Notes, Cautions and Warnings
Throughout this article, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.
References to Bank-1 and Bank-2
References to Bank-1 and Bank-2 are made with regard to the engine. When viewed from the flywheel the right-hand bank will be Bank-1 and the left-hand bank will be Bank-2.
Disconnecting/Connecting the Battery
Always stop the engine before disconnecting the battery negative lead and make sure the battery positive lead is isolated i.e. wrapped in a suitable cloth.
| WARNING | Radio code saving devices must not be used when conducting work on Air Bag or Fuel systems. It must be noted that, when using these devices, the vehicle electrical system is still live albeit with a reduced current flow. |
Note. Before disconnecting the battery make sure that the radio receiver/cassette player/mini disc player and compact disc player keycodes are known and, that no data is required from the engine control module (ECM) as battery disconnection will erase any fault codes and idle/drive values held in the Keep Alive Memory (KAM). It is not necessary to disconnect or remove electronic control modules.
Always disconnect the battery before commencing repair operations which require
- The vehicle to be jacked up
- Work on the engine
- Work underneath the vehicle
- Arc welding
Alternatively a Radio Code Saver may be used. With the battery disconnected, a Radio Code Saver will allow sufficient current to pass to maintain the radio receiver/cassette player/mini disc player and compact disc player memory, operate the clock and supply the door operated interior lights while isolating the battery in the event of a short circuit.
Reconnecting the Battery
| WARNING | If the battery has been on bench charge the cells may be giving off explosive hydrogen gas. Avoid creating sparks, and if in doubt cover the vent plugs or covers with a damp cloth. |
Always make sure that all electrical systems are switched OFF before reconnecting the battery to avoid causing sparks or damage to sensitive electrical equipment.
Always reconnect the battery positive lead first and the negative last, ensuring that there is a good electrical contact and the battery terminals are secure.
Restart the clock (where fitted) and set it to the correct time.
Re - enter the radio receiver/cassette player/mini disc player and compact disc player keycodes and preset' frequencies, if known.
Following reconnection of the battery, the engine should be allowed to idle until it has reached normal operating temperature as the stored idle and drive values contained within the ECM have been lost. Allow the vehicle to idle for a further three minutes. Drive the vehicle at constant speeds of approximately 48 km/h (30 mph), 64 km/h (40 mph), 80 km/h (50 mph), 96 km/h (60 mph) and 112 km/h (70 mph) for three minutes each. This may cause a driveability concern if the procedure is not carried out. This will allow the ECM to relearn idle values.
Connecting a Slave Battery Using Jump Leads
| WARNING | If the slave battery has recently been charged and is gassing, cover the vent plugs or covers with a damp cloth to reduce the risk of explosion should arcing occur when connecting the jump leads. |
| CAUTION | A flat battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jump leads are connected. |
| CAUTION | While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. In such an instance the discharged battery must be recharged immediately after jump starting to avoid permanent damage. |
- Always make sure that the jump leads are adequate for the task. Heavy duty cables must be used.
- Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel.
- Always make sure that switchable electric circuits are switched off before connecting jump leads. This reduces the risk of sparks occurring when the final connection is made.
Scheme 1
| WARNING | Make sure that the ends of the jump leads do not touch each other or ground against the vehicle body at any time while the leads are attached to the battery. A fully charged battery, if shorted through jump leads, can discharge at a rate well above 1000 amps causing violent arcing and very rapid heating of the jump leads and terminals, and can even cause the battery to explode. |
Always connect the jump leads in the following sequence.
- Slave battery positive first then vehicle battery positive.
- Slave battery negative next and then vehicle ground at least, 300 mm (12 in) from the battery terminal e.g. engine lifting bracket.
Always reduce the engine speed to idle before disconnecting the jump leads.
Before removing the jump leads from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear screen, to reduce the voltage peak when the leads are removed.
Always disconnect the jump leads in the reverse order to the connecting sequence and take great care not to short the ends of the leads.
Do not rely on the alternator to restore a discharged battery. For an alternator to recharge a battery, it would take in excess of 8 hours continuous driving with no additional loads placed on the battery.
Component Cleaning
To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods
- Dry Cleaning
- Removal of loose dirt with soft or wire brushes.
- Scraping dirt off with a piece of metal or wood.
- Wiping off with a rag.
| CAUTION | Compressed air is sometimes wet so use with caution, especially on hydraulic systems. |
- Blowing dirt off with compressed air. (Eye protection should be worn when using this method).
- Removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material dust (asbestos particles).
- Steam Cleaning
Use of Control Modules
Control modules may only be used on the vehicle to which they were originally fitted. Do not attempt to use or test a control module on any other vehicle.
