Jaguar XJ-S. Service manual - part 5

 

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Jaguar XJ-S. Service manual - part 5

 

 

 
 

15

GENERAL

 

 

GETTING SERVICE:  Keeping your Jaguar in good working order is like anything else:  If you want it done right, do 
it yourself.  Doing as much of your own maintenance as possible is highly recommended, based on experiences shared 
on the online discussion lists (many of which are related in this book).  You might be thinking, “Yeah, but wouldn’t I 
be better off hiring somebody with a lot of experience working on these cars?”  The answer:  You’re holding all the 
experience you’re ever likely to need.  That’s why the book was so named. 

Nevertheless, there will be owners who don’t want to get dirty, or don’t have the time, or don’t have the tools, or don’t 
have a garage, or for whatever other reason would simply prefer to pay someone else to work on their car than do it 
themselves.  There’s nothing wrong with such a strategy; it simply must be made clear that such a decision should not 
be made with the expectation that the car will get better service.  More convenient, maybe; quicker, quite possibly.  But 
a long history of experiences with Jaguar dealers, specialists, mechanics, and the like indicate that the XJ-S owner 
should expect more problems if he takes his car somewhere for service than if he maintains it himself using this book as 
a guide. 

That said, some guidelines on finding a good mechanic:  First, note that the XJ-S has been out of production for some 
time now, and Jaguar dealerships are not likely to be all that enthused about working on it.  Some dealers might be 
lucky to even have a mechanic on staff that was there when these cars were built, and all the newer mechanics will have 
been trained on the current models rather than the older models.  When you pull into a dealer for service, don’t be 
surprised if the only enthusiasm displayed towards you and your car comes from a salesman anxious to talk you into 
trading in that old pile of junk on a brand new whatever. 

With a car such as the Jaguar XJ-S, you will invariably be far better off finding an “enthusiast” -- a guy who loves these 
cars and loves to work on them.  Even if he works in a dilapidated shack, you’re likely to be much happier with his 
work than you would taking the car to a shiny dealership that doesn’t care about your car. 

Of course, enthusiasts can be hard to find.  One excellent idea would be to ask other Jaguar owners who they take their 
cars to.  If there is a Jaguar club in the area, ask them.  Finally, if there simply are no enthusiasts in your area, consider 
finding out where the nearest one is anyway; even if you don’t take your car that far away for oil changes and the like, 
there may come a day when you need someone to call who can really help. 

Striking out totally in the enthusiast search, your next best option would be to simply find a good independent 
mechanic.  If he’s willing to tackle a Jaguar, he will probably be capable of fixing most of the problems likely to crop 
up; it’s not that different from other cars.  If you do a little reading in this book before you go, quite likely the two of 
you can get started in the right direction towards getting your problems sorted. 

I’d like to suggest that you simply make a copy of this book and give it to your mechanic to help him work on your car, 
but experience shows that this doesn’t work very well.  Many mechanics seem to consider it an insult that you would 
suggest that he needs help from a book.  Others apparently can’t read.  And almost none of them are inclined to put that 
kind of time into learning about Jaguars, especially since they have never seen a book like this one and are unaware 
anything of the sort exists.  So, perhaps you might offer a copy, or perhaps just discuss your car with him and if he asks 
how come you know so much you can tell him about it.  If you happen to find a mechanic who expresses an interest in 
the book, I’d suggest you have a keeper; if he actually reads a significant portion of it, he will be the best mechanic 
you’re likely to find. 

Meanwhile, if you will read this book, you will find yourself far better able to judge whether or not a mechanic is up to 
snuff on the Jaguar XJ-S.  You will become an informed consumer. 

 

PARTS REPLACEMENT STRATEGIES:  For those obsessed with keeping their cars in original condition, obviously 
only original parts will do.  The suggestions throughout this book are for those who simply want their cars to run and to 
minimize cost and grief in the process. 

 
 

16

Experienced British car enthusiasts will agree that most of their reliability problems come from two sources:  Non-
metallic parts and Lucas electrics.  This is especially true for Jaguars, where the rest of the car is generally excellent. 

Rumors abound as to why the rubber and plastic parts on British cars tend to crap out so soon.  One rumor says there is 
a law in Britain requiring the use of natural rubber rather than the far superior synthetic elastomers.  Whatever the 
cause, the Jaguar owner is well advised to replace the original Jaguar seals, hoses, belts, etc., with non-British 
substitutes whenever feasible. 

