battery location JAGUAR XJ6 1994 2.G Workshop Manual

Driveshafts & Final Drive
9.8 FINAL DRWE UNIT RENEW
SRO 51.25.13
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear and remove the rear road
wheels.
Disconnect brake pad wear sensor multi-plug at RH hub
carrier and remove tie straps from wishbone. Release
ABS speed sensors at
RH and LH hub carriers and remove
tie straps from wishbones.
. Remove rear brake calipers, see Section 12, and support
at bump stop. Disconnect main handbrake cable at com- pensator, short cables at joining piece and remove com- pensator.
. Remove fixings, FLEXIBLE coupling to differential DRIVE FLANGE.
CAUTIW: Under no circumstances must the flexible
coupling (or itsfixings) be loosened or removed
from the drive shaft flange.
. Remove fixings center bearing to crossmember (1 Fig. 1) and push drive shaft rear section forward to disengage
from pinion spigot. Fig. 1
w: Take account of any shims located between the center bearing and the crossmember.
. Release fixings and remove, over axle exhaust pipe mounting from wide mounting bracket.
. Support the rear suspension assembly from below and remove fixings from RH and LH sides in the following order:
1. Shock absorber to body upper fixings.
2. Differential strut to body (1 Fig. 2).
3. 'A' frame bush (2 Fig. 2).
4. Lower mounting bracket assembly to body (3 Fig. 2).
. Carefully lower the unit clear of the vehicle and place in a safe working location.
. Release handbrake cable to wide mounting bracket clips.
. Disconnect RH and LH axle shafts from differential couplings, note camber shim and discard fixings.
. Remove wishbone pivot bolt, washers and remove wisbone / hub / axle shaft assembly RH and LH.
issue 1 August 1994 6 X300 VSM

Body Components & Trim ~
issue 1 August 1994 X300 VSM 21
13.3.17 Fascia Board, Renew
SRO 76.46.01
. Remove
the battery cover and disconnect the battery.
Remove the drivers side and passenger side underscuttle
pads, see sub
-sections 13.3.19 and 13.3.20.
. Remove the drivers airbag module, see section 15.5.
Remove the steering wheel, section 10.
Remove the drivers side and passenger side fascia closing
. Remove the fascia center veneer panel, see subsection
Remove the fascia board for access, see subsection
. Disconnect the air conditioning differential potentiometer
Remove the differential potentiometer assembly.
. Displace and reposition the through panel connectors
from the fascia assembly.
. Displace the fascia vent motor / gearbox assemblies har- ness multi-plug from the mounting bracket.
. Disconnect and reposition the fascia harness to console
harness
multi-plug from the mounting bracket.
. Disconnect the BPU harness multi-plugs.
Remove the tiestraps securing the harness to the fascia.
. Reposition the fascia on a bench.
= Displace and reposition the solar sensor assembly from
Disconnect the solar sensor harness multi-plug.
Remove the solar sensor assembly.
= Undo and remove the defrost vents securing screws.
Displace and reposition the defrost vent assemblies.
. Disconnect the tweeter speaker harness multi-plugs.
. Remove the defrost vent assemblies.
. Displace the fascia harness grommet from the fascia.
. Route the harness through the aperture.
Remove the fascia harness assembly.
. Undo and remove passenger airbag deployment door to
fascia securing bolts ( one bolt is removed with the fascia).
. Displace and remove the deployment door assembly.
. Undo and remove the passenger airbag module to fascia
. Displace and remove the airbag module assembly.
. Undo and remove the airbag module I BPU mounting
bracket assembly to fascia securing nuts 1 bolts.
= Displace and remove the mounting bracket assembly.
. Retrieve the spacing washers.
. Displace and remove the side vent outlets from the fascia.
. Displace and remove the side vent ducts securing clips.
. Displace and remove the side vent ducts.
. Undo and remove the center vent flap assembly to fascia
. Displace and remove the center vent flap assembly.
Undo and remove fascia location bracket securing nuts.
Displace and remove the location bracket.
panels, see
sub
-sections 13.3.22 and 13.3.21.
13.3.23. 13.3.17.
harness multi
-plug.
the fascia.
securing bolts.
securing nuts.

Body Components & Trim -
. From behind the fascia passenger side, disconnect the
passenger airbag harness multi-plug.
. With assistance, remove the fascia from the vehicle and
place on a suitably protected bench.
Place the fascia
in position in the vehicle with the center
location peg correctly engaged.
Reconnect the passenger airbag module harness multi-
Plug.
. Carefully fit and align the fascia to the mounting position.
. Fit and tighten the fascia to outer body brackets securing
bolts.
Fit and tighten the fascia assembly lower securing nut.
Reposition and
fit the airbag control module to the mount-
ing bracket.
Reposition and fit the fascia harness ground eyelets to the
ground stud.
Fit and tighten the ground eyelet securing
nut.
harness multi-plug. . Reconnect the left hand fascia harness to cabin housing
. Reconnect the fascia harness to console harness multi- plugs.
Fit and align the passenger side outlet duct.
. Fit and tighten the fascia to console securing screws.
. Reconnect the speed control harness multi-plug.
. Reconnect the speaker tweeter harness multi-plug.
. Reconnect the exciter coil harness multi-plug.
Reconnect the column switchgear and column motor har-
. Reconnect the right hand fascia harness to cabin harness
. Place the instrument pack / fascia switchpack in position.
. Reconnect the instrument pack harness multi-plugs.
. Reposition and fitthe instrument packassemblytothefas-
cia.
Reconnect the fascia switchpack harness multi-plugs.
Reconnect the steering column harness multi
-plugs.
. Reposition and fit the switchpack harness multi-plug mounting bracket.
ness
multi
-plugs.
multi-plug.
. Fit and tighten the instrument pack/ switchpack securing
bolts.
- Fit and align the fascia tie bars.
. Fit and tighten the tie bar securing nuts.
9 Refit the center veneer panel.
Refit the fascia closing panels.
. Refit the steering wheel.
. Refit the drivers airbag module.
. Refit the underscuttle pads.
. Reconnect the battery and refit the battery covers.
Issue 1 August 1994 X300 VSM 25