Preparation
Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed by component removal, with tapered hardwood plugs or readily visible plastic plugs. Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts. Before dismantling a component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the materials within the component. Clean the bench and obtain marking materials, labels, containers and locking wire before dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems. Clean all tapped holes, crevices, oilways and fluid passages with compressed air. Do not permit compressed air to enter an open wound. Always use eye protection when using compressed air.
Make sure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to make sure that they are replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of causing distortion or the initiation of cracks, which could occur if a center punch or scriber were used. Wire together mating parts where necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to parts requiring further inspection before being passed for reassembly. Place labelled parts and other parts for rebuild in separate containers. Do not discard a part which is due for renewal until it has been compared with the new part, to make sure that the correct part has been obtained.
Circuit Diagrams
To understand the relationship between the vehicle electrical system and the system circuit diagrams, Refer to the Electrical information.
In the interest of clarity, single lines may represent multiple wires. Refer to the color code (1st alpha) followed by the wire reference (numeric/alpha/numeric) to trace origin and destination.
e.g. BW 647B002. BW (black with white trace) 647 (wire reference) B002 (stage from origin).
Glossary of Terms
This glossary of terms is intended to cover mainly emissions-related (to SAE J 1930) terminology, and other abbreviations that may be used in this article.
The required term may be looked-up in the left-hand column, and subsequent columns give the standard acronym, unit or abbreviation, and definition.
| Term(s) | Acronym/Unit/Abbreviation | Definition |
|---|---|---|
| Accelerator Pedal | AP | |
| Accelerator Pedal Position Sensor | APP | Is a multitrack sensor which inputs the drivers demand into the engine control module (ECM) |
| After Bottom Dead Center | ABDC | Event occurring after BDC |
| After Top Dead Center | ATDC | Event occurring after TDC |
| Airbag/Supplementary Restraint System | Airbag, SRS | Airbag restraint system for driver and front seat passenger |
| Air Cleaner | ACL | |
| Air Conditioning | A/C | |
| Air Conditioning Control Module | A/CCM | Module controlling air conditioning, heating and ventilation |
| Air Conditioning Signal | ACS | Air conditioning compressor clutch operation is signalled to the ECM which induces idle speed corrections to compensate for engine load changes |
| Alternating current | Ac | |
| Air Fuel Ratio | AFR | Nominally 14.7 parts air to one part fuel |
| Ampere | A | SI unit of current |
| Ampere hour | Ah | |
| ABS Control Module | ABS CM | System which prevents wheel lock-up under braking by sensing lack of rotation of a wheel(s) and diverting fluid pressure away from it (them) |
| ABS/Traction Control Module | ABS/TCCM | System which prevents wheel lock-up under braking by sensing lack of rotation of a wheel(s) and diverting fluid pressure away from it (them) |
| Atmosphere | Atm | Unit of pressure (1.01325 bar) |
| Barometric Absolute Pressure Sensor | BARO Sensor | Sensor measuring the pressure of surrounding air at any given temperature and altitude |
| Battery positive voltage | B+ | The positive voltage from a battery or any circuit connected directly to it |
| Before Bottom Dead Center | BBDC | Event occurring before BDC |
| Before Top Dead Center | BTDC | Event (usually ignition) occurring before TDC |
| Blower | BLR | Device which supplies a current of air at moderate pressure, e.g. heater or A/C blower |
| Body Processor Module | BPM | Control module for body electrical systems, e.g. interior lamps, windshield wash/wipe control |
| Bottom Dead Center | BDC | Lowest point of piston travel in a reciprocating engine |
| Brake horsepower | BHP | Effective horsepower developed by an engine or motor, as measured by a brake applied to its output shaft |
| Brake Mean Effective Pressure | BMEP | The part of the effective pressure developed in a cylinder that would result in a cylinder output equal to the bhp of the engine |
| Brake On/Off | BOO | Indicates the position of the brake pedal |
| British Standard | BS | Standard specification issued by the British Standards Institution |
| British Standard Automotive | BSau | |
| Bus | Topology of a communication network | |
| Bypass Air | BPA | Mechanical control of throttle bypass air |
| Camshaft Position Sensor | CMP Sensor | Indicates camshaft position |
| Canadian Motor Vehicle Safety Standard | CMVSS | |
| Canister Purge | CANP | Controls purging of the EVAP canister |
| Carbon dioxide | CO2 | Colorless gas with a density of approximately 1.5 times that of air |
| Carbon monoxide | CO | Poisonous gas produced as the result of incomplete combustion |
| Case Ground | CSE GND | Control module casing ground |
| Catalytic converter | In-line exhaust system device used to reduce the level of engine exhaust emissions | |
