Recall - Power Brakes: Overview
RECALLNo: 5
RECALL CAMPAIGN D348
Date: June, 1990
Model:
88-89 SEDAN RANGE
KEYPOINTS:
1988-1989 SEDAN RANGE HIGH PRESSURE HOSE/ACCUMULATOR SWITCHES
Jaguar Cars Exports Ltd. has determined that on a range of 1988 and 1989 Sedan Range vehicles, it is possible that the high pressure hydraulic supply hose may rupture, causing loss of fluid and consequent loss of power boost. The possibility also exists for a small but persistent leak to occur past the internal seal of the accumulator switches. This leak may occur in the vicinity of the electrical wiring to the accumulator switches causing interruption of electrical power and preventing the power assist feature of the brakes from recharging.
D348 SEDAN RANGE BRAKE POWER ASSIST HOSE/ACCUMULATOR SWITCH
AFFECTED VIN RANGES
DEALER VEHICLE CAMPAIGN LIST
"Dealer Campaign List" not included listing affected vehicles which were invoiced to you.
If a campaign list is not enclosed, then (according to our records) you did not receive any of the affected vehicles.
You may be required to perform recall campaign work on a vehicle that was not invoiced to your dealership (i.e., transient owner, etc.).
If this occurs, normal repair procedures should be followed.
OWNER NOTIFICATION
All owners on record will be issued recall notifications via first class mail. Included will also be a letter advising them of this condition. (A copy of the owner's letter is shown).
Owners will be asked to contact their selling dealer (or nearest authorized dealer) and make an appointment for repair work. They will also be asked to sign and return the "Campaign Claim" form to the dealer.
PARTS INFORMATION
NOTE:
Ensure that your Parts Manager receives a copy of this bulletin.
Hoses and switches will be shipped to you, chargeable by your Zone office on an allocation basis. Initial supplies will arrive at your dealership by the recall launch date. Reimbursement will be through the normal campaign procedures. Adequate supplies of 'D348' campaign completion labels are enclosed in your bulletin package.
WARRANTY INFORMATION
Complete the applicable "Campaign Claim" form (See Section I of the Warranty Manual). Insert the "Repair Code" box on the "Campaign Claim" the appropriate repair code. Direct entry dealers should refer to their instructional guide.
To replace the power hydraulic high pressure hose on sedan range vehicles, the following procedure should be used:
HOSE REMOVAL:
^ Depressurize the power hydraulic system by switching off the ignition and repeatedly depressing the brake pedal until high resistance is felt.
^ Remove the high pressure hose mounting bolts at the cylinder head and valve block mounting brackets, (fig. 1 A & B).
^ Detach the air conditioning hose support clip rubber mount from the high pressure hose.
^ Disconnect the high pressure hose (fig. 1 D) from the power hydraulic pump.
^ Disconnect the hose from the solenoid valve block. Remove and discard the hose.
HOSE REINSTALLATION:
^ Remove the protective plugs from each end of the new hose.
^ Position the new high pressure hose to the power hydraulic pump.
^ Route the new hose as indicated in fig. 1 and position to the solenoid valve block.
NOTE:
Care should be taken to prevent the ingress of dirt or other forms of contamination.
^ Position the hose mounting bolts (fig. 1 A & B) and fully tighten the hose connections at the valve block and pump unions. Fully tighten the hose mounting bolts.
^ Attach the A/C hose support clip and rubber mount to the new hose. On vehicles before VIN 576391, proceed to the following "Check Accumulator Switch Specification" operation.
^ On vehicles after VIN 576390, start the engine and allow the hydraulic system to pressurize, and check for any leaks.
^ Check and top up the hydraulic system reservoir if necessary using only the recommended Hydraulic System Mineral Oil (HSMO).
CAUTION:
Do not overfill the reservoir. Add fluid only until the red level indicator pin does not show.
CHECK ACCUMULATOR SWITCH SPECIFICATION:
^ Raise the vehicle on a lift and locate the power hydraulic accumulator at the front of the vehicle, mounted below the Right-Hand crush tube, (fig. 2 A).
^ Inspect the accumulator switch cables to determine the color of the cable sleeves, (fig. 3).
NOTE:
Be sure to inspect both switches.
^ The latest specification accumulator charge and low pressure switches are identified by green end wrap (fig. 3 A) or a pink band (fig. 3 B) around the switch cable. If these are not included, proceed to the following "Replace Accumulator Switch(es)" operation.
^ If the correct accumulator switches are incorporated, start the engine and allow the hydraulic system to pressurize. Check the system for any leaks.
^ Check and top up the hydraulic system if necessary. Again, use only the recommended HSMC and do not overfill the reservoir.
NOTE:
The charge switch (JLM 1562) and the low pressure warning switch (JLM 1563) are identified by their cable colors, (fig. 3).
REPLACE ACCUMULATOR SWITCH(ES):
^ Ensure that the power hydraulic system is still depressurized by switching off the ignition and depressing the brake pedal repeatedly until high resistance is felt.
^ Cut the tie strap that retains connector R525 (green PM4, located in the position marked fig. 1 C). Disconnect the connector and feed the accumulator harness and multi-plug down through the engine compartment area.
^ From below, cut and remove the heat shrink sleeve holding the two accumulator switch harnesses together.
^ Remove the anti-back-out plate from the rear of the multi-plug.
^ Note the positions of the connections in the multi-plug and remove the seal. Remove the appropriate connector pins from the plug using Service Tool JD 137.
NOTE:
For additional pin removal information, refer to book 4, section 86, page 86-69 of the XJ6 Service Manual.
^ Thoroughly clean the accumulator switch(es) and ensure that all dirt, etc. is removed from the surrounding area.
Remove the switch(es) from the accumulator body and discard.
REINSTALLATION PROCEDURE:
^ Install the new switch(es) to the accumulator body and tighten to 31-39 Nm.
^ Position the harness pins through the anti-back-out plate and seal. Fully install the pins into their correct positions in the multi-plug, (fig. 3).
Fully install the seal and anti-back-out plate into the multi-plug socket.
^ Using insulating tape, tape the two switch harnesses together.
^ Feed the accumulator harness up through the engine bay to the socket.
NOTE:
Ensure that the plug and socket pin connections are clean and free from any oil contamination before connecting them together.
^ Lower the vehicle and connect RS25 plug and socket. Secure using a tie strap.
^ Start the engine and allow the hydraulic system to pressurize. Check the system for any leaks.
^ Check and top up the hydraulic system if necessary. Again, use only the recommended HSMO and do not overfill the reservoir.
Adhere the D348 campaign identification label to the rearmost crossbrace on the underside of the hood.