204 JAGUAR X308 1998 2.G Workshop Manual

TABLE OF CONTENTS  
 
    1: General  Information  
 
        
100:
 Service  Information  
 
             100‐00:  General  Information  
                 Description  and  Operation  
                     General Service  Information  
                     Terminology  Glossary  
 
             100‐01:  Identification  Codes  
                 Description  and  Operation  
                     Identification  Codes  
 
             100‐02:  Jacking  and  Lifting  
                 Description  and  Operation  
                     Jacking 
                     Safety Precautions  
                     Vehicle Recovery  
                 General Procedures  
                     Using the  Vehicle  Ja
ck  
                     Using the  Workshop  Jack  
 
    2:  Chassis 
 
        204:  Suspension 
 
             204‐00:  Suspension  System  ‐ General  Information  
                 Specification  
                                     
                 General
 Procedures  
                     Front
 Camber  and  Caster  Adjustment  (57.65.02)  
                     Front
 Camber,  Caster and  Toe  Adjustment  (57.65.03)  
                     Front
 Toe  Adjustment  (57.65.01)  

                    Rear Toe  Adjustment  (57.65. 08) 
                     Whee
l
  Bearing  Circlip  Inspection  
                     Wheel Bearing  Inspection  
 
             204‐01:  Front  Suspension 
                 Specification  
                 Description  and  Operation  
                     Front Suspension  
                 Removal and  Installation  
                     Ball Joint  (60.15.02)  
                     Rear Lower  Arm  (60.35.54)  
                     Rear Lower  Arm  Bushing  (60.35.56)  
                     Front Shock  Absorber  (60.30.04)  
                     Spring 
                     Spring Seat  (60.20.03)  
                     Front Sta
bilizer  Bar  (60.10.01)  
                     Front Stabilizer  Bar  Bushing  (60.10.04)  
                     Front Stabilizer  Bar  Link  (60.10.02)  
                     Upper Arm  Bushing  
                     Front Wheel  Bearing  (60.25.40)  
                     Wheel Hub  
                     Wheel Knuckle  (60.25.23)  
                     Wheel Knuckle  and Wheel  Hub  Assembly  (60.25.38.90)  
                     Wheel Knuckle  and Wheel  Hub  Assembly  Conversion  (60.25.43)  
 
             204‐02:  Rear  Suspension 
                 Specif
ication  
                 Description  and  Operation  
                     Rear Suspension  
                 Removal and  Installation  
                     Axle Bump  Stop  (64.30.15)  
                     Rear Suspension  and Axle  Assembly  (64.25.01)  
                     Rear Shock  Absorber  (64.30.02)  
                     Shock Absorber  Lower  Bushing  (64.30.39)  
                     Spring (64.20.01)  
                     Rear Stabilizer  Bar  (64.35.08)  ‐ 4.0L  SC  V8 ‐ AJ26  
                     Rear Stabilizer  Bar  Bushing  (64.35.18)  ‐ 4.0L  SC V8 ‐ AJ26  

                    Stabilizer Bar  Mount i
ng
 Frame  (64.25.12)  
                     Stabilizer Bar  Mounting  Frame  Bushing  (64.25.13)  
                     Rear Wheel  Bearing  (64.15.14)  
                     Wheel Hub  Seal  (64.15.15)  
                     Wheel Knuckle  Bushing (64.15.24)  
 
             204‐04:  Wheels  and Tires  
                 Specification  
                 Description  and  Operation  
                     Wheels and Tires  
                 Diagnosis  and  Testing  
                     Wheels and Tires  
                 Removal and  Installation  
                     Whee
l  and  Tire  (74.20.05)  
 
             204‐05:  Vehicle  Dynamic  Suspension 
                 Description  and  Operation  
                     Vehicle Dynamic  Suspension  
                 Diagnosis  and  Testing  
                     Vehicle Dynamic  Suspension  
 
        205:  Driveline  
 
             205‐00:  Driveline  System  ‐ General  Information  
                 Description  and  Operation  
                     Driveline System  
 
             205‐01:  Driveshaft  
                 Specification  
                 Description  and  Operation  
                     Drives
haft 
                 Removal and  Installation  
                     Driveshaft (47.15.01) 
 
             205‐02:  Rear  Drive  Axle/Differential  
                 Specification  
                 Description  and  Operation  

Suspension System - General Informatio
n -
Lubric
ants, Fluids, Sealants and Adhesives
Front Suspension Dimensions
• NO
TE: When a component reaches its maximum / minimum dimension limit the component must be replaced.
Rear sus
p
ension Dimensions
•
NO
TE: When a component reaches its maximum / minimum dimension limit the component must be replaced.
Vehicle ride
height