| Celsius | C | SI term for the Centigrade scale, with freezing point at zero and boiling point at 100 degrees |
| Central Processor Unit | CPU | The section of a computer that contains the arithmetic, logic and control circuits. It performs arithmetic operations, controls instruction processing, and provides timing signals and other housekeeping operations |
| Cylinder Head Temperature Sensor | CHT Sensor | A sensor for measuring the temperature of the cylinder head |
| Closed Loop | CL | |
| Closed Loop System | CL System | Control system with one or more feedback loops |
| Column/Mirror Control Module | C/MCM | A self-contained group of electrical/electronic components, designed as a single replaceable unit, and controlling one or more processes |
| Controller Area Network | CAN | A communication system which allows control modules to be linked together. |
| Crankshaft Position Sensor | CKP Sensor | Generates crankshaft position information in conjunction with the CKPTR (also generates speed information in certain applications) |
| Crankcase Ventilation System | CV | System which scavenges camshaft cover and crankcase emissions and feeds them into the inlet manifold |
| Cubic centimeter | Cm 3 | |
| Curb weight | Weight of vehicle with fuel, lubricants and coolant, but excluding driver, passengers or payload | |
| Data Link Connector | DLC | Connector providing access and/or control of the vehicle information, operating conditions, and diagnostic information |
| Data Output Line | DOL | Circuit that sends certain information from the ECM to the instrument cluster |
| Degree | Deg, ° | Angle or temperature |
| Department of Transportation (US) | DOT | Which is a fibre optic ring network, can be diagnosed through the SCP network, and with the optical bus tester. |
| Deutsche Institut fur Normung | DIN | German standards regulation body |
| Diagnostic Module | DM | Supplemental Restraint System (non -controlling) module for diagnostics overview |
| Diagnostic Test Mode | DTM | A level of capability in an OBD system. May include different functional states to observe signals, a base level to read DTCs, a monitor level which includes information on signal levels, bi-directional control with on/off board aids, and the ability to interface with remote diagnosis |
| Diagnostic Trouble Code | DTC | An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic (OBD) system |
| Differential pressure | Pressure difference between two regions e.g. between intake manifold and atmospheric pressures | |
| Differential Pressure Feedback EGR | DPFE | An EGR system that monitors differential EGR pressure across a remote orifice to control EGR flow |
| Direct current | Dc | Current which flows in one direction only, though it may have appreciable pulsations in its magnitude |
| Domestic Data Bus | D2B | |
| Exhaust Gas Recirculation Temperature Sensor | EGRT | Sensing EGR function based on temperature change |
| Engine Management System | EMS | The engine management system conditions and reads inputs, supplies processing capability, and provides output drivers to control actuators as directed by software and calibration |
| Engine Oil Pressure | EOP | |
| EGR Vacuum Regulator | EVR | Controls EGR flow by changing vacuum to the EGR valve |
| EGR Valve Position | EVP | An EGR system that directly monitors EGR valve position to control EGR flow |
| Electrically Erasable Programmable Read-Only Memory | EEPROM | |
| Electrically Programmable Read-Only memory | EPROM | |
| Electronic Secondary Air Injection | EAIR | A pump-driven system for providing secondary air using an electric air pump |
| Engine Control Module | ECM | |
| Engine Coolant Level | ECL | |
| Engine Coolant Temperature | ECT | |
| ECT Sensor | ECTS | Thermistor which provides engine coolant temperature signal to the ECM to trigger enrichment circuits which increase injector 'on' time for cold start and warm-up |
| Engine speed | RPM | |
| Environmental Protection Agency | EPA | |
| Evaporative Emission | EVAP | System designed to prevent fuel vapor from escaping into the atmosphere. Typically includes a charcoal filled canister to absorb fuel vapor |
| Evaporative Emission Control Valve | EVAPP | |
| Exhaust Gas Recirculation | EGR | System which reduces NOx emissions by adding exhaust gases to the incoming fuel/air charge |
| Exhaust Gas Recirculation Solenoid Vacuum Valve | EGRS | |
| Exhaust Gas Recirculation Temperature Sensor | EGRT Sensor | |
| Exhaust Gas Recirculation Valve | EGR Valve | |
| Fan Control | FC | Engine cooling fan control |
| Federal Motor Vehicle Safety Standard (US) | FMVSS | |
| Figure | Fig. | Illustration reference |
| Flash Electrically Erasable Programmable Read-Only Memory | FEEPROM | |
| Flash Erasable Programmable Read-Only Memory | FEPROM | |
| Flywheel Sensor | CKFS | Sensor mounted so as to be triggered by each flywheel ring gear tooth to give an engine speed signal |
| Fuel Injection | FI | Solenoid operated devices that spray a metered quantity of fuel into the inlet ports |
| Fuel Pressure Regulator Control | FPRC | Controls fuel pressure regulator; used primarily to give extra fuel at cold start-up |
| Fuel Pump | FP | Pumps fuel from the fuel tank to the fuel injection system |
| Fuel Pump Monitor | FP Module | Monitors operation of fuel pump |
