General Information: Other Jaguar XF I

References to left-hand (LH) and right-hand (RH)

All left-hand (LH) and right-hand (RH) references to the vehicle are taken from a position sitting in the driver seat looking forward.

Vehicle LH and RH definition

Scheme 1

All left-hand (LH) and right-hand (RH) references to the engine are taken from a position at the flywheel looking towards the crankshaft front pulley.

Powertrain LH and RH definition

HOW TO USE REPAIR PROCEDURES

This information has been written in a format that is designed to meet the needs of technicians worldwide. It provides general descriptions for accomplishing repair work with tested and effective techniques.

Important Safety Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this information must first establish that personal safety or vehicle integrity is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Information

Note. Notes are used to provide additional essential information required to carry out a complete and satisfactory repair.

Generic warnings or cautions are in their relevant description and operation procedure . If the generic warnings or cautions are required for a procedure, there will be a referral to the appropriate description and operation procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustmark Authoring Standards (TAS) Repair Procedures

Note. TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures will have the following note at the beginning of the procedure

Note. Removal steps in this procedure may contain installation details.

Reuse of fasteners and seals and gaskets

The following list details the general policy for the reuse of fasteners and seals and gaskets.

Types of self-locking nuts and bolts

Note. There are more types of self-locking fasteners available than shown in following illustration.

Scheme 2

1. All types of seals and gaskets must be discarded and new seals and gaskets installed unless otherwise stated within the procedure.
2. Nuts and bolts with a chemical coating for locking and/or sealing and/or antiseize must be discarded unless the procedure advises to reapply the coating with a specified material.
3. Nuts and bolts with a mechanical locking such as thread inserts, thread deformation or locking washers must be discarded and new nuts and bolts installed unless otherwise stated within the procedure.
4. Torque to yield bolts must be discarded and new torque to yield bolts installed unless otherwise stated within the procedure, recognizable by a tightening torque with more than one stage together with a torque angle.

Specification data

Specification procedures will only contain technical data that is not already part of a repair procedure.

Sequence of tasks

If components must be removed or installed in a specific sequence, the sequence will be identified numerically in a graphic and the corresponding text will be numbered accordingly.

Special Tools, Equipment, Materials and Torque Figures

Special tools will be shown with the tool numbers in the illustration. The special tool numbers, general equipment, materials and torque figures used for the procedure step will be shown in the text column.

TAS Graphics

Colors used in the graphic are as follows

1. Blue - Component to be removed/installed or disassembled/assembled.
2. Green and Brown - Additional components that need to be removed/installed or disassembled/assembled prior to the target component.
3. Yellow - Component that is touched or affected in a way but remains in the vehicle. It may be detached, attached, moved, modified, checked, adjusted etc.
4. Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps and clips.
5. Pale Blue - Special tool(s) and general equipment.

One illustration may have multiple steps assigned to it.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps and clips.

Items in the illustration can be transparent or use cutouts to show hidden details.

Scheme 3

Scheme 4

Scheme 5

TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display. The following paragraphs describe the various types and categories of symbols. Refer to: Symbols Glossary .

Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks. These symbols are

Scheme 6

Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce the risk or severity of possible injuries.

Scheme 7

Warning symbols are used to indicate potential risks resulting from a certain component or area.

Scheme 8

Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.

Scheme 9

Location symbols are used to show the location of a component or system within the vehicle.

Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever position is to be set.

Pointer symbols are used to draw attention to components and give special instructions such as a required sequence or number of components. The number of components is reflected by the value inside the luty arrow. A sequence number is located inside the circle. Numbers inside circles are also used to allocate special information such as tightening torques or chemicals to a particular component.

Scheme 10

Movement arrows are used to show three dimensional or rotational movements. These movements can include specific values inside the symbol if required.

Scheme 11

Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values if required.

Scheme 12

The following graphic illustrates a set of symbols that are used to provide detailed information on where to apply a material.

Scheme 13

Measurement symbols provide detailed information on where to carry out a specific measurement. These symbols can include specific values if required.

Scheme 14

BATTERY AND BATTERY CHARGING HEALTH AND SAFETY PRECAUTIONS

BRAKE SYSTEM HEALTH AND SAFETY PRECAUTIONS

DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS

Note. Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

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.

