with rust inhibiting paint.
12Before filling is done, block the hole in
some way. This can be done with sheet metal
riveted or screwed into place, or by stuffing
the hole with wire mesh.
13Once the hole is blocked off, the affected
area can be filled and painted. See the
following subsection on filling and painting.
Filling and painting
14Many types of body fillers are available,
but generally speaking, body repair kits which
contain filler paste and a tube of resinhardener are best for this type of repair work.
A wide, flexible plastic or nylon applicator will
be necessary for imparting a smooth and
contoured finish to the surface of the filler
material. Mix up a small amount of filler on a
clean piece of wood or cardboard (use the
hardener sparingly). Follow the
manufacturer’s instructions on the package,
otherwise the filler will set incorrectly.
15Using the applicator, apply the filler paste
to the prepared area. Draw the applicator
across the surface of the filler to achieve the
desired contour and to level the filler surface.
As soon as a contour that approximates the
original one is achieved, stop working the
paste. If you continue, the paste will begin to
stick to the applicator. Continue to add thin
layers of paste at 20-minute intervals until the
level of the filler is just above the surrounding
metal.
16Once the filler has hardened, the excess
can be removed with a body file. From then
on, progressively finer grades of sandpaper
should be used, starting with a 180-grit paper
and finishing with 600-grit wet-or-dry paper.
Always wrap the sandpaper around a flat
rubber or wooden block, otherwise the
surface of the filler will not be completely flat.
During the sanding of the filler surface, the
wet-or-dry paper should be periodically rinsed
in water. This will ensure that a very smooth
finish is produced in the final stage.
17At this point, the repair area should be
surrounded by a ring of bare metal, which in
turn should be encircled by the finely
feathered edge of good paint. Rinse the repair
area with clean water until all of the dust
produced by the sanding operation is gone.
18Spray the entire area with a light coat of
primer. This will reveal any imperfections in
the surface of the filler. Repair the
imperfections with fresh filler paste or glaze
filler and once more smooth the surface with
sandpaper. Repeat this spray-and-repair
procedure until you are satisfied that the
surface of the filler and the feathered edge of
the paint are perfect. Rinse the area with
clean water and allow it to dry completely.
19The repair area is now ready for painting.
Spray painting must be carried out in a warm,
dry, windless and dust free atmosphere.
These conditions can be created if you have
access to a large indoor work area, but if you
are forced to work in the open, you will have
to pick the day very carefully. If you are
working indoors, dousing the floor in the work
area with water will help settle the dust which
would otherwise be in the air. If the repair area
is confined to one body panel, mask off the
surrounding panels. This will help minimise
the effects of a slight mismatch in paint
colour. Trim pieces such as chrome strips,
door handles, etc., will also need to be
masked off or removed. Use masking tape
and several thickness of newspaper for the
masking operations.
20Before spraying, shake the paint can
thoroughly, then spray a test area until the
11•2 Bodywork and fittings
3261 Jaguar XJ6

selector towards the rear of the vehicle. Pull
up on the rear half of the radio trim bezel while
gently detaching the clips securing the front,
then remove the bezel from the vehicle.
6Remove the radio and heater control
assembly (see Chapter 12).
7Remove the dashboard centre trim panel
(see Section 26), then remove the centre air
conditioning duct from the vehicle (see
illustration).
8Remove the retaining screws located in the
air conditioning duct opening (see illustration).
9Remove the plastic screws securing the
lower front section of the console (see
illustration).
10Unplug any electrical connectors that will
interfere with the removal of the console.
11Pull the console towards the rear of the
vehicle, then lift the console up over the shift
lever and remove it from the vehicle.
12Refitting is the reverse of removal.
Overhead console
13Remove the plastic screw securing the
overhead console, then carefully pull the
console out of the headliner (see illustration).
14Disconnect the electrical connectors from
the lights.
15Refitting is the reverse of removal.