R i
de height is measured from
the center of the wheel to the apex of the wheel arch, through the wheel center line.
Showroom is with a
ll fluids at full an
d 9 liters (9.5 US quarts) of fuel.
Curb is
with all fluids at full and a full tank of fuel.
All f
i
gures quoted assume a ±
15 mm (0.59in) anticipated bu ild variance and condition.
Whee
l Alignment - Front Camber - XJR Excluding NAS, and German Super-8

Al l the above fi
gures
are at "showroom" height. (See ride height section above).
Tires must be infl
ated
to normal pressure.
For additional informat ion, refer to Section 204
-04
Wheels and Tires
.
Whe
e
l Alignment - Front Camber - XJR NAS, and Comfort/Sport/Daimler Super-8
UnitSp
ecification
Loctite27
0
Greas eShell Retin a
x 'A'
Greas
eCastro l 'NT
R'
Com
p
onent
Di
mensi
on
Hub face
-
maximum run-out
0.
03
8 mm
Com
p
onent
Di
mensi
on
Hub face
-
maximum run-out
0.
05
7 mm
Mod
e
l
Mod
e
l Year
V
I
N RANGE
Mark
et
Sh
owroom mm(in)
Curb mm(i
n)
FromToFron
t
RearFr
on
t
Rear
Com
f
ort suspension
1
998
to 2003.5
8
123
17
F
595
25
All3
90 (
15.11)
3
84 (
15.11)
3
89 (
15.31)
3
73 (
14.68)
Sport su
spe
nsion
"""All3
89 (
15.31)
3
81 (
15.00)
3
88 (
15.27)
3
72 (
14.64)
XJR"""NAS3
89 (
15.31)
3
82 (
15.03)
3
88 (
15.27)
3
72 (
14.64)
XJR"""RO
W367 (
14.44)
3
65 (
14.37)
3
66 (
14.40)
3
58 (
14.09)
Supercharged super 8"""All3
89 (
15.31)
3
82 (
15.03)
3
88 (
15.27)
3
72 (
14.64)
XJR

Excluding NAS, and German Super-8
1998 to

2003.5
VIN - 812317 to F59525
Units
Cambe r
Left
- Hand
Rig
h
t - Hand
Bal
a
nce (RH - LH)
MinMaxMinMaxMinMax
All Right-Hand driv
e and JapanDegrees
/minutes
-
1
° 28'
-0
°
28'
-
1
° 13'
-
0
° 13'
-0
° 45'+1 °
15'
Decimal degrees-1.
4
7°
-0
.4
7°
-1
.2
2°
-0.
2
2°
-0
.7
5°
+1
.25
°
R
e
st of World
De
grees
/minutes
-
1
° 13'
-0
°
13'
-
1
° 28'
-
0
° 28'
-1
° 15'+0 °
45'
Decimal degrees-1.
2
2°
-0
.2
2°
-1
.4
7°
-0.
4
7°
-1
.2
5°
+0
.75
°
XJR

NAS, and Comfort/Sport/Daimler Super-8
1
998 to
2003.5
VIN - 812317 to F59525
Units
Cambe r
Left
- Hand
Rig
h
t - Hand
Bal
a
nce (RH -
LH)
MinMaxMinMaxMinMax
All Right-Hand drive and JapanDegrees
/minutes
-1°
02'-0
° 02'
-0°

47'
+0°

13'
-0° 45'+1°

15'
Decimal degrees-1.0
3°
-0.0
3°
-0.7
8°
+0.22
°
-0.7
5°
+1.25
°
USA, Canada an
d Mexico,
Dominican
Republic (NAS)
De grees
/minutes
-0°
32 '+0 °

28'
-1 °

02'
-0 °
02'
-1°
30 '+0 °

30'
Decimal degrees-0. 5
3°
+0
.47
°
-1
.0
3°
-0
.0
3°
-1.
5
0°
+0
.50
°
R
e
st of World
De
grees
/minutes
-0°
47 '+0 °

13'
-1 °

02'
-0 °
02'
-1°
15 '+0 °

45'

Decimal degrees-0. 7
8°
+0
.22
°
-1
.0
3°
-0
.0
3°
-1.
2
5°
+0
.75
°

Al
l the above figures
are at "showroom" height. (See ride height section above).
Ti
res must be inflated
to normal pressure.
For additional informat ion, refer to Section 204
-0
4 Wheels and Tires
.
Whe
el Alignment - Front Castor - XJR Excluding NAS, and German Super-8