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).

Always disconnect the battery before commencing repair operations which require

1. The vehicle to be jacked up
2. Work on the engine
3. Work underneath the vehicle
4. Arc welding

Alternatively a Radio Code Saver may be used, when not working on the Air Bag or Fuel systems. 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

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 installed) and set it to the correct time.

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 will allow the ECM to relearn idle and drive values, and may cause driveability concerns if the procedure is not carried out.

CONNECTING A SLAVE BATTERY USING JUMP LEADS

1. Always make sure that the jump leads are adequate for the task. Heavy duty cables must be used.
2. Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel.
3. 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 15

Always connect the jump leads in the following sequence.

1. Slave battery positive first then vehicle battery positive.
2. 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, 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 generator to restore a discharged battery. For a generator 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

1. Dry Cleaning
2. Removal of loose dirt with soft or wire brushes
3. Scraping dirt off with a piece of metal or wood
4. Wiping off with a rag

1. Blowing dirt off with compressed air (Eye protection should be worn when using this method)
2. Removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material dust (asbestos particles)
3. Steam Cleaning

USE OF CONTROL MODULES

Control modules may only be used on the vehicle to which they were originally installed. 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 oil ways, 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, oil ways and fluid passages with compressed air.

Make sure that any O-rings used for sealing are correctly reinstalled 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 Guide.

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 information.

The required term may be looked-up in the left-hand column, and subsequent columns give the standard acronym, unit or abbreviation, and definition.

HEALTH AND SAFETY PRECAUTIONS

The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken. Some of these chemicals may be included in the following list either in their own right or as an ingredient in a sealer or adhesive.

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 - General

Highly flammable, explosive - observe No Smoking policy.

Used as a part of the Supplemental Restraint System (SRS), 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.

1. Wash affected areas thoroughly with water
2. Seek medical assistance if necessary

Note. The storage, transportation, disposal and/or recycling of air bag modules must be carried out in accordance with all applicable federal, state and local regulations including, but not limited to, those governing building and fire codes, environmental protection, occupational health and safety and transportation.

Air Bags - Do's

1. Do store in an air bag safe when not installed to the vehicle.
2. Do store modules in an upright position
3. Do keep modules dry
4. Do carry modules with the cover side pointing away from the body
5. Do place modules with their cover side upwards
6. Do carefully inspect modules for damage
7. Do stand to one side when connecting modules
8. Do make sure all test equipment is properly calibrated and maintained
9. Do wash you hands after handling deployed air bags
10. Do wear safety glasses when carrying out repairs to the SRS or when handling an air bag module
11. Only carry out a system test with the air bag modules fully installed
12. Do inspect the condition of the impact sensor mounting bracket and sensor flylead if the vehicle has been involved in an impact. Replace if damaged, even if there has been no deployment.

Air Bags - Do Nots

1. Do not store highly flammable material together with modules or gas generators
2. Do not store gas generators at temperatures exceeding 80° C
3. Do not store modules upside down
4. Do not attempt to open a gas generator housing
5. Do not expose gas generators to open flame or sources of heat
6. Do not place anything on top of a module cover
7. Do not use damaged modules
8. Do not handle a deployed device or gas generator for at least 20 minutes
9. Do not probe air bag module electrical connectors or any other SRS component

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

1. Do not expose refrigerant bottles to sunlight or heat
2. Do not expose refrigerant bottles to frost
3. Do not drop refrigerant bottles
4. Do not vent refrigerant to atmosphere under any circumstance
5. Do not mix refrigerants i.e. R12 (Freon) and R134a

ANTIFREEZE

See also FIRE , SOLVENTS .

e.g. isopropanol, ethylene glycol, methanol.

Highly flammable, 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 subsection.

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

1. 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
2. Do remove chemical materials from the skin and clothing as soon as practical after soiling. Change heavily soiled clothing and have it cleaned
3. 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
4. Do wash before breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials
5. Do keep work areas clean, uncluttered and free from spills
6. Do store chemical materials according to national and local regulations
7. Do keep chemical materials out of the reach of children

Chemical Materials - Do Nots

1. 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
2. Do not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are inside a vehicle
3. 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
4. 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.
5. Do not transfer chemical materials to unlabeled containers
6. 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
7. Do not use emptied containers for other materials except when they have been cleaned under supervised conditions
8. 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

1. Switch off the power supply before approaching the victim
2. If this is not possible push or drag the victim from the source of electricity using dry non-conductive material
3. Commence resuscitation if trained to do so
4. 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.

