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JA~Technical Guide

X J SEDAN & X JS RANGES1996 MY UPDATEAUGUST 1995

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JA~ HSROYALH GHNESSTEPR NCEOFWALESMA,NUFACTJRERSOFDAlMLERANDJAGUARCAASJ AG )A R C AR S L M T ED C OV EH TR YTechnical Guide

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XJ SEDAN & XJS RANGES1996 MY UPDATEAUGUST 1995

Published by Service Communications Jaguar Cars LimiteAugust 1995 Publication Part No JIM 18 15 99/6

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Sedan/XJS Preface

This Technical Guide is produced as an outline description of the model year program changes to the XJSedan and XJS ranges, for Dealer workshop personnel. As a cohesive package, it complementsupdates to the Service Manuals. However, in order to keep the contents concise, no attempt is madeto cover technical details to the depth of the Service Manuals.Most of the changes are programmed for vehicle volume production in August 1995. Some are runningchanges to be included as close as possible to this date. Subsequent vehicle launch will vary accordingto market destination.The information contained in this publication should be considered as preliminary information. Whileevery effort is made to ensure accuracy, changes may occur between going to press and vehiclelaunch.Since the Technical Guide contents will not be updated, the reader is encouraged to study subsequentinformation sources, such as Service Bullet ins and Service Manual Supplements.

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Contents Sedan/XJS

Subject Page

IntroductionContents Overview 2Vehicle Identification Number (VIN) 2BodyExterior Trim 3Interior Trim 3AJ16 EngineEngine - Mechanical 4Exhaust Gas Recirculation (EGR)SystemTransmissionTransmission - MechanicalFuel SystemFuel DeHvery SystemEvaporative Loss Control System 9

.~~ Exhaust SystemCatalytic Converters 14Electrical/ElectronicHarnesses 15Occupant ProtectionSeat Belts 16DiagnosticsEngine Control Module 17

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Sedan/XJS

2

Introduction

Contents OverviewJ76-120B

Most of the changes covered by this Technical Guide concern the XJ Sedan range, although a numberof AJ16 engine related changes also apply to the 4.0 liter XJS. Of special significance at this ModelYear is the withdrawal of the V12 version of the XJS.Changes to the Sedan include the deletion of the front passenger door lock barrel and changes ofmaterial for some interior finishers. In addition, a percentage of vehicles have a revised evaporative losscontrol system and new fuel lines in the engine compartment.Changes to the AJ 16 engine include revised valve timing. A new transmission oil filler tube and exhaustmanifold heat shield accommodate the introduction of an exhaust gas recirculation system on thesupercharged engine. The down-pipe catalytic converters are standardised with those used in the Restof the World.Both the Sedan and XJS incorporate changes to the diagnostic software of the engine control module.

Vehicle Identification Number (VIN)TYPICAL VIN FOR SEDANS

SAJHX1740TCoooooo[

[ SERIAL NUMBER

MANUFACTURING PLANT:

CLASS: X = USA SPEClMANUFACTURER:

SAJ=JAGUAR~

MODEL RANGE: H = XJ6 __jJBODY VARIANT:1 = 4 DOOR SEDANTRANSMISSION & STEERING: __ ..I

4 = AUTOMATIC, LH

INGINE: 7 = 4.0 LITER AJ16I I MODEL YEAR: T = 1996

C = BROWNS LANE

1.--__ CHECK DIGITJ76 -1123

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Body

Exterior TrimPassenger Door Lock BarrelAs currently practised by competitor carmanufacturers, the Sedan front passenger dooris designed without a lock barrel. Since thecommon way to lock and unlock the doors iswith the remote control key-ring transmitter, thefrequent use of the key has diminished. Thekey's function now is as a recourse for thedriver's door should the transmitter fail.Deletion of the lock barrel has the side benefit ofimproving security to the front passenger door.Associated deleted components are the link, clipand lever, reset switch and cable.

Interior TrimDoor Switch Pack FinishersThe door window switch pack veneer finishersare replaced by satin finish injection mouldedplastic versions on XJ6 and XJR Sedans.The moulded finishers are color-keyed to thedoor trim casing in one of five colors. Fitment isby a spring steel strip latch moulded onto theforward edge of the switchpack and by a screwand spring steel retaining clip at the rearwardedge.

Door Speaker GrillesAll door speaker grilles and finishers on non-premium ICE vehicles have undergone a materialchange from metal to plastic. There is noperceived difference in appearance between thenew and previous parts but the plasticcomponents possess a higher impact resistance.