25 Instrument cluster housing-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering column or instrument panel.
The manufacturer recommends that, on
airbag equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.
1Disconnect the negative battery cable. Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Remove the drivers side knee bolster (see
Section 26).
3Place the steering wheel in the full rearward
position. If the vehicle is equipped with a tilt
column, place the steering wheel in the lowest
position.
4Remove the instrument cluster housing
screws (see illustration).
5Pull the instrument cluster housing outward
to access the electrical connections on the
backside (see illustration).
6Disconnect all electrical connections from
the backside of the cluster housing and
remove the housing from the vehicle.
7Refitting is the reverse of removal.
11•12 Bodywork and fittings
24.3b Pull the ash tray towards the rear of
the vehicle to remove it - don’t pull it
straight up24.4 Working through the ash tray opening,
remove the radio trim bezel wingnuts
(arrowed) located under the trim bezel24.7 After removing the centre trim panel,
detach the air conditioning duct
24.8 Remove the retaining screws in the
air conditioning duct opening24.9 Remove the plastic screws (arrowed)
from each side of the console24.13 Remove the plastic screw, then pull
the overhead console down and unplug
the electrical connectors
3261 Jaguar XJ6
25.4 Working in the knee bolster opening,
remove two retaining screws from each
end of the instrument cluster housing25.5 Pull outward on the instrument
cluster housing and unplug the electrical
connectors from the backside

26 Dashboard trim panels-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering column or instrument panel.
The manufacturer recommends that, on
airbag equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery
Knee bolster
1Knee bolsters are located on the lower half
of the instrument panel on the driver and
passenger sides of the vehicle. The removal of
these covers will allow access to a variety of
electrical, heating and air conditioning
components.
2Detach the retaining screws along the
edges of the knee bolster (see illustration).
3Pull outward on the lower edge of the knee
bolster and detach it from the vehicle.
4Refitting is the reverse of removal.
Centre trim panel
5Carefully pull outward to detach the centre
trim panel from the instrument panel (see
illustration).
6Refitting is the reverse of removal.
Glove box
7Detach the passenger side knee bolster as
described in Steps 2 and 3.8Remove the glove box door hinge bolts
(see illustration).
9Open the glove box door, then detach it
from the vehicle.
10Detach the heater duct and the relay
mounting panel from the bottom of the glove
box.
11Detach the remaining screws securing the
upper edge of the glove box (see illustration).
12Disconnect the lamp from the glove box
and remove the assembly from the vehicle.
13Refitting is the reverse of removal.
27 Steering column cover-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could cause
Bodywork and fittings 11•13
11
3261 Jaguar XJ6 26.2 Remove the retaining screws along the outer edge of the
knee bolster, then remove it from the vehicle
26.5 Grasp the centre trim panel with both hands, then unsnap
the retaining clips (arrowed) from the dashboard assembly
26.8 With the passenger side knee bolster removed, unscrew the
glove box door hinge bolts26.11 Remove the screws along the top edge (arrowed), pull the
glove box out and remove the lamp assembly

3261 Jaguar XJ6
12
Chapter 12
Body electrical system
1 General information
The electrical system is a 12-volt, negative
earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid-type battery which is charged by
the alternator.
This Chapter covers repair and service
procedures for the various electrical
components not associated with the engine.
Information on the battery, alternator,
distributor and starter motor will be found in
Chapter 5.
It should be noted that when portions of the
electrical system are serviced, the cable
should be disconnected from the negative
battery terminal to prevent electrical shorts
and/or fires.
2 Electrical fault finding-
general information
A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links, in-line fuses or
circuit breakers related to that component
and the wiring and electrical connectors that
link the component to both the battery andthe chassis. To help you pinpoint an electrical
circuit problem, wiring diagrams are included
at the end of this Chapter.
