Section A
SECTION A - REPAIR PROCEDUREPremature Bulb Failure Modification
1. Open the hood and fit fender covers.
2. Note the customer's preset AM/FM memory stations. Open the trunk, remove the battery cover and disconnect the battery ground cable
3. Remove the spare wheel trim cover, spare wheel, wheel changing tools, trunk floor carpet, front liner trim panel and both side liner trim panels.
Left Hand Front Lighting System
4. At the LH front of the vehicle, within the engine compartment, release the air cleaner cover clips and remove the cover and element.
5. Detach the White multi-plug for the bulb failure module from its mounting bracket and disconnect it from the module.
6. Remove and retain the Yellow plastic insert from the multi-plug.
7. Locate the Brown wire with Green tracer at the back of the multi-plug, release and extract its spade terminal
NOTE:
Use a small jeweller's screwdriver to hold back the anti-backout lug of the terminal during extraction. The same technique is used to remove all the terminals identified in this procedure.
8. Bend back the extracted wire (Brown with Green tracer) and connector away from the White multi-plug.
9. Remove the plug from a Diode Assembly (Part No. LSJ 3998AA). Insert the spade terminal, previously extracted from the multi- plug, into the plug. Refit the diode to the plug.
10. Insert the spade terminal, of the Brown wire leading from the diode/plug assembly, to the vacant port of the multi-plug. (The port previously occupied by the connector of the Brown with Green tracer wire.)
11. Refit the Yellow plastic insert to the multi-plug, ensuring that it is fully seated.
12. Fold the wires of the diode assembly and secure to the multiplug harness with a ratchet strap (Part No. C 46294). Cut off the protruding tail of the ratchet strap.
13. Reconnect the White multi-plug to the bulb failure module and fit the multi-plug into its mounting bracket.
14. Release the Black multi-plug from its mounting bracket and disconnect it from the bulb failure module.
15. Remove and retain the Yellow plastic insert from the Black multi-plug.
16. Extract from the multi-plug the two spade terminals connected to Black wires. (Ground connections.)
17. Cut off the spade terminals from both Black wires.
18. Form the new Headlamp Ground Lead (Part No. LSJ 3998CA) into a coil of approximately 5Omm diameter, with ends protruding according to the dimensions indicated in Fig. 1. Use adhesive tape to secure the wire in a coil, as shown.
NOTE:
Markers are fitted on each end of the wire. The 100 mm. dimensions in Fig.1 are measured from the centers of these markers.
19. Release the air cleaner intake grommet at its top edge. Carefully peel it away from its aperture, to give access to the cavity behind.
20. Insert the coiled ground lead into the cavity. Position the coil forward of the grommet aperture, so that it can be secured to the side harness using a ratchet strap (Part No. C 46294). See Fig. 2.
21. Cut off the protruding tail of the ratchet strap.
22. Draw the end leads of the ground wire coil through the same opening in the air cleaner intake grommet, through which the side harness passes. See Fig.2.
The ends of the leads must be positioned BELOW the side harness, with the two markers aligned to the position of the intake grommet when refitted to its aperture.
23. Refit the air cleaner intake grommet in the fender aperture. Ensure that the ground lead ends will clear the air intake trumpet when it is installed later.
24. Remove the nut and washer from the ground stud, located in front of the wheel arch contour. Onto this stud, install the eyelet of the wire leading from the coiled headlamp ground lead. Refit the washer. See Item 1 Fig.3. Then refit and fully tighten the nut on the ground stud.
The wire should be routed to follow the contour of the inner fender, as shown in Fig. 3.
25. Route the Black wires, with twin spade terminals, along the side harness. Connect the spade terminals to the vacant ports in the Black multi-plug (from which the Black wires and their terminals were previously extracted). The polarity of these terminals is not important, as both are connected to chassis ground via the coiled lead. Refit the Yellow insert to the multi-plug.
26. Tape the new ground wire to the side harness, together with the cut ends of the original two Black ground wires (the spade terminals were cut off previously)
27. Refit the Black multi-plug to the bulb failure module and fit the multi-plug to its mounting bracket.
28. Refit the air cleaner element and cover. Secure the cover with the over center retaining clips.
Right Hand Front Lighting System
29. Repeat all of the operations for the LH front lighting system, described above, on the RH front lighting system.
NOTE:
On XJ6 vehicles, as no air cleaner or associated components are fitted on the RH side of the vehicle, references to these components in the procedure for the LH side should be ignored.
Left Hand Rear Lighting System
30. Detach the White multi-plug, for the LH bulb failure module, from its mounting bracket and disconnect it from the module.
31. At the rear of the White multi-plug, release the latch.
32. Locate the Brown wire with Green tracer, release and extract its spade terminal.
33. Bend back the extracted wire and terminal away from the multi- plug.
34. Remove the socket from a Diode Assembly (Part No. LSJ 3998BA). After opening the latch on the rear of the socket, insert the spade terminal of the Brown with Green tracer wire, fully into the socket. Close the latch.
35. Refit the diode to the socket.
36. Insert the spade terminal of the Brown wire leading from the diode/socket assembly, into the vacant port of the multi-plug (previously occupied by the Brown with Green tracer wire).
37. Close the latch at the rear of the multi-plug.
38. Fold the wires of the diode assembly and secure to the multiplug harness with a ratchet strap (Part No. C 46294). Cut off the protruding tail of the ratchet strap.
39. Reconnect the White multi-plug to the bulb failure module and fit the multi-plug to its mounting bracket.
NOTE:
In the following operations, reference is made to "LONG LIFE" lamp bulbs.
"LONG LIFE" lamp bulbs are identified as follows:
On the metal cap of the bulb, the word "Motorcraft" AND the letter "L" is embossed. This is in addition to identification of the bulb voltage and wattage.
Also, in some Long Life bulbs, the ceramic bead which locates the lead-in wires within the bulb is BLUE in color.
40. Remove the two hand wheels from the rear of the LH lamp unit and withdraw the bulb mounting board.
41. Remove and inspect each bulb, to determine whether or not it is of "Long Life" specification (see note above).
If YES: Refit the bulb.
If NO: Replace the bulb with a "Long Life" bulb as follows:
42. Refit the rear lamp bulb mounting board, install and tighten the hand wheels.
Right Hand Rear Lighting System
43. Repeat the operations for the LH lighting system, described above, on the RH system.