It has been suggested that the various vinyl and rubber protectants on the market, such as STP Son Of A Gun, can be 
used to help many rubber components last longer. Sandy Gibbs:  “When I owned a TR8 I had many of the same 
problems regarding engine heat and rubber components.  I found Armor All and Son of a Gun were useless unless 
applied every three or four days (if you drive the car much).  What did work was brake fluid, of all things.  You have to 
soak the part in question pretty well then rub the fluid in.  Let the part dry before running the car.  This procedure may 
have to be repeated two or three days in a row but then the rubber is revitalized, after that one need only repeat the 
procedure every two or three months.  The key here is keeping the brake fluid off anything but the rubber part.  This 
process works on nearly any rubber part except, for some reason, tires.” 

Lucas has been called the “Father of Darkness”.  Contrary to popular opinion, Lucas did not invent darkness -- they 
merely perfected it to a fine art!  The owner is well advised to replace Lucas electrical components with alternative 
products when feasible.  It should be noted that many of the electrical parts on a Jag are not really Lucas; the “Jaguar” 
stereo is probably made in Japan, and many of the EFI components are Bosch relabelled as Lucas. 

Other than electrical and non-metallic parts, Jaguar components are typically excellent, and most are reasonably priced. 
 Whether it is better to replace a broken item with the Jaguar original or a substitute must be decided on an individual 
basis.  A good general rule is:  If the original failed of its own accord, it might be better to try another source.  But if the 
failure was secondary (due to something else failing first), the Jaguar parts may very well be the best there are; 
substitutions are in order only where the prices of the originals are unreasonable. 

Regarding rebuilt parts, Randy Wilson says, “There are many companies out there that rebuild to a price, replacing only 
the “common” failure part.  Their attitude is it’s cheaper to only replace the one part and let the consumer figure out 
which units need more work than it is to full rebuild and test every unit.  This is true with electrical, a/c, steering gear, 
and other things.  The real sad part is these unscrupulous clowns often drive the reputable rebuilders out of the market 
by the price difference.  Rebuilds are a pain.  The cheap ones are no bargain.  And just buying an expensive one is no 
guarantee.  It may be a thorough rebuild, or it may be a cheap one that your vendor is making a killing on.” 

 

REPAIR MANUALS:  For a listing of sources for manuals, see “PUBLICATIONS AND PERIODICALS” starting on 
page 719. 

As mentioned on the flyer page, this book is not intended to substitute for a proper repair manual; you will need to buy 
one if you intend to do any work on the car.  In general, there appear to be three to choose from: an XJ-S Repair 
Operation Manual
 from Jaguar intended for owners, a set of XJ-S Service Manuals from Jaguar intended for dealers 
and authorized mechanics, and a Haynes manual.  The Jaguar publications come in several varieties for different model 
years, while the Haynes has been published in only one version. 

The XJ-S Repair Operation Manual (commonly referred to as “the ROM”), is expensive (around $100) and mediocre; 
not only is it somewhat difficult to follow, it is also fraught with errors.  Nevertheless, it’s still probably the best choice 
here. 

From the introduction of the XJ-S until 1982, Jaguar offered a basic ROM, part no. AKM 3455, ©1975.  This edition 
does not cover the GM400 automatic transmission. 

With the introduction of the H.E. in 1982, Jaguar issued an addendum titled Jaguar XJ-S H.E. - Supplement to the 
Repair Operation Manual
, part no. AKM 3455/S1, ©1982, commonly known as “the H.E. Supplement”.  They also 
issued an updated edition of the ROM, AKM 3455 Ed 3 “incorporating H.E. Supplement”, ©1982.  Understandably, 
the H.E. Supplement included in Ed 3 is identical to the Supplement available as a separately bound volume.  Ed 3 does 
cover the GM400 automatic transmission, though. 

 
 

17

In 1984 part no. AKM 3455 Ed 4 was issued; this apparently represents the last correction and update to the ROM 
itself, even though rather than incorporate the H.E. data into the main part of the manual it continued to feature an H.E. 
supplement.  From 1984 on, the ROM was updated solely by the addition of supplements; “Ed 4” comes with 
Supplement A only, “Ed 4/2” (©1989) comes with Supplements A & B, and “Ed 4/3” (©1995) comes with 
Supplements A, B, and C: 

1979 - 1984 

H.E.  