Al
l the above figures
are at "showroom" height. (See ride height section above).
Ti
res must be inflated
to normal pressure.
For additional informat ion, refer to Section 204
-0
4 Wheels and Tires
.
Whe
el Alignment - Front Castor - XJR NAS, and Comfort/Sport/Daimler Super-8

Al
l the above figures
are at "showroom" height. (See ride height section above).
Ti
res must be inflated
to normal pressure.
For additional informat ion, refer to Section 204
-0
4 Wheels and Tires
.
Whe
el Alignment - Front Toe - XJR Excluding NAS, and German Super-8

Al
l the above figures
are at "showroom" height. (See ride height section above).
Ti
res must be inflated
to normal pressure.
For additional informat ion, refer to Section 204
-0
4 Wheels and Tires
.
Whe
el Alignment - Front Toe - XJR NAS, and Comfort/Sport/Daimler Super-8
XJR
Excluding NAS, and German Super-8
1

998 to 2003.5
VIN - 812317 to F59525
Units
Castor

Le
ft - Hand
Rig
ht - Hand
Bal
ance (RH - LH)
MinMaxMinMaxMinMax
All Right

-Hand drive and Japan
De
grees/minutes
+4
° 00'
+8
° 00'
+4
° 00'
+8
° 00'
-1
° 12'
+1
° 12'
Decimal degrees+4

.00°
+8
.00°
+4
.00°
+8
.00°
-1.
20°
+1
.20°
R

est of World
De
grees/minutes
+4
° 00'
+8
° 00'
+4
° 00'
+8
° 00'
-1
° 12'
+1
° 12'
Decimal degrees+4

.00°
+8
.00°
+4
.00°
+8
.00°
-1.
20°
+1
.20°
XJR

NAS, and Comfort/Sport/Daimler Super-8
1

998 to 2003.5
VIN - 812317 to F59525
Units
Castor

Le
ft - Hand
Rig
ht - Hand
Bal
ance (RH -
LH)
MinMaxMinMaxMinMax
All Right
-Hand drive and Japan
De
grees/minutes
+4
°
00'
+8
°
00'
+4
°
00'
+8
°
00'
-1
°
12'
+1
°
12'
Decimal degrees+4
.00°
+8
.00°
+4
.00°
+8
.00°
-1.
20°
+1
.20°
USA, Canada an

d Mexico, Dominican
Republic (NAS)
De
grees/minutes
+4
°
00'
+8
°
00'
+4
°
00'
+8
°
00'
-1
°
12'
+1
°
12'
Decimal degrees+4
.00°
+8
.00°
+4
.00°
+8
.00°
-1.
20°
+1
.20°
R

est of World
De
grees/minutes
+4
°
00'
+8
°
00'
+4
°
00'
+8
°
00'
-1
°
12'
+1
°
12'
Decimal degrees+4
.00°
+8
.00°
+4
.00°
+8
.00°
-1.
20°
+1
.20°
XJR

Excluding NAS, and German Super-8
1

998 to 2003.5
VIN - 812317 to F59525
Units
Fr
ont Toe

To

tal Toe
MinMax
All Right-Hand driv

e and Japan
De
grees/minutes
0
° 05'
+0
° 25'
Decimal degrees0.

08°
+0
.42°
R

est of World
De
grees/minutes
0
° 05'
+0
° 25'
Decimal degrees0.

08°
+0
.42°
XJR

NAS, and Comfort/Sport/Daimler Super-8
1

998 to 2003.5
VIN - 812317 to F59525
Units
Fr
ont Toe

To

tal Toe
MinMax
All Right-Hand driv

e and Japan
De
grees/minutes
0
° 05'
+0
° 25'
Decimal degrees0.

08°
+0
.42°


USA, Canada an

d Mexico
, Dominican Repulic (NAS)
De
grees/minutes
0
° 05'
+0
° 25'
Decimal degrees0.

08°
+0
.42°
R

est of World
De
grees/minutes
0
° 05'
+0
° 25'
Decimal degrees0.

08°
+0
.42°

All the above fi
gures
are at "showroom" height. (See ride height section above).
Tires must be infl
ated
to normal pressure.
For additional informat ion, refer to Section 204
-04
Wheels and Tires
.
Wh
eel Alignment - Rear Camber

All the above figu res
are at "s
howroom" height. See vehicle ride height section above.
Tires must be infl
ated
to normal pressure.
For additional informat ion, refer to Section 204
-04
Wheels and Tires
.
W
h
eel Alignment - Rear Toe

All the above figu res
are at "s
howroom" height. See vehicle ride height section above.
Tires must be infl
ated
to normal pressure.
For additional informat ion, refer to Section 204
-04
Wheels and Tires
.


