XK8 Roof Operational Test Box

As most of you know I have provided a lot of information on the XK8 and it’s roof operation. Over the past several weeks I have been working on a test box that would take the guess work out of trouble shooting the roof operating system and this is what I came up with. 

This is my first attempt to test the motor and solenoid operation.  It worked well with the exception of a low voltage operation that was the result of a poor connection at the pump.  That was my fault.

Link to Test Box #1 Open operation  https://www.youtube.com/watch?v=roCzkOpx3d4

Link to Test Box#1 Closed operation  https://www.youtube.com/watch?v=bh_OohLHkDQ

As you can see it worked well but I was not satisfied. I wanted to know more information on the full operation so I contacted my friend  whitexkr on http://jaguarforums.com/ his web page http://thejagwrangler.com/ and asked him if it was something he could make and he said sure.  We talked about the operation and what I was looking for and showed him what I came up with on the first test box and as a result we came up with this test box.

This test box covers all operation with switch status, solenoid operation and motor operation.  After checking the roof operation with this test box it matched the operating sequence as outlined in the Jaguar TSB 501-11A without exception.  I was pleased to see that this could be done.

Link to TSB 501-11AM  http://jagrepair.com/images/AutoRepairPhotos/501-11AM.pdf

Now keep in mind that this roof operation is dependent on all the switches in the header and rams operating properly, the pump, switches and solenoids being in sequence with the Engine and Security module on demand with the roof switch in the car and the key switch in the drivers door.  This unit will take the guess work out of improperly operating roof.

Links below will show the open and closed roof operation with this test box.

Link to Test Box#2 Open https://www.youtube.com/watch?v=lwq7VA8jytw

Link to Test Box#2 Close  https://www.youtube.com/watch?v=QcuGjIvTmSU

Now let me show you how this Test Box#2 connects.  First I always remove the ground lead to the battery each and every time I pull a plug apart.

I was a little overwhelmed with all the connections I saw at first but it was not as difficult as it appears. Most of it is plug and play. 

This header switch connector is located in the header behind the center light fixture.  I removed the light fixture and unplugged the white plug to the left.  The same type and size plug is located on the right but that is for the power to the header light.

Installed the test plug in the header

Installed the test plug at the pump

Now the a test plug was supplied but the plug is located under the rear seat on the right so I elected to tap into that lead for the ram switches that is located in the trunk at the wheel well to keep from pulling the interior apart.  Note that the color codes are different between pre and post 2000 cars.

On the 1996 -1999 a factory plug was not provided on the leads going to the solenoids so a pigtail was made to tap into the leads.  However, 2000 – 2006 does.  Note that the color codes are different between pre and post 2000 cars.

is the pigtail.  Note that the color codes are different between pre and post 2000 cars.

This is how I connected the pigtail to the leads to the solenoids.  Note that the color codes are different between pre and post 2000 cars.

And this is how it connects to the test box leaving the other plug out of the process.

This was my last connection to the battery and I was ready to make my tests.