Rear Struts/Installing Non-Leveling Dampers/Repair (SECTION 64, NO. 14)

REAR STRUTS/INSTALLING NON-LEVELING DAMPERS/REPAIR

TECHNICAL SERVICE BULLETIN

REAR STRUTS - INSTALLING NON-LEVELING DAMPERS - REPAIR PROCEDURE

Model(s): 1988-93 Jaguar XJ6 w/3.6 and 4.0 Engines

Section: 64 - Rear Suspension

Bulletin No.: 64-14

Date: May 1994

ISSUE

Jaguar Cars recognizes that many independents are offering rear suspension springs and dampers as a lower cost alternative to replacing the ride leveling struts. In an effort to help dealers retain these customers, Jaguar Cars is now offering a factory tested and approved spring and damper conversion fully covered under the Jaguar Cars 12 month/unlimited miles parts and labor warranty when installed by a Jaguar Dealer.

Once completed, this conversion will effectively change the rear suspension specification to that of a 1994 MY sedan. Since this conversion deletes the ride leveling function of the rear suspension, it can only be offered as an alternative to the repair of the ride leveling system - at the owners discretion. You must document the customer's authorization with a statement on the repair order indicating the ride level function will be deleted.

ACTION

Deactivate the ride leveling system, remove the ride leveling struts and install non-leveling rear dampers, using the following procedures:

• Clamp a new non-leveling damper across the lower mounting eye in a vice. Apply multi-purpose grease to the guide bushing bore and upper face where it contacts the top mounting plate. Using spring compressor tool number JD 125, build up the rear damper assembly. See Fig 1 .
  Fig 1: Rear Suspension Components w/Guide Bushing

  
• Install the top nut and tighten to 23 to 28 ft-lbs.
• Repeat previous operations on the second non-leveling damper.
• Remove the luggage compartment front trim panel and locate the rear axle harness connector:
• On 1988-92 MY vehicles, the connector is a black, 8-way PM4. On 1993 MY vehicles, the connector is a white, 8-way multi-lock.
• Remove the following wires from the rear axle harness side of the connector:
  DELETED REAR AXLE HARNESS WIRE
  
  

  Connector Pin #	Wire Color 1988-92 My Vehicles	Wire Color 1993 My Vehicles
  1	Brown/Blue	Brown/Orange
  2	White/Slate	White/Slate
  5	Yellow/Brown	Yellow/Orange
  6	Yellow/Blue	Yellow/Blue

• Tape the wires removed from the connector to the rear axle harness. Do not remove the brake pad sensor wires from the connector.
• Refit the luggage compartment trim.
• Raise the vehicle on a lift and remove the ride leveling strut assemblies. Refer to XJ6 Service Manual section 66.20.01.
• Remove the hydraulic crossover pipe from the body clips above the rear subframe and remove the pipe from the vehicle.
• Install the new non-leveling spring and damper assemblies.

The next operation requires access to the hydraulic valve block. On 1988-92 MY vehicles, the valve block is located in the engine compartment on the right inner fender. On 1993 MY vehicles, the valve block is located under the right front crush tube.

• Disconnect the rear suspension feed pipe from the hydraulic valve block. Plug the valve block rear suspension port with bleed screw part number CAC 8293. Torque the bleed screw to 12 to 14 ft-lbs.
• Remove the rear suspension hydraulic feed pipe from the under body clips and remove the feed pipe from the vehicle.
• Start the engine and check the hydraulic valve block bleed screw for leaks. Rectify any leaks.

JLM 11698 - REAR SUSPENSION CONVERSION KIT

Description	Part Number	Qty.
Spring kit with spacers	JLM 657	1
Spring support, lower	CAC 4771	2
Spring collet	CAC 4772	4
Spring pan, upper	CAC 9439	2
Top mounting plate	CBC 1426	2
Isolator	CAC 9449/60	2
Guide bushing	CBC 2933	2
Damper	CCC 6923	2
Bleed screw	CAC 8293	1

WARRANTY INFORMATION

This conversion may not be completed under the new car warranty.

Repair Time: 2.0 hrs.