1 998 to
2003.5
VIN - 812317 to F59525
Units
Cambe r

Left
Hand
Rig
h
t Hand
Bal
a
nce (RH - LH)
Min MaxMin MaxMinMax
All MarketsDe
grees
/Minutes
-
1
° 12'
-0
° 06'-1° 12'-0
° 06'
-1
°
00
+1
°
00
De
ci
mal Degrees
-1.
2
0°
-0
.1
0°
-1.
2
0°
-0.
1
0°
-1.
0
0°
+1
.00
°
1
998 to
2003.5
VIN - 812317 to F59525
Units
To e

Left
Hand
Rig
h
t Hand
To
t
al Toe
Thr
u
st Angle
MinMaxMinMaxMin MaxMin Max
All MarketsDe
grees
/Minutes
+0
°
05'
+0
° 15'+0°
05'
+0
° 15'0°
10'
+0
° 30'-0° 05'+0 °
05'
De
ci
mal Degrees
+0
.08
°
+0
.25
°
+0
.08
°
+0
.25
°
0.
17
°
+0
.50
°
-0.
0
8°
+0
.08
°

Suspension System - General Information - Front Camber
, Caster and Toe
Adjustment
Gen e
ral Procedures

1.
NOTE: Before checking or adju sting any alignment, examine
the vehicle for curb impact dama ge on wheels and subsequent
damage to steering and suspension components.
• NOTE: Wheel alignment must no t be carried out with a space
saver wheel installed on any of the hubs.
• NOTE: Before carrying out any ch ecking or adjustment of wheel
alignment, ensure that the vehicl e wheels, tires and tire pressures
are to Jaguar specification.
• NOTE: Position steering wheel in straight ahead position before
adjusting front wheel toe evenly on both tie rods to maintain
centralization of steering wheel.
Position alignment checking equipment on vehicle and following
equipment manufacturer's instructions, check and if necessary
adjust to Specifications in Section 204-01.
2. Check and as necessary adjust front wheel caster. Refer to
57.65.05.
3. Check and as necessary adjust front wheel camber. Refer to
57.65.06.
4. Check and as necessary adjust fr ont wheel alignment. Refer to
57.65.01.

Suspension System - General Infor
mation - Front Toe Adjustment
Gen
eral Procedures

1.
NOTE: Before checking or adju sting front wheel alignment,
examine the vehicle for curb impact damage on wheels and
subsequent damage to steering and suspension components.
• NOTE: Wheel alignment must no t be carried out with a space
saver wheel installed on any of the hubs.
• NOTE: Before carrying out any ch ecking or adjustment of wheel
alignment, ensure that the vehicl e wheels, tires and tire pressures
are to Jaguar specification.
• NOTE: Position steering wheel in straight ahead position before
adjusting front wheel toe evenly on both tie rods to maintain
centralization of steering wheel.
Position alignment checking equipment on road wheels and
following equipment manufacturer's instructions, check and if
necessary adjust front wheel toe to Specifications in Section
204-01.

Suspension System - General Inform
ation - Rear Toe Adjustment
Gen
e
ral Procedures

1.
NOTE: Wheel alignment must not be carried out with a space
saver wheel installed on any of the hubs.
• NOTE: Before carrying out any ch ecking or adjustment of wheel
alignment, ensure that the vehicl e wheels, tires and tire pressures
are to Jaguar specification.
• NOTE: Before checking or ad justing rear wheel alignment,
examine the vehicle for curb impact damage on wheels and
subsequent damage to suspension components.
Position alignment checking equipment on road wheels and
following equipment manufacturer's instructions, check and if
necessary adjust rear wheel alignment to Specifications in
Section 204-02.

Front Suspension - Ba
ll Joint
Re
moval and Installation
Remov

al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
The ball joint must be returned for wa rranty purposes, care must therefore be exercised to avoid damaging it during
removal. Any damage incurred during removal must be noted and recorded.
S
pecial Tool(s)

Ball

Joint Taper Separator
204-192 (JD 219)

Front Camber Tie-do
wn Link
204-114 (JD 133)

B
all Joint Remover
204-200 (JD 240)

B
all Joint Installer
204-199 (JD 239)
1. R
aise front of vehicle.
Refer to Section 100-02.

2. F
ully slacken adjuster nut of special tool 204-114 and position
tool in center of road spring .