Sedan/XJS

3

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Sedan/XJS AJ16 Engine

VALVE TIMING DIAGRAMTDC72 I 72

\ I EXHAUST CLOSESINLET OPENS ~:-_

\

EXHAUSTM.O.P.1142 BTDC.>:

INLETM.O.P.< 1142ATDC~

MOP: Maximum Opening Point J12 882IM)

EXHAUST MANIFOLD HEAT SHIELD

'=======~'=======~~

4

Engine - MechanicalValve limingOn 4,0 liter normally aspirated engines, valveoverlap is reduced from 22 to 14 degrees ofcrankshaft movement, to improve engine idlequality, The change in performance due to therevised timing is minimal and within thetolerances of existing power curves,The reduced valve overlap is achieved by theintroduction of camshafts with re-positionedtiming gauge slots, The new camshafts retardinlet valve opening and advance exhaust valveopening by 4 degrees each, Introduction of thenew camshafts began in May 1995 and they arenow build standard for all Sedan and XJSnormally aspirated AJ16 engines.If required, the valve overlap of earlier 4.0 liternormally aspirated AJ16 engines can be reducedto 14 degrees using their existing camshafts (fordetails see Technical Bulletin 03.1-04 for Sedan,or JD 38-95 for XJS).

Exhaust Manifold Heat ShieldThe heat shield now has an aluminum finish,instead of chromed, to match the other enginecovers, A profile change at the rear of the heatshield accommodates the exhaust gasrecirculat ion valve on XJR Sedans.

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AJ16 Engine Sedan/XJS

Exhaust Gas Recirculation (EGR) SystemEGR is introduced on the supercharged engine ofXJR Sedans. The system is essentially the sameas on the normally aspirated AJ 16, but withrevised installation.The EGR valve is located on a casting attached tothe exhaust manifold. Also, the EGR valvefunction sensor and the transfer pipe outlet areconnected to an adapter block on the throttlebody adapter.To protect the starter motor cable, a heat shieldis installed on the upper mounting stud of thestarter motor. In addition, a protective sleeve isinstalled on the starter motor cable between thestarter motor and the first cable clip on thetransmission housing. The transfer pipe issecured in a clip on the heat shield.

EGR VALVE - SUPERCHARGED ENGINE

J1834

EGR VALVE FUNCTION SENSOR - SUPERCHARGED ENGINE

J1S-350

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Sedan/XJS AJ16 Engine

EGR TRANSFER PIPE - SUPERCHARGED ENGINE

EGR SYSTEM - SUPERCHARGED ENGINE

ECM

Transfer Pipe

EGR

6

J18 -351

J18 -352

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Transmission

Transmission - MechanicalFiller TubeOn XJR Sedans, a new transmission fluid fillertube is introduced to accommodate theinstallation of the EGR valve. A slotted bracketsecures the top of the tube to the forward side ofthe EGR valve mounting, enabling the tube to berepositioned for checking and replenishing thetransmission fluid.WARNING:TAKE CARE TO PREVENT TRANSMISSIONFLUID BEING SPILLED. WHEN CHECKINGOR REPLENISHING THE TRANSMISSIONFLUID, THE FILLER TUBE MUST BEREPOSITIONED AS SHOWN TO AVOIDSPILLAGE OF TRANSMISSION FLUIDONTO THE EXHAUST AND HEATSHIELDING.

After checking/replenishing the transmissionfluid, the tube must be returned to the normalposition and the securing bolt tightened to 15.5to 20.5 N.m (138 to 181 Ibf.in).

\_ DipstickA longer dipstick is introduced to match theincreased length of the new filler tube. The fluidlevel markings on the dipst ick are unchanged.

Sedan/XJS

FILLER TUBE AND DIPSTICKNormal Position

Checking/ReplenishingPositionJ44 - 7

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Sedan/XJS

8

Fuel System

Fuel Delivery SystemENGINE COMPARTMENT FUEL LINES

J19511

On USA XJ6 Sedans with the twin canisterevaporative loss control system (see Page 9),revised fuel lines are introduced in the enginecompartment.The fuel lines are changed to P-CAP tubing toreduce evaporative losses through the fuel linewalls. A fire resistant rubber sleeve is installedover the P-CAP. Pulse dampers are introduced toboth the supply and return fuel lines. The pulsedampers absorb the pressure pulses produced byfuel injector operation, to prevent knockingsounds in the semi-rigid fuel lines.