GASOLENE (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 , CHEMICAL MATERIALS 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 relevant information sections.

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 .

GENERAL WORKSHOP TOOLS AND EQUIPMENT

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

1. The Factories Act (1961)
2. The Asbestos Regulations (1969)
3. Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972)
4. Control of Pollution Act (1974)
5. Health and Safety at Work Act (1974)
6. The Classification, Packaging and Labelling of Dangerous Substances Regulations (1978, 1981, 1983, 1984)
7. Control of Lead at Work Regulations (1980)
8. Control of Substances Hazardous to Health (COSHH) Regulations (1989)
9. Abrasive Wheels Regulations (1970)
10. 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 inspectorate 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.

There are publications describing the problems and advising on precautionary measures. For the UK a typical Health and Safety Executive publication is: SHW 397: Cautionary Notice: Effects of mineral oil on the skin.

Health Protection Precautions

1. Avoid prolonged and repeated contact with oils, particularly used engine oils
2. Wear protective clothing, including impervious gloves where practicable
3. Do not put oily rags into pockets
4. Avoid contaminating clothing with oil
5. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly
6. First Aid treatment should be obtained immediately for open cuts and wounds.
7. Use barrier creams, applying them before each work period, to enable easier removal of dirty oil and grease from the skin
8. 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
9. Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
10. If skin disorders develop, obtain medical advice without delay
11. Where practical, degrease components prior to handling
12. 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 Inspectorate 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.

0-RINGS (FLUOROELASTOMER)

See VITON .

PAINTS

See also body and paint manual.

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

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 16

Scheme 17

1. Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.
2. 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 in this subsection.
3. Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol. See Asbestos in this subsection.
4. Components or assemblies displaying this symbol give warning that the component contains a corrosive substance. See Acids and Alkalis in this subsection.
5. 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 in this subsection.
6. 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

Whenever possible, use a ramp or pit whilst 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.

COPYRIGHT STATEMENT

Copyright.© Jaguar Cars Ltd. 2005

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means, without prior written permission from the Service Division of Jaguar Cars Ltd.

WORKSHOP INFORMATION ORGANIZATION

This information covers descriptive, diagnostic (including OBD), and repair aspects to service the vehicle effectively.

The information is arranged in sections, each section dealing with a specific part of a vehicle system. For example, Section 412-03 [Air Conditioning] covers air conditioning, which is part of the climate control system.

The first digit of the section number indicates the group (in the above example this being Electrical). There are five groups

1. General Information.
2. Chassis.
3. Powertrain.
4. Electrical.
5. Body and Paint.

The second and third digits of the section number indicate the vehicle system (12 in the above example being Climate Control).

The last two digits of the section number indicate the part of the system covered by the section (03 in the example denotes Air Conditioning).

IMPORTANT SAFETY INFORMATION

Safety Notice

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the safety of the person doing the work. This information provides general directions for accomplishing service and repair work with tested effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the person doing the work. This information cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in the information must first establish that neither personal safety or vehicle integrity is compromised from choices of methods, tools or parts.

PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS

SOLVENTS, SEALANTS AND ADHESIVES

The Solvents, Sealers and Adhesives subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken.

ADHESIVES AND SEALERS

Highly flammable, 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 and Isocyanate Adhesives/Sealers.

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

1. The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards
2. If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed
3. There is adequate room to jack up the vehicle and remove the wheels, if necessary
4. Fender covers are always installed if any work is to be carried out in the engine compartment
5. The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up

1. If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available.

SCREW THREADS

1. Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap or die impairs the strength and fit of the threads and is not recommended.

Note. During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and thread is used.

Note. New Taptite bolts when used cut their own threads on the first application.

1. Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
2. Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing. Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an adjustment.
3. Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split the housing and also give a false torque reading.
4. Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque reading.
5. Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve tightening by degrees.
6. To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified torque figure.
7. Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.