Electrical rl
15.2 INSTRUMENTS
15.2.1 General Description
The instruments measure, monitor and display data relevant to the vehicle’s performance. Data is received from
sensors positioned at various locations around the vehicle via two multi-pin sockets located at the rear of the
instrument panel and is than presented using three different visual display methods described as follows:
15.2.2 Analog Display
This is used to display road speed, engine speed, oil pressure, battery condition, fuel level and coolant temperature.
15.2.3 Indicator Lamps
These indicate the presence of any hazard /fault conditions or operational actions.
15.2.4 LCD (Liquid Crystal Disp/ay)
This single line, six digit seven segment display is normally used to display the odometer reading but can also be used
to display vehicle condition messages associated with particular warning lamps and trip computer information.
15.2.5 Transducers
These devices listed as follows transmit vehicle condition to the instruments:
0 Engine Coolant Temperature Transmitter
0 Low Coolant Level Probe
0 Oil Pressure Transmitter - AJ16N12
0 Fuel Gauge Tank Unit - AJlW12
Fault conditions and their causes displayed by the instruments and warning lamps are covered in more detail
by further information contained within the
Electrical Diagnostic Manual.
15.2.6 Instrument Panel, General
2 I I 3 1
1. 24 Way Connector 3. Identification Label 2. 4% Way Connector 4. Bulb Holder
Fig.
1 Instrument Panel, Rear View
X300 VSM Issue 1 August 1994 8
c

15.5.8 wific Gravity Test
The specific gravity of the electrolyte determines the level of the float in the liquid. With the float in a high position
the specific gravity is high and when the specific gravity is low the float sinks to the lower position.
Using
a hydrometer the specific gravity readings are taken when the liquid level crosses the scale on float. This should
give a accurate indication of the state charge of the battery.
The volume and the specific gravity of the electrolyte varies with the change in temperature.
15.5.9 Electrolyte Temperature Correctkm
For every 10- below 15% subtract 0.007 from the hydrometer reading, and for every 10°C above 15OC add 0.007 to
the hydrometer reading.
Note: Use only distilled water for topping up electrolyte. The electrolyte must not exceed 51.66OC during charging.
If after 30 minutes charging the battery current is not equal or greater than 3A, dispose of the battery.
15.5.10 Heahh and Sakty Precautions
As batteries contain sulphuric acid and explosive mixtures of hydrogen and oxygen gases, it is strongly recommended
that protective clothing is worn.
Avoid spilling acid to prevent damage to clothing and skin bums.
If accidentalty spilled or splashed on clothing or skin, rinse with cold water. As a neutralizer, a solution of baking soda
or ammonia and water may be used.
In the event of skin or eye contact rinse the affected areas with water and should this not
be sufficient seek medical
attention.
Any trace of acid spilled or splashed on the vehicle should be rinsed with clean water.
BEFORE AND WHILST WORKING WITH THE BATTERY BE AWARE OF THE FOLLOWING SAFETY PRECAUTIONS
o particularly during charging, highly explosive hydrogen is emitted.
0 do not smoke when working near the battery.
o avoid sparks, short circuits or other sources of ignition.
o switch off current before connecting or disconnecting any electrical terminals.
o always disconnect battery ground lead first and reconnect last.
o ensure battery is charged in a well ventilated area.
o switch off the charger before disconnecting.
WARNING: WHEN PREPARING ELECTROLYTE OF A DESIRED SPECIFIC GRAVITY, ALWAYS POUR THE
CONCENTRATED ACID SLOWLY INTO THE WATER AND NOT WATER INTO THE ACID.
HEAT IS GENERATED WHEN MIXING ACID WITH WATER, HENCE ADD SMALL AMOUNTS OF ACID AND
STIR SLOWLY INTO THE WATER. ALLOW TO COOL IF NOTICEABLE HEAT DEVELOPS. EXCEPT FOR LEAD
DO NOT STORE ACID
IN EXCESSIVELY WARM LOCATIONS OR DIRECT SUN LIGHT.FUEL VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL
SYSTEM. LINED
CONTAINERS, ALWAYS USE NON
- METALLIC CONTAINERS AND / OR FUNNELS.
Issue 1 August 1994 14 X300 VSM

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

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.
0
0
0
X300 VSM Issue 1 August 1994 4