Before tackling any troublesome electrical
circuit, first study the appropriate wiring
diagrams to get a complete understanding of
what makes up that individual circuit. Trouble
spots, for instance, can often be narrowed
down by noting if other components related to
the circuit are operating properly. If several
components or circuits fail at one time,
chances are the problem is in a fuse or earth
connection, because several circuits are often
routed through the same fuse and earth
connections.
Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a blown fuse, a melted fusible
link or a bad relay. Visually inspect the
condition of all fuses, wires and connections
in a problem circuit before diagnosing it.
If testing instruments are going to be
utilised, use the diagrams to plan ahead of
time where you will make the necessary
connections in order to accurately pinpoint
the trouble spot.
The basic tools needed for electrical fault
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used), a continuity tester, which includes a
bulb, battery and set of test leads, and a
jumper wire, preferably with a circuit breaker
incorporated, which can be used to bypasselectrical components. Before attempting to
locate a problem with test instruments,
use the wiring diagram(s) to decide where to
make the connections.
Voltage checks
Voltage checks should be performed if a
circuit is not functioning properly. Connect
one lead of a circuit tester to either the
negative battery terminal or a known good
earth. Connect the other lead to a electrical
connector in the circuit being tested,
preferably nearest to the battery or fuse. If the
bulb of the tester lights, voltage is present,
which means that the part of the circuit
between the electrical connector and the
battery is problem free. Continue checking the
rest of the circuit in the same fashion. When
you reach a point at which no voltage is
present, the problem lies between that point
and the last test point with voltage. Most of
the time the problem can be traced to a loose
connection. Note:Keep in mind that some
circuits receive voltage only when the ignition
key is in the Accessory or Run position.
Finding a short
One method of finding shorts in a circuit is
to remove the fuse and connect a test light or
voltmeter in its place. There should be no
voltage present in the circuit. Move the wiring
harness from side to side while watching the
test light. If the bulb goes on, there is a short Airbag system - general information . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bulb renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Central locking system - description and check . . . . . . . . . . . . . . . . 25
Circuit breakers - general information . . . . . . . . . . . . . . . . . . . . . . . . 5
Cruise control system - description and check . . . . . . . . . . . . . . . . . 23
Direction indicators/hazard flashers - general information . . . . . . . . 7
Electric aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric side view mirrors - description and check . . . . . . . . . . . . . . 26
Electric sunroof - description and check . . . . . . . . . . . . . . . . . . . . . . 27
Electric window system - description and check . . . . . . . . . . . . . . . 24
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Fuel, oil and temperature gauges - check . . . . . . . . . . . . . . . . . . . . . 11
Fuses - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Headlight housing (1992 to 1994 models) - removal and refitting . . . 19Headlights - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Headlights - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heated rear window - check and repair . . . . . . . . . . . . . . . . . . . . . . 16
Horn - check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ignition switch and key lock cylinder - removal and refitting . . . . . . 9
Inertia switch - description and check . . . . . . . . . . . . . . . . . . . . . . . . 22
In-line fuses - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Instrument cluster - removal and refitting . . . . . . . . . . . . . . . . . . . . . 12
Instrument panel switches - removal and refitting . . . . . . . . . . . . . . 10
Radio and speakers - removal and refitting . . . . . . . . . . . . . . . . . . . 13
Relays - general information and testing . . . . . . . . . . . . . . . . . . . . . . 6
Steering column switches - removal and refitting . . . . . . . . . . . . . . . 8
Windscreen wiper motor - removal and refitting . . . . . . . . . . . . . . . . 15
Wiring diagrams - general information . . . . . . . . . . . . . . . . . . . . . . . 29
12•1
Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321

of the airbag, which could cause personal
injury or damage to the airbag system, DO
NOT work in the vicinity of the steering
column or instrument panel. The
manufacturer recommends that, on airbag
equipped models, the following procedure
be performed at a dealer service
department or other properly equipped
repair facility because of the special tools
and techniques required to disable the
airbag system.