| Fuel Pump Relay | FP Relay | Relay which controls electrical current to fuel pump |
| Fuel rich/lean | Qualitative evaluation of air/fuel ratio based on a ratio known as stoichiometry or 14.7:1 (Lambda) | |
| Generic Electronic Module | GEM | |
| Generator | GEN | Rotating machine which converts mechanical energy into electrical energy |
| Gramme centimeter | Gcm | |
| Gramme (force) | Gf | |
| Gramme (mass) | G | |
| Ground | GND | Electrical conductor used as a common return for an electrical circuit or circuits, and with a relative zero potential |
| Hard fault | A fault currently present in the system | |
| Headlamp | HL | |
| Heated Oxygen Sensor | HO2S | Electrically heated oxygen sensor which induces fueling corrections |
| Hertz (frequency) | Hz | Frequency, one cycle per second |
| High Mounted Stoplamp | HMSL | |
| High tension | HT | |
| Hour | Hour | |
| Hydrocarbon | HC | |
| Idle Air Control | IAC | Stepper motor driven device which varies the volume of air by-passing the throttle to maintain the programmed idle speed |
| Ignition amplifier | IA | Device which amplifies the ignition system output |
| Ignition ground | IGN GND | |
| Injection Pressure Sensor | IPS | |
| Inertia Fuel Shut-off | IFS | An inertia system that shuts off the fuel supply when activated by pre-determined force limits brought about by (e.g.) collision |
| Inertia Fuel Shut-off Switch | IFS Switch | Shuts down fuel and ignition systems in the event of a vehicle impact |
| Intake air | Air drawn through a cleaner and distributed to each cylinder for use in combustion | |
| Intake Air Temperature | IAT | Temperature of intake air |
| Intake Air Temperature Sensor | IAT Sensor | Device used to measure IAT |
| Intake Air Temperature Sensor Ignition | IAT Sensor Ignition | Thermistor which signals the ECM to retard the ignition timing in response to high inlet air temperatures |
| Intake Air Temperature Sensor Injection | IAT Sensor Injection | Thermistor which inputs air density information to the ECM |
| Internal diameter | I.dia | |
| International Standards Organization | ISO | |
| Kilograms (mass) | Kg | |
| Kilogram (force) | Kgf | |
| Kilogram force per square centimeter | Kgf/cm 2 | |
| Kilometer | Km | |
| Kilometer per hour | Km/h | |
| Kilopascal | KPa | |
| Kilovolt | KV | |
| Knock Sensor | KS | Sensor which detects the onset of detonation, and signals the ECM to retard the ignition |
| Left-hand | LH | |
| Left-hand drive vehicle | LHD | |
| Left-hand thread | LHthd | |
| Liquid Crystal Display | LCD | Optical digital display system, applied voltage to which varies the way the crystals reflect light, thereby modifying the display |
| Litre | L | |
| Low Tension | LT | Primary circuit of the ignition system, linking the battery to the primary winding in the ignition coil |
| Malfunction Indicator Lamp | MIL | A required on-board indicator to alert the driver of an emission related malfunction |
| Manifold Absolute Pressure | MAP | Absolute pressure of the intake manifold air |
| Manifold Absolute Pressure Sensor | MAP Sensor | Sensor located in the ECM and ported to the intake manifold |
| Manifold Surface Temperature | MST | |
| Mass Air Flow | MAF | System which provides information on the mass flow rate of the intake air to the engine |
| Mass Air Flow Sensor | MAF Sensor | Hot-wire sensor which monitors air flow into the intake manifold for fueling and ignition control |
| Maximum | Max. | |
| Meter (measurement) | M | |
| Metric (screw thread, e.g. M8) | M | |
| Microfarad | MFD | Unit of electrical capacitance, one millionth of a farad |
| Millimeter | Mm | |
| Millimeter of mercury | MmHg | |
| Millisecond | Ms | |
| Minimum | Min. | |
| Minute | Minute | |
| Model year | MY | |
| Motorized In-Car Aspirator | MIA | Device which constantly samples cabin temperature by passing air over a sensor, and communicates with the A/CCM to modify A/C system performance to suit |
| Multi Protocol Adapter | MPA | An interpreter for the various data languages present on a vehicle |
| National Institute of Occupational Safety and Health (US) | NIOSH | |
| Newton | N | SI unit of force. 1 N = 0.2248 pounds force |
| Newton Meter | Nm | SI unit of torque. Must not be confused with nm (nanometer) |
| Nox | Compounds of nitrogen and oxygen formed at high temperatures. Major source of exhaust-gas air pollution | |
| Non-Volatile Random Access Memory | NVRAM | RAM which retains memory even if power supply is interrupted |
| Normally aspirated | N/A | Fueling system using intake air at atmospheric pressure; not supercharged or turbocharged |
| Normally Closed | NC | |
| Normally Open | NO | |
| North American Specification | NAS | Vehicles for sale in the USA and Canadian markets |
| Number | No. | |
| Occupational Safety and Health Administration (US) | OSHA | |
| On-Board Diagnostic | OBD | A system that monitors some or all computer input and output control signals. Signal(s) outside the pre-determined limits imply a fault in the system or a related system |
| Original Equipment Manufacturer | OEM | |
| Outside Diameter | O. dia | |
| Oxides of nitrogen | Nox | |
| Oxygen Sensor | O2S | A sensor which detects oxygen content in the exhaust gases |
| Parameter Identification | PID | An index number referring to a parameter within a module without knowledge of its storage location |