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Fuel System

Evaporative LossControl SystemEvaporative Loss FlangeOn all Sedan models, a steel evaporative lossflange replaces the previous plastic design. Anew roll-over valve and fuel pump electricalconnector are installed in grommets on the newflange. The flange locking ring is unchanged, buta revised flange to tank sealing arrangementmeans the two types of flange are notinterchangeable.

Twin Canister SystemIn the USA, to comply with evaporativeemissions and On-board Diagnostics legislat ion, anumber of XJ6 Sedans (constituting 20% ofannual Sedan sales) have a twin canisterevaporative loss control system. The twincanister system provides further reductions inevaporative emissions and enables the EngineControl Module (ECM) to test for leaks equivalentto a hole of 1mm (0.040in) diameter minimum.Differences from the single canister system aredetailed below:Vapor PipesThe flexible vapor pipes are changed to P-CAP toreduce losses through the pipe walls. Vitonrubber hoses and hose clamps provide the in-lineand component connections.Carbon CanisterA second carbon canister is added to reduce theconcentration of fuel in the vapor that vents toatmosphere. It is installed under the right rearseat pan and connected in series with the firstcanister.Running Loss Control ValveA normally open, running loss control valvereplaces the vacuum/pressure relief valve(Rochester valve). The running loss control valvepermits free venting of the tank, but preventsfuel entering the vent line during refueling.During refueling, the incoming fuel creates apressure differential between the tank interiorand the filler neck. On sensing the pressuredifferential the valve closes, shutting-off the ventline.

Sedan/XJS

EVAPORATIVE LOSS FLANGE AND ROLL-OVER VALVE

J19 - 518

RUNNING LOSS CONTROL VALVE

======

J19 - 517

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Sedan/XJS ue

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Fuel System

Fuel Tank Pressure SensorA fuel tank pressure sensor is installed in arubber grommet in the evaporative loss flange.The sensor provides a vapor pressure signal tothe ECM.Canister Close Valve and FilterA canister close valve and filter assembly isinstalled on a bracket attached to the undersideof the vehicle, above the right axle shaft.The canister close valve is a normally opensolenoid valve connected to the atmospheric sideof the second carbon canister. Operation of thevalve is controlled by the ECM.A hose connects the atmospheric side of thecanister close valve to the filter. The filter, a non-service item, prevents contamination of the valveduring inward venting.

Sedan/XJS

FUEL TANK PRESSURE SENSOR

J19514

CANISTER CLOSE VALVE AND FILTER

o ~~O~~ __ -UV000 0

~()~Canister Close Valve

J19513

11

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Sedan/XJS

12

Fuel System

Twin Canister System Leak TestThe ECM runs a diagnostic leak test once everyengine start/stop cycle, provided the followingconditions occur: from "cold", the engine has warmed up to

within the normal running temperature range a period of time (currently 15 minutes but

subject to change) has elapsed since ignitionON

the fuel vapor concentration in the evaporativeloss system is not excessive

the car is stationary with the engine at idleRPM after a driving cycle which included aminimum of approximately 5 minutes at asteady speed

the fuel tank is between 10 and 90 % full.During the test, the ECM checks that therequired fuel tank pressure changes occur inresponse to the opening and closing of the purgevalve and the canister close valve. It alsomonitors the canister close valve and the fueltank pressure sensor for circuit continuity andcorrect signals.Test SequenceWhen the required conditions occur, the ECMbegins the test by ensuring that the purge valve

is closed. A few seconds later the canister closevalve is also closed, causing system vaporpressure to increase. This condit ion is maintainedfor approximately 5 seconds, after which theECM begins to progressively open the purgevalve. System vapor pressure then begins todecrease, due to the depression in the intakemanifold. At approximately 2.5 kPa (0.36 Ibf/in2)below ambient pressure, the ECM closes thepurge valve. Approximately 5 seconds later, theECM opens the canister close valve, systempressure returns to ambient and the test iscomplete.Total test duration is approximately 25 to 30seconds.The test is discontinued if any of the followingoccur: no pressure decrease after the purge valve is

opened excessive fuel vapor concentration in the

system engine speed changes from idle.FaultsAny faults detected during the test are logged asDiagnostic Trouble Codes (DTC) in the ECMmemory (see Diagnostics section for details).