The direction indicator and hazard flasher
systems are governed by the central
processing unit. The central processing unit
requires special testers and diagnostic
procedures which are beyond the scope of
this manual.
If the direction indicator/hazard flasher
system fails and the indicator bulbs are in
working condition take the vehicle to a dealer
service department or an automotive
electrical specialist for further diagnosis and
repair.8 Steering column switches-
removal and refitting
1
Warning: Later models are
equipped with airbags. To
prevent accidental deployment
of the airbag, which could cause
personal injury or damage to the airbag
system, DO NOT work in the vicinity of the
steering column or instrument panel. The
manufacturer recommends that, on airbag
equipped models, the following procedure
be performed at a dealer service
department or other properly equipped
repair facility because of the special tools
and techniques required to disable the
airbag system.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.1Disconnect the negative battery cable.
2Remove the steering wheel (Chapter 10).
3Remove the lower steering column cover
(see Chapter 11).
4Remove the switch retaining screw(s) (see
illustration).
Body electrical system 12•5
12
3261 Jaguar XJ6 1993 to 1994 relay location details
8.4 Remove the switch retaining screws,
disconnect the electrical connectors and
pull the switches outward (arrowed)

5Disconnect the electrical connectors from
underneath the steering column and remove
the switch or switches from the vehicle.
6Refitting is the reverse of removal.
9 Ignition switch
and key lock cylinder-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent accidental deployment
of the airbag, which could cause
personal injury or damage to the airbag
system, DO NOT work in the vicinity of the
steering column or instrument panel. The
manufacturer recommends that, on airbag
equipped models, the following procedure
be performed at a dealer service
department or other properly equipped
repair facility because of the special tools
and techniques required to disable the
airbag system.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.1Disconnect the negative battery cable.
2Remove the steering wheel (Chapter 10).
3Remove the steering column trim covers
(see Chapter 11).
4Remove the steering column switch
mounting plate screws (see illustration).
5Remove the shear-head bolts retaining the
ignition switch/lock cylinder assembly and
separate the bracket halves from the steering
column. This can be accomplished by drilling
out the centre of the screws and using a screw
extractor to remove them (see illustration).
6Place the new switch assembly in position,
refit the new shear-head bolts and tighten
them until the heads snap off.
7The remainder of the refitting is the reverse
of removal.
10 Instrument panel switches-
removal and refitting
1
Warning: Later models are
equipped with airbags. To
prevent accidental deployment
of the airbag, which could cause
personal injury or damage to the airbagsystem, DO NOT work in the vicinity of the
steering column or instrument panel. The
manufacturer recommends that, on airbag
equipped models, the following procedure
be performed at a dealer service
department or other properly equipped
repair facility because of the special tools
and techniques required to disable the
airbag system.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
1Remove the lower trim cover(s) (see
illustration).
2To remove the vehicle condition monitor
(VCM) switch assembly, simply depress the
switch retaining clip and lower the switch
assembly from the instrument panel (see
illustration).
3To remove the headlight switch assembly,
detach the switch knob and remove the hex
nut securing the switch to the instrument
panel (see illustration). Depress the retaining
clip securing the switch, disconnect the
electrical connectors and remove the switch
assembly from the instrument panel.
4Refitting is the reverse of removal.
12•6 Body electrical system
10.1 Remove the lower trim cover(s) from
the instrument panel switch assembly10.2 Depress the clip on the front, lower
the switch assembly from the instrument
panel and unplug the connectors10.3 Detach the headlight switch knob,
then remove the hex nut securing the
switch to the instrument panel (arrowed)
3261 Jaguar XJ6 9.4 Remove the switch mounting plate screws (arrowed). Lower
the mounting plate and switch assembly to access the ignition
switch/key lock cylinder
9.5 To remove the ignition switch/lock cylinder assembly, drill out
the centre of the two retaining bolts (arrowed) and remove them
with a screw extractor