| Park Neutral Position | PNP | |
| Park Neutral Position Switch | PNP Switch | Indicates the selected non-drive modes of the (automatic) transmission |
| Part number | Part no. | |
| Pulse Width Modulated | PWM | |
| Programmable Electronic Control Units System | PECUS | Process whereby a common ECM is programmed on the production line to suit the market requirements of a particular vehicle |
| Programmable Read-only Memory | PROM | ROM with some provision for setting the stored data after manufacture |
| Random Access Memory | RAM | Fast access memory store which is accessible for entry or extraction of data |
| Read-Only Memory | ROM | Fast access memory in which data is fixed and may not be changed |
| Reservoir | RES | Container, usually for oils, coolants or hydraulic fluids |
| Rest Of The World | ROW | |
| Return | RTN | A dedicated sensor ground circuit |
| Revolutions Per Minute | RPM | Shaft speed of a device, usually an engine or motor |
| Right-hand | RH | |
| Right-hand drive | RHD | |
| Scan Tool | ST | Device that interfaces with and communicates information on a data link |
| Seat Control Module | SCM | Module controlling the seat motor systems (not electric raise/lower-only seats) |
| Secondary Air | Air provided to the exhaust system | |
| Secondary Air | AIR | System used for a period of time each time the engine is started, unless certain temperature criteria are met. Pumps air directly into the exhaust system which generates extra heat and reduces the time taken for the catalytic converters to reach operating temperature |
| Secondary Air Injection Bypass | AIR Bypass | Vents secondary air to atmosphere |
| Secondary Air Injection Check Valve | AIR Check Valve | Valve which prevents back-flow of exhaust gas to the AIR system when the system is inoperative |
| Secondary Air Injection Diverter | AIR Diverter | Diverts secondary air to either the catalyst or exhaust manifold |
| Secondary Air Injection Magnetic Clutch | AIR Clutch | Clutch mounted on the AIRP drive shaft |
| Secondary Air Injection Pump | AIR Pump | Mechanically driven rotary vane pump, driven through the AIRPC |
| Secondary Air Injection Relay | AIR Relay | Controls the injection of air into the exhaust system |
| Secondary Air Injection Switching Valve | AIR Switching Valve | Vacuum operated valve backing-up the AIRC |
| Security & Locking Control Module | SLCM | Module controlling the vehicle's security and closure-locking functions |
| Sensor | S | Generic name for a device that senses either the absolute value or a change in a physical quantity such as temperature, pressure or flow rate, and converts that change into an electrical quantity signal |
| Service Repair Operation (number) | SRO | Number generated by Jaguar Methods & Techniques system which relates to the time allowed to complete a repair operation. Further information on the system can be found in the separate Jaguar Publications (for each model range) entitled 'Repair Operation Times' |
| Shift Solenoid | SS | Controls shifting in an automatic transmission |
| Signal return | SIG RTN | |
| Sliding Roof Control Module | SRCM | |
| Society of Automotive Engineers | SAE | |
| Speed Control Module | SCCM | Module controlling Speed Control System |
| Square centimeter | Cm 2 | |
| Standard | Std | |
| Standard Corporate Protocol | SCP | A high-speed, serial communications system linking all body system control modules. Control messages and data are passed between modules at up to 786 messages per second |
| Supercharger | SC | An intake system which utilizes a supercharger (mechanically driven device that pressurizes intake air, thereby increasing density of charge air and the consequent power output from a given displacement) |
| Supercharger Bypass | SCB | |
| Tachometer | TACH | A circuit that provides input for an electronic tachometer display |
| Thermal Vacuum Valve | TVV | Controls vacuum levels or routing based on temperature |
| Throttle Body | TB | Device containing the throttle |
| Throttle Position | TP | |
| Throttle Position Sensor | TP Sensor | Interprets throttle position and movement to identify idle, acceleration and full-power demands |
| Throttle Manifold Absolute Pressure Sensor | TMAP | Combines the inlet air temperature and manifold pressure sensor in one component |
| Top Dead Center | TDC | |
| Torque Converter Clutch | TCC | |
| Transmission Control Module | TCM | Controls the shifting pattern of the (automatic) transmission |
| Transmission Control Switch | TCS | Modifies the operation of electronically controlled transmissions |
| Transmission Oil Temperature | TOT | Indicates temperature of transmission fluid |
| Transmission Range | TR | The range in which the transmission is operating |
| Turbine Shaft Speed | TSS | Indicates rotational speed of transmission output shaft or turbine shaft |
| Vacuum Solenoid Valve | VSV | Vacuum operated valve used in the speed control system |
| Vacuum Solenoid Valve (atm) | VSV(VA) | Vacuum atmospheric valve used in the speed control system |
| Vacuum Solenoid Valve (rel) | VSV(VR) | Vacuum release valve used in the speed control system |
| Vacuum Solenoid Valve (vac) | VSV(VV) | Vacuum valve used in the speed control system |
| Variable Valve Timing | VVT | A system by which the relationship of the crankshaft and camshaft may be altered during engine running |