1984 - 1988 1/2 

Lucas 'P', cabriolet from VIN 112586, 30 pages  

1988 1/2 - on 

6.0 litre, 4-speed  A/T, ABS, new body, convertible, 168 pages 

Physically, the ©1975 ROM and ©1982 Supplement came as separate softcover books with off-white covers, while in 
the Ed 3 and Ed 4 versions Jaguar incorporated the manual and supplements into a single binding.  John M. Smith has 
the Ed 4 printing, and somehow got a hardbound copy:  “Pre-H.E. sections in white pages.  H.E. supplement at rear in 
green pages.”  Steve Draper reports on his Ed 4/2:  “It is a single softbound volume.”  Chris Carley got the Ed 4/3, 
“One book soft bound in Jag green. Each supplement has black edge at the beginning page with heading so you can 
flick through & see it.” 

Supplement A in the Ed 4 books is apparently quite similar to the ©1982 separately-bound H.E. Supplement, even 
though the ©1982 Supplement is 63 pages while Supplement A is 74 pages.  The pages must be counted by hand since 
neither of these supplements have sequentially numbered pages.  This book contains many references to the ©1982 
Supplement, since the author owns a copy; readers should generally presume that the references apply equally well to 
Supplement A. 

Unfortunately, when you actually try to buy a repair manual, you not only may have trouble telling which version 
you’re getting -- you may have trouble telling if it’s a ROM!  For some reason, many booksellers have an aversion to 
actually listing the title as clearly printed on the front of the book.  Rather than offering an XJ-S Repair Operation 
Manual
, they will call it an “Official Shop Manual”, “Official Jaguar Repair Manual”, or whatever other name they can 
dream up to confuse the customer.  In general, if the price is in the $80-$120 range, you can assume it’s the XJ-S Repair 
Operation Manual
, but it never hurts to ask to make sure before shelling out the cash. 

Also note:  With some bookstores, if you tell them what year car you have, you may get only what they think you need; 
this author has an ’83, and ended up with the ©1975 edition ROM and the ©1982 Supplement.  While this may be 
considered acceptable, a later ROM is always better since they still contain the earlier info; the Ed 4 is clearly an 
improvement over the ©1975 ROM even if you own a mid-70’s XJ-S simply due to the corrections incorporated.  And 
there is always the possibility that you may decide to upgrade some part of your car with the parts from a later car.  Just 
about the only reason to accept an earlier ROM is if you find a clearance price. 

Note that if you have the GM400 transmission, you will want to insist upon the Ed 3 or Ed 4 edition; the ©1975 ROM 
covers only the Borg-Warner, and the ©1982 Supplement doesn’t help.  The Ed 4 edition covers the GM400 quite 
thoroughly, as described by Patrick MacNamara:  “My ROM AKM 3455 Ed 4 has an extensive chapter on removal, 
fault finding and overhaul for the GM 400.  It also contains everything on the BW except removal.  Interestingly, the 
table of contents lists both transmissions and all related chapters as the same for both (ie 44.00.00 is data and 
description for the GM, while 44.00.00 is hydraulic flow charts for the BW).  You just have to make sure you are 
looking at the correct chapter 44 in the text as there are two.” 

If you happen to get stuck with the ©1975 ROM and wish to work on your GM400 automatic transmission, your best 
bet would be to get a separate repair manual for the tranny.  Andrew Kalman suggests How To Work With And Modify 
The Turbo Hydra-matic 400 Transmission
 by Ron Sessions, Motorbooks International, 1987, 224 pages, 300 
illustrations; ISBN 0-89738-267-8.  Kalman says:  “It seems quite complete, with a historical overview, basic 
maintenance, operation, overhaul, modifications and speed tuning.”  This book is highly recommended by many; for 
example, Mark Johnson says, “If Kirby had compiled a book on transmissions, this would be it.”  How’s that for an 
endorsement! 

Of course, you will still lack instructions on how to remove and reinstall the GM400 in an XJ-S, but you can pretty 
much make that up as you go along (with help from the transmission mount info starting on page 341 in this book) -- or 
you could just buy a Haynes manual, described below.  The Sessions book plus the Haynes manual will still be cheaper 
than buying another ROM to get the GM400 info. 