Where it is stated that bolts and screws may be reused, the following procedures must be carried out

1. Check that threads are undamaged.
2. Remove all traces of locking agent from the threads.

1. Make sure that threads are clean and free from oil or grease.
2. Apply the specified locking agent to the bolt threads.

SUPPLEMENTARY RESTRAINT SYSTEM (SRS) PRECAUTIONS

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The following guidelines and precautions are intended to alert personnel to potential sources of danger and emphasize the importance of ensuring the integrity of the SRS components installed to the vehicle.

1. The correct procedures must always be used when working on SRS components.
2. Persons working on the SRS system must be fully trained and have been issued with the safety guidelines.
3. The airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids or heavy metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contact with electricity before the unit has been deployed.
4. Always replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing shows signs of fraying.
5. Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with an SRS system.

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The same care should be exercised when working on ancillary systems and components located in the vicinity of SRS components; these include but are not limited to

1. Steering wheel airbag, rotary coupler.
2. Passenger front airbag.
3. Head airbag modules - front and rear.
4. Seat belt pre-tensioners.
5. SRS harnesses, link leads and connectors.
6. Side (thorax) air bags.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the following operations

1. Remove the ignition key.
2. Disconnect battery, earth lead first.
3. Wait 2 minutes for the SRS power circuit to discharge before commencing work.

Note. The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure under crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to avoid the risk of accidental deployment.

Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is ready for effective operation in the event of a collision. Carefully inspect SRS components before installation. Do not install a part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.

1. Do not install accessories or other objects to trim panels which cover ITS airbags.
2. Never install used SRS components from another vehicle or attempt to repair an SRS component.
3. When repairing an SRS system, only use genuine new parts.
4. Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure.
5. Special fixings are necessary for installing an airbag module - do not use other fixings and make sure that all fixings are tightened to the correct torque.
6. Always use new fixings when replacing an SRS component.

Note. Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but will need to be replaced as soon as possible to make sure full SRS protection.

Note. If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following

Handling and storage

Always observe the following precautions when handling SRS components

1. Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and must be handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to a strong shock.
2. Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the cover uppermost and the base away from your body.
3. Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle. Always use the luggage compartment of the vehicle for carrying airbag modules and seat belt pre-tensioner units.
4. Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow anything to rest on top of an airbag module.
5. Always keep components cool, dry and free from contamination.
6. Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
7. Always store an airbag module with the deployment side uppermost. If it is stored deployment side down, accidental deployment will propel the airbag module with sufficient force to cause serious injury.
8. Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the empty packaging for carriage.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring

1. Never attempt to modify, splice or repair SRS wiring.
2. Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in such a way that it could generate electrical interference in the airbag harness. Seek specialist advice when installing such equipment.

Note. SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe protective coverings are sometimes used).

Side impact crash sensor inspection

After any degree of side body damage, inspect the side impact crash sensors. Replace a crash sensor if there is any sign of damage.

Rotary coupler

1. Do not unlock and rotate the rotary coupler when it is removed from the vehicle.
2. Do not turn the road wheels when the rotary coupler is removed from the vehicle.
3. Always make sure the rotary coupler is removed and installed in its central position and with the front road wheels in the straight ahead position - refer to SRS repair section for the correct removal and installation procedure.
4. If a new rotary coupler is being installed, make sure the locking tab holding the coupler's rotational position is not broken; units with a broken locking tab must not be used.

Airbag location labels

WAITING AIRBAG LOCATION AND DESIGN LABELS - DUE MARCH - NEIL HARRISON 46404

AIRBAG AND PRE-TENSIONER DEPLOYMENT

Deployment procedures and precautions as detailed in this information should be strictly adhered to. Only personnel who have undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The following precautions must be complied with

1. Only use deployment equipment approved for the intended purpose.
2. Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been designated for the purpose.
3. Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
4. Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner units.
5. When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away from the deployment zone.
6. Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of this information. In particular, make sure deployment tool is NOT connected to battery supply before connecting to airbag module connector.
7. When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
8. When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and seal deployed units in a plastic bag.
9. Following deployment of any component of the SRS system within the vehicle, all SRS components must be replaced. DO NOT reuse or salvage any parts of the SRS system.
10. Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this case airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its correct mounting position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped, deploy the module outside of the vehicle.