| Vehicle Battery Adapter | VBA | Provides electrical power to the Jaguar approved diagnostic system and supplies a battery reference level |
| Vehicle Control Monitor | VCM | Instrument panel display which warns of faults |
| Vehicle Emission Control Information Label | VECI Label | |
| Vehicle Identification Number | VIN | Number assigned to the vehicle by the manufacturer, primarily for licensing and identification purposes |
| Vehicle Interface Adapter | VIA | Extends the Jaguar approved diagnostic system capability and provides a parallel interface to vehicle harnesses and ECMs |
| Vehicle Speed Sensor | VSS | Sensor which provides vehicle speed information |
| Viscosity Index | VI | |
| Voltage Regulator | VR | Device which regulates the variable output voltage of a generator |
| Watt | W | SI unit of power (1 hp = 745.7 watts) |
| Wide Open Throttle | WOT | Full throttle position |
Acids and Alkalis
See also Battery Acids .
e.g. caustic soda, sulfuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.
Ensure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire & Chemical Materials
Highly flammable, explosive - observe No Smoking policy.
Used as a part of the Supplemental Restraint System, mounted in various positions around the vehicle.
The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500°C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles should be worn during the handling process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site.
Following any direct contact with gas generant.
- Wash affected areas thoroughly with water
- Seek medical assistance if necessary
Air Bags - Do's
- Do store in an air bag safe when not installed to the vehicle.
- Do store modules in an upright position
- Do keep modules dry
- Do carry modules with the cover side pointing away from the body
- Do place modules with their cover side upwards
- Do carefully inspect modules for damage
- Do stand to one side when connecting modules
- Do make sure all test equipment is properly calibrated and maintained
- Do wash you hands after handling deployed air bags
Air Bags - Do Nots
- Do not store highly flammable material together with modules or gas generators
- Do not store gas generators at temperatures exceeding 80° C
- Do not store modules upside down
- Do not attempt to open a gas generator housing
- Do not expose gas generators to open flame or sources of heat
- Do not place anything on top of a module cover
- Do not use damaged modules
- Do not touch a fired module or gas generator for at least 10 minutes
- Do not use any electrical probes on the wiring circuit
Air Conditioning Refrigerant
See also Chlorofluorocarbons (CFC) & Chemical Materials
Highly flammable, combustible - observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots
- Do not expose refrigerant bottles to sunlight or heat
- Do not expose refrigerant bottles to frost
- Do not drop refrigerant bottles
- Do not vent refrigerant to atmosphere under any circumstance
- Do not mix refrigerants i.e. R12 (Freon) and R134a
Antifreeze
See also Fire & Solvents .
e.g. isopropanol, ethylene glycol, methanol.
Highly flammable, combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed can be fatal and medical attention should be sought immediately.
These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or drinking water supplies.
Asbestos
Used in brake and clutch linings, transmission brake bands and gaskets. Jaguar original production and replacement items are asbestos free.
See also Warning Symbols on Vehicles at the end of this information.
Breathing asbestos dust may cause lung damage or, in some cases, cancer.
The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.
Asbestos dust waste should be dampened, placed in a sealed container and marked to make sure safe disposal. If any cutting or drilling is attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis .
Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.
Ensure adequate ventilation.
Brake and Clutch Linings and Pads
See Asbestos .
Brazing
See Welding .
Chemical Materials
See also Legal Aspects .
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life-expectancy.
Chemical Materials - Do's
- Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers
- Do remove chemical materials from the skin and clothing as soon as practical after soiling. Change heavily soiled clothing and have it cleaned
- Do organize work practices and protective clothing to avoid soiling of the skin and eyes, and the breathing in of vapors, aerosols, dusts or fumes
- Do wash before breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials
- Do keep work areas clean, uncluttered and free from spills
- Do store chemical materials according to national and local regulations
- Do keep chemical materials out of the reach of children
Chemical Materials - Do Nots
- Do not mix chemical materials except under the manufacturer's instructions; some chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together
- Do not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are inside a vehicle
- Do not apply heat or flame to chemical materials except under the manufacturer's instructions. Some are highly flammable and some may release toxic or harmful fumes
- Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits etc.