LEAK TEST OPERATING SEQUENCECanisterCloseValveCloses

PurgeValveStarts toOpen

PurgeValveCloses

CanisterCloseValveOpens

TIME

J19 - 516

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Fuel System Sedan/XJS

TWIN CANISTER SYSTEM SCHEMATIC

ECM

IntakeManifold

J19 - 515 (M)

PressureSensor

Running LossControl Valve PurgeValve

FilterFuel Tank

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Sedan/XJS

14

Exhaust System

Catalytic Converters4.0 liter normally aspirated Sedan and XJSmodels now have down-pipe catalytic converterswhich use palladium as the catalyst material(instead of platinum/rhodium) to give improvedemissions performance.

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Electrical/Electronic

Wiring HarnessesXJS vehicles have revised harnesses to accommodate the installation of a dealer fit voice activatedtelephone.Changes consist of: a new connector behind the left side of the fascia for connection to the voice activation switch a new two-way multi-lock connector in the center console for connection to the handset base two new RF connectors in the trunk, below the battery tray.Color coded dust caps protect the two RF connectors. The RF connector with the gray dust cap is forthe cable from the center console; the RF connector with the black dust cap is for the cable from thetelephone antenna.

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Sedan/XJS

16

Occupant Protection

Seat BeltsXJS vehicles have new seat belts for the front and rear passenger seats.On convertibles, all of the new belts have a reel that can be set to the emergency locking retractor(ELR) or automatic locking retractor (ALR) mode, as on Sedan models. Pulling the full length of the beltout of the reel engages the ALR mode, allowing the belt to retract fully into the reel returns the belt tothe ELR mode.On coupes the new belt for the front passenger seat also has an ELR/ALR reel. However, the new rearbelts retain the standard reel, but have a new insertion tongue with an integral clamping device. Oncethe lap section of the belt is tightened, the clamping device grips the belt, preventing the lap sectionfrom being loosened until the buckle is released. The upper section of the belt can still extend andretract on the reel in the normal manner.

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Diagnostics

Engine Control ModuleOn both the Sedan and XJS models, new diagnostic software is incorporated in the engine controlmodule.

AJ16 On-board DiagnosticsThe following new Diagnostic Trouble Codes (DTC), already introduced on extended wheelbaseSedans, are introduced on standard wheelbase Sedans and the XJS:

OTC ExplanationFixed sensor output when changing output is expected.0111 Intake air temperature

rationalityThrottle position rationality0121

P0461P0560

Fuel level rationalitySystem voltage malfunction

Throttle position is not consistent with engine speed andairflow.Fuel level signal does not f luctuate.Battery supply voltage is outside limits.

USA XJ6 Sedans with the twin canister evaporative loss control system (see Fuel System section) alsoinclude the following new DTC's:

OTCP0442 System leak

P0446 Vent control malfunctionP0451 Fuel tank pressure rationality

P0452 Fuel tank pressure sensorlow inputP0453 Fuel tank pressure sensorhigh input

P1440 Purge valve stuck openP1447 Closure valve flow fault

P1448 System 2 fault

P1496 System 1 fault

ExplanationMinor leak detected equivalent to hole of approximately1 mm in diameter.Electrical fault with canister close valve or drive circuit.Pressure signal within limits but not consistent with purgevalve/canister close valve configuration.Pressure signal below limits.

Pressure signal above limits.

Unexpected decrease in pressure during leak check.No pressure increase after canister close valve signalledopen.Some pressure decrease when purge valve signalled open,no fueling feedback change detected.Pressure decrease after purge valve signalled open, nofueling feedback change detected.

Sedan/XJS

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Sedan/XJS

18

Diagnostics

V12 On-board DiagnosticsThe following new and revised DTC's are introduced on all V12 Sedans:

DTCP0106 Bank A manifold absolute

pressure (MAP) rationalityP0116 Coolant temperature rationality

P0441 Bank A purge flowP0461 Fuel level rationalityP0462 Fuel level sensor low inputP0463 Fuel level sensor high inputP1106 Bank B MAP rationality

P1441 Bank B purge flow

Explanation/ChangeRevised to include detection of disconnectedsensor hose.Revised to enable faster detection of sensor faults and toinclude detection of failure to enter closed-loop fueling.Revised fuel level inhibit values.New. Fuel level signal is not consistent with fuel used.New. DTC number changed (was P1199).New. DTC number changed (was P1198).Revised to include detect ion of disconnectedsensor hose.Revised fuel level inhibit values.

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