FRONT AIRBAG DEPLOYMENT - DRIVER AND PASSENGER

1. Driver airbag module
2. Passenger airbag module
3. Fly leads (where applicable) connecting front airbag modules to SRS harness
4. Front seat belt buckle pre-tensioner
5. Rear seat belt pre-tensioners - if installed
6. Driver's seat belt retractor - if installed
7. Rotary coupler
8. Any front impact sensors that have been physically damaged or if a fault is being registered
9. Restraints control module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary

1. Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
2. Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
3. Fascia moulding adjacent to passenger airbag module
4. Steering wheel
5. Front seat frames and head restraints
6. Steering column - if adjustment is lost or if there are signs of collapse
7. Seat belt height adjusters
8. Rear seat belts

Side Air Bags

1. Side (thorax) airbag
2. Any side impact sensors that have been physically damaged or if a fault is being registered
3. Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary

1. Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
2. Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
3. Front seat frame and head restraints
4. Door trim casing
5. Seat belt height adjusters
6. Rear seat belts

Head airbag modules

1. Head airbag modules
2. Link lead between airbag gas generator and restraints control module (RCM) harness
3. Airbag retaining clips
4. Internal trim finisher
5. Front seat belt buckle pre-tensioners
6. Any side impact sensors that have been physically damaged or if a fault is being registered
7. Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary

1. Headlining
2. Component mounting brackets
3. Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
4. Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
5. Adjacent trim components
6. Seat belt height adjusters

Rear impacts

1. Seat belt pre-tensioners
2. Front and rear seat belt retractors used during the impact
3. Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary

1. Seat belt height adjusters
2. Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
3. Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

SYMBOLS GLOSSARY

Symbols are used inside the graphics and in the text area to enhance the information display.

Movement Symbols

Movement symbols provide detailed information to a required component movement. These component movements can be rotational or 1-3 dimensional movements.

Scheme 18

Turn Symbols

Turn symbols are used to provide further information on the direction or angle of component turns.

Scheme 19

Steering Wheel Symbols

Steering wheel symbols are used to provide further information to a required steering wheel position or steering column lock status.

Scheme 20

Scheme 21

Gearshift lever and selector lever position symbols

Gearshift lever and selector lever position symbols are used to show the lever position that is required to be selected to carry out a procedure step.

Screwdriver symbols

The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure step.

Scheme 22

Pliers symbols

The pliers symbols are used to show which pliers is recommended to carry out a procedure step.

Scheme 23

Drill symbols

The drill symbols are used to show which type and size of drill bit is recommended to carry out a procedure step.

Scheme 24

Cutting tool symbols

The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure step.

Scheme 25

Apply Chemical or load symbols

The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry out a procedure step.

Scheme 26

Measurement symbols

The measurement symbols are used to show where to measure which type of measurement to carry out a procedure step.

Scheme 27

General equipment symbols

The general equipment symbols are used to show where to use which type of general equipment to carry out a procedure step.

Scheme 28

Material symbols

The material symbols are used to show where to use which type of material to carry out a procedure step.

Miscellaneous symbols

These symbols provide further information that is required to carry out a procedure step.

Scheme 29

Mandatory Protective equipment - Health and safety symbols

The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce possible health and safety risks.

Scheme 30

Prohibition - Health and safety symbols and component damage

The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible component damage and health and safety risks.

Scheme 31

Warning symbols - Health and safety and component damage

The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible component damage and health and safety risks.

Scheme 32

Control Diagram symbols - Description and Operation procedures

These symbols provide further information on the type of connectivity, direction of flow or type of data bus of a system.

Scheme 33

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HEALTH AND SAFETY PRECAUTIONS

STARTING THE ENGINE

With the ignition switched off, check

1. The parking brake is applied
2. The transmission selector lever is in Park
3. All instrument gauges (except fuel gauge) read zero

With the ignition switched on, check

1. Ignition controlled warning lamps come on
2. Engine coolant temperature gauge registers a reading compatible with the engine coolant temperature
3. Fuel gauge registers a reading appropriate to the fuel level in the tank
4. The operation of the parking brake and brake fluid level warning lamps

WINDOW GLASS HEALTH AND SAFETY PRECAUTIONS