 
 

18

Your second repair manual option is to purchase the XJ-S Service Manuals, which come as sets of several volumes 
each.  If you thought the Repair Operation Manual was expensive, the series of XJ-S Service Manuals ought to be good 
for a major coronary:  Several hundred bucks a set.  On top of that, you may end up having to buy more sets than you 
anticipated; while the later edition ROM’s contain all the info on earlier cars, the multi-volume Service Manuals do not. 
 Richard Mansell:  “Now that I have the manuals in my hot little hands it appears to be more complicated than I 
thought.  The pre-H.E. to 87-88 manuals (JJM 10 04 06) appear to be based around the pre-H.E. with extra sections to 
cover the differences between these and the H.E. (pretty logical so far).  The new manuals, up to 91, (JJM 10 04 06-20) 
come in 5 volumes rather than the earlier 4 but only appear to cover the additions since the earlier manuals for the 5.3 
plus a random selection of the original information.  Oh, and it covers the 4.0 engine too.  In other words, if you have 
an ’89 to ’91 5.3 and you want to know about the new ignition, etc., you will need both sets as the later volume set 
refers to many sections that only exist in the earlier set; e.g. under the heading “Cylinder heads overhaul” it says: 
 

Remove left and right hand cylinder heads, see 12.29.01.  

Where is 12.29.01?  Only in the earlier set!  Since the five-volume set costs more than the earlier one, I assumed it 
would be a complete guide to the later cars.  Wrong! 

“The only thing of great value in the five-volume set that is not in the four is the Marelli ignition. 

“Each set comprise of hardback green ring bound folders with a white growler and the words Service Manual on the 
front.  The copyright of the first manual is 1988.  JJM 10 04 06-20 has the copyright date of 1991. 

“I understand that there are add-ons, JJM 10 04 06-201 and 202 that cover models ’92 to ’96. 6.0L engine plus other 
changes.”  The H. D. Rogers web site (page 709) confirms this, and reiterates that these later manuals are not stand-
alone either -- if you have a ’92-on car you will need all of these sets to cover it. 

Robert Woodling says, “I have purchased both the factory four-volume set and the Repair Operation Manual.  The 
four-volume set in some instances provides better detail while the ROM provides a better step-by-step approach.” 

Before buying the multi-volume Service Manuals, you might want to consider the CD-ROM mentioned below.  In fact, 
you might have to; Keith Lumsdaine says,  “As of December 2000, the official Jaguar Workshop Manual part number 
JJM 100406 20 for the 1991-on cars is no longer available, as Jaguar have now [Feb 2001] issued it with the 
Supplements JJM100406 201 & JJM 100406 202 in CD-ROM form.” 

The only XJ-S repair manual made by anyone other than Jaguar is a Haynes manual, Jaguar XJ12 & XJS.  This was 
manual #478 in Haynes’ old numbering scheme, and is #49015 in their new numbering scheme -- but it’s the same 
book either way.  It’s a lot cheaper than the Jaguar publications (under $20), cheap enough you might as well pick one 
up even if you plan on buying the Jaguar books anyway.  It’s based on portions of the factory manuals with some 
photos of a teardown of a Daimler Double Six added.  This repair manual is referred to simply as “the Haynes manual” 
throughout this book. 

Classic Motorbooks catalogs list a Haynes manual titled Jaguar 12-Cylinder 1972-85, but this is actually the same book 
-- Classic Motorbooks simply cannot bring themselves to list the correct title. 

The Haynes manual benefits from some recall and technical bulletin info that does not appear in the Jaguar manuals.  It 
includes some basic procedures for the GM400 automatic, including a removal/reinstallation procedure, but no 
overhaul info.  It only covers up to 1985, so owners of later cars will not get any info on the ABS brakes, Marelli 
ignition, etc., and would therefore be better advised to get the Repair Operation Manual with suitable supplements. 

Gross errors in the ROM as well as the Haynes are addressed in this book, since the author owns both books; it is 
suggested that owners mark all corrections in their manuals as they read about them. 

 

REPAIR MANUALS -- 6-CYLINDER XJ-S’S:  The Jaguar XJ-S Repair Operation Manual, AKM 3455, does not 
cover the 6-cylinder engines at all, nor their respective transmissions.  Gerda Kennedy of Bookspeed (page 720) says, 
“There is a separate manual for the XJS 6-cylinder 3.6 and 4.0” and that Bookspeed can provide it.  The part number is 
AKM 9063.  Unfortunately, Walter Petermann counters:  “I picked up the AKM 9063.  It only covers the 3.6.  

 

 

 

 

 

 

 

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