- Do not transfer chemical materials to unlabeled containers
- Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities
- Do not use emptied containers for other materials except when they have been cleaned under supervised conditions
- Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful
Chlorofluorocarbons (CFC)
There is concern in the scientific community that CFCs and Halons are depleting the upper ozone layer which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet radiation may result in increases in skin cancer, cataracts and immune system suppression in humans, as well as decreased productivity of crops and aquatic systems.
CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol propellants. Halons are used as fire extinguishants.
Jaguar supports worldwide elimination of CFC usage and it is recommended that Company subsidiaries and affiliates should phase out CFC usage as soon as acceptable substitutes are commercially available.
Clutch Linings and Pads
See Asbestos .
Corrosion Protection Materials
See also Solvents & Fire .
Highly flammable, flammable - observe No Smoking policy.
These materials are varied and the manufacturer's instructions should be followed. They may contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.
Cutting
See Welding .
Dewaxing
See Solvents and Fuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and/or sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.
Ensure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably removed from the work station.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.
Ensure that electrical equipment and flexes do not come into contact with water.
Ensure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.
Ensure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution
- Switch off the power supply before approaching the victim
- If this is not possible push or drag the victim from the source of electricity using dry non-conductive material
- Commence resuscitation if trained to do so
- SUMMON MEDICAL ASSISTANCE
Engine Oils
See Lubricants and Greases .
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of irritation before toxic or harmful effects arise. These may be immediate or delayed.
Fibre Insulation
See also Dusts .
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of gloves.
Fire
See also Welding , Foams - Polyurethane , Legal Aspects .
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes.
Ensure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving the information on the container or label. Do not induce vomiting unless this action is indicated on the label.
Fluoroelastomer
See Viton .
Foams - Polyurethane
See also Fire .
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapor/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation.
Freon
See Air Conditioning Refrigerant .
Fuels
See also, Fire , Legal Aspects , Chemicals and Solvents .
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs e.g. through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe pain.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.
Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid .
Gas - oil (Diesel Fuel)
See warnings and cautions in the appropriate article.
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.
Gas Cylinders
See also Fire .
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 13.790 kPa, (2000 lb/in 2 ) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
Gases
See Gas Cylinders .
Gaskets (Fluoroelastomer)
See Viton .
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never over - load equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment.
Ensure adequate ventilation to control dusts, mists and fumes.
Halon
See Chlorofluorocarbons (CFC) .
Legal Aspects
Many laws and regulations make requirements relating to health and safety in the use and disposal of materials and equipment in workshops. Some of these laws which apply in the UK are listed. Similar laws exist for other territories
- The Factories Act (1961)
- The Asbestos Regulations (1969)
- Highly Flammable Liquids and Liquefied Petroleum Gases Regulations (1972)
- Control of Pollution Act (1974)
- Health and Safety at Work Act (1974)
- The Classification, Packaging and Labelling of Dangerous Substances Regulations (1978, 1981, 1983, 1984)
- Control of Lead at Work Regulations (1980)
- Control of Substances Hazardous to Health (COSHH) Regulations (1989)
- Abrasive Wheels Regulations (1970)
- Reporting of injuries, diseases and dangerous occurrences regulations 1985 (RIDDOR)
Workshops should be familiar, in detail, with these and associated laws and regulations.
Consult the local factory inspector if in any doubt.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Health Protection Precautions
- Avoid prolonged and repeated contact with oils, particularly used engine oils
- Wear protective clothing, including impervious gloves where practicable
- Do not put oily rags into pockets
- Avoid contaminating clothing with oil
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to enable easier removal of dirty oil and grease from the skin
- Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed
- Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay
- Where practical, degrease components prior to handling
- Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. In the UK the heating system must meet the requirements of HM Inspector of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed waste disposal sites, or to the waste oil reclamation trade, batteries should also be disposed off under similar arrangements. If in doubt, contact the relevant local authority for advice on disposal facilities.
It is illegal to pour used oil, antifreeze and automatic transmission fluid on to the ground, down sewers, drains, or into water courses.
O-Rings (Fluoroelastomer)
See Viton .
Paints
See also body and paint information.
See also Solvents & Chemical Materials .
Highly flammable, flammable - observe No Smoking policy
Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test Equipment .
Solder
Solders are a mixture of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Solvents
See also Chemical Materials , Fuels (Kerosene), Fire .
e.g. acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and de-waxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.
Sound Insulation
See Fibre Insulation & Foams - Polyurethane .
Suspended Loads
| CAUTION | Never improvise lifting tackle. |
There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load e.g. suspended engine, etc.
Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are adequate and suitable for the job, in good condition and regularly maintained.
Transmission Brake Bands
See Asbestos .
Underseal
See Corrosion Protection Materials .
Viton
In common with many other manufacturers' vehicles, some components installed to the Jaguar range have 'O' rings, seals or gaskets which contain a material known as 'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.
'O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.
Welding
See also Fire , Electric Shock , Gas Cylinders .
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding (and cutting).
Resistance Welding (Spot Welding)
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Arc Welding
This process emits a high level of ultraviolet radiation which may cause arc-eye and skin burns to the operator and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultraviolet emission is much less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the warnings.
Scheme 2
Scheme 3
- Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant article of the owners handbook before touching or attempting adjustments of any kind.
- Components or assemblies displaying the warning triangle with the electrified arrow and open book symbol give warning of inherent high voltages. Never touch these with the engine running or the ignition switched on. See «Electric Shock»(ref-311255-S31328028532009032500000) .
- Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol. See «Asbestos»(ref-311255-S13121037932009032500000) .
- Components or assemblies displaying this symbol give warning that the component contains a corrosive substance. See «Acids and Alkalis»(ref-311255-S26904928572009032500000) .
- Vehicles displaying the caution circle with a deleted lighted match symbol, caution against the use of naked lights or flames within the immediate vicinity due to the presence of highly flammable or explosive liquids or vapors. See «Fire»(ref-311255-S33523610642009032500000) .
- All vehicles with the passenger air bag installed from the factory have a warning sticker attached to the instrument panel, prohibiting the use of rear facing child seats in the front seating position. Failure to follow this instruction may result in personal injury.
White Spirit
See Solvents .
Safety Precautions
| WARNING | Working on the fuel system results in fuel and fuel vapor being present in the atmosphere. Fuel vapor is extremely flammable, hence great care must be taken while working on the fuel system. Adhere strictly to the following precautions: Do not smoke in the work area Display 'no smoking' signs around the area Disconnect the battery before working on the fuel system Do not connect/disconnect electrical circuits, use electrical equipment or other tools or engage in working practices which in any way may result in the production of sparks Ensure that a CO 2 fire extinguisher is close at hand Ensure that dry sand is available to soak up any fuel spillage Empty fuel using suitable fire proof equipment into an authorized explosion proof container Do not empty fuel while working in a workshop or a pit Ensure that working area is well ventilated Ensure that any work on the fuel system is only carried out by experienced and well qualified maintenance personnel Ensure that fume extraction equipment is used where appropriate |
| WARNING | Fume extraction equipment must be in operation when solvents are used e.g. Trichloroethane, white spirit, sbp3, methylene chloride, perchlorethylene. Do not smoke in the vicinity of volatile degreasing agents. |
Whenever possible, use a ramp or pit while working beneath a vehicle, in preference to jacking. Position chocks at the wheels as well as applying the parking brake. Never rely on a jack alone to support a vehicle. Use axle stands, or blocks carefully placed at the jacking points, to provide a rigid location. Check that any lifting equipment used has adequate capacity 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 vehicle battery. Do not disconnect any pipes of the air conditioning refrigeration system 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 used.
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 the work area. Wear protective overalls and use barrier cream when necessary.
Environmental Protection
In some countries it is illegal to pour used oil onto 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 installed. 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.
Starting the Engine
Note. On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator pedal at full travel while the engine is cold.
With the ignition switched off, check
- The handbrake is applied.
- The gear lever is in neutral.
- All instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check
- Ignition controlled warning lights come on.
- Engine temperature gauge registers a reading compatible with the engine temperature.
- Fuel gauge registers a reading appropriate to the fuel level in the tank.
- The operation of the handbrake warning light and fluid level warning indicator light.
Adhesives and Sealers
Highly flammable, combustible - observe No Smoking policy.
Generally should be stored in No Smoking' areas. Cleanliness and tidiness in use should be observed e.g. disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.
Solvent - based Adhesives/Sealers - See Solvents
Follow manufacturer's instructions.
Water - based Adhesives/Sealers
Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut - out and adequate extraction.
Resin - based Adhesives/Sealers e.g. Epoxide and Formaldehyde Resin - based
Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (Super - glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and/or respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and seek immediate medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation to the nose and eyes.
For two - pack systems see Resin - based Adhesives/Sealers e.g. Epoxide and Formaldehyde Resin - based .
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin - based Adhesives/Sealers e.g. Epoxide and Formaldehyde Resin - based
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapor concentrations may result in adverse health effects.
Prolonged contact with the skin may lead to skin irritation and, in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
Protecting the Vehicle
Always install covers to protect the fenders before commencing work in the engine compartment. Always install the interior protection kit, wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid, antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use polythene sheets in the luggage compartment to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw threads by replacing nuts or installing caps.
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that
- The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards
- If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed
- There is adequate room to jack up the vehicle and remove the wheels, if necessary
- Fender covers are always installed if any work is to be carried out in the engine compartment
- The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up
| CAUTION | When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of current causing damage to the internal components of the generator. |
- If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available.