light JAGUAR X308 1998 2.G Workshop Manual

Instrument Panel and Console - Floor Console Ashtray
Removal and Installation
Removal
Installation

1.
Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
2. Remove center console for access . Refer to operations in this
section.
3. Open ashtray lid and remove cigar lighter.

4. Remove cigar lighter housing.
Remove tape securing harnes s to console underside..
Slacken and remove retaining ring from underside and
remove housing complete with cable.
5. Release bulb housing tangs and withdraw bulb and housing
from underside complete with flying lead.

6. Position console for access, slacken and remove the four
ashtray securing screws and remove ashtray from console.
1. Position ashtray on center console.
2. Fit and tighten the four ashtray securing screws.
3. Fit and fully seat cigar lighter housing in ashtray and fit and
tighten retaining ring.
4. Fit cigar lighter housing and illumination bulb.
5. Tape cables to underside of console.
6. Fit cigar lighter in housing.
7. Close ashtray lid.
8. Fit center console assembly. Refer to 76..
9. Connect multiplug at rear of centre console.
10. Fit centre console rear air distribution control grill.
11. Connect earth cable to battery te rminal and fit battery cover.
Refer to 86.15.15.

Instrument Panel and Console - Overhead Console
Removal and Installation
Removal
1. Remove battery cover and disconnect ground cable from
battery terminal. Refer to 86.15.19.

2. Open roof console sun glasses compartment.

3. Rotate fastener 1/4 turn to release console.

4. Lower console from roof and disconnect lighting module
harness multiplug and hands- free microphone harness
multiplug if telephone is fitted.

5. Release roof console from retaining clips and remove from
vehicle.

Installation

1.
Position roof console at headlini ng and connect lighting harness
multiplug and hands-free microphone multiplug if fitted.
2. Engage console in retaining clips.
3. Aligning with headlining aperture, seat console and rotate
fastener 1/4 turn to secure.
4. Close sunglasses compartment.
5. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.

lock motor link rods.
3.
Fit and tighten lock assembly securing bolt.
4. Connect lock switch multiplug and install in mounting clip.
5. Reposition trunk lid liner and secure with new fasteners.
6. Position lock finisher and fi t and tighten securing bolts.
7. Fit and fully seat covers over finisher securing bolts.
8. Fit trunk light. Refer to 86.45.16.

Installation




7. Position upper trim finisher fo r access and withdraw release
button harness grommet from trunk lid aperture.

8. Position upper trim finisher for access and slacken and remove
release button securing screws.
9. Withdraw release button asse mbly from trim finisher.
1. Position trunk release button as sembly on trim finisher and
install securing screws.
2. Position trim finisher/release button assembly at trunk lid and
route harness through lid aperture.
3. Position grommet over harness and install in trunk lid aperture.

4. Position trim finisher/release button assembly on trunk lid and
install securing nuts.
5. Connect release button harness connector and install on
retaining clip.
6. Reposition rear of trunk lid liner and secure with new fasteners.

7. Position lock finisher and install securing bolts.
8. Install covers over finisher securing bolts.
9. Install trunk lights. Refer to 86.45.16.

lock motor link rods.
3.
Install lock assembly securing bolt.
4. Connect lock switch multiplug and install on mounting clip.
5. Reposition trunk lid liner and secure with new fasteners.
6. Position lock finisher and install securing bolts.
7. Install covers over finisher securing bolts.
8. Install trunk light. Refer to 86.45.16.

cooling duct.
The windshield washer is operated by pressing the button at the end of the wiper control stalk switch. Pressing and
releasing the button operates the washer for 1 to 1.4 seconds and the wiper completes three sweeps. An optional drip wipe
function adds a further sweep of the wiper after a 4 second delay, to clear residual fluid from the windshield. If the button is
held depressed, the washer and wiper will operate continuous ly for up to 20 seconds. When the button is released, the
wiper will again complete three further sweeps.
Headlamp Powerwash

The headlamp powerwash system incorporates a chromed twin nozzle assembly mounted on the chromed bumper blade
immediately in front of each pair of he adlamps. Each nozzle assembly is connected via snap fittings to a powerwash pump
mounted adjacent to the windshield wash pump on the rear face of the washer fluid reservoir.The powerwash system
operates in conjunction with the windshield washers when the ignition switch is in position II and the headlamp switch is in
the dip or main beam position. When powerwash is initially activated, a wash cycle commences, consisting of two 400 ms
pulses separated by a three second delay. If powerwash is still selected on completion of this cycle, it will continue to
operate at the same frequency for a maximum period of 20 se conds. To conserve washer fluid, headlamp powerwash will
only function on every sixth operation of the windshie ld wash switch.When the 'WASHER FLUID LOW' message is
illuminated, the windshield washer will continue to operat e for a limited period but the headlamp powerwash will not
function until the fluid level is restored.
Rain Sensing System
The rain sensing system installed form so me markets, provides automatic wiper operation when rain is detected on the
windshield. The system detects differing le vels of rainfall and varies wiper operation ranging from intermittent to maximum
continuous, to suit prevailing requirements.
The system which is brought into operation by selecting AUTO on the wiper control switch bezel, does not preclude normal
manual control of wiper operation.
The system consists of a rain sensor, an electronic control module and a dedicated wiper control switch.
The rain sensor is an optical transducer that is sensitive to changes in infra-red light penetration of the windshield created
by the refractive effects of water drople ts. The sensor elements consist of two groups of light emitting diodes which
alternately project infra-red light onto th e windshield and a photo-diode that receiv es resulting reflections from the glass. A ll
of the infra-red light is reflected back from a moisture-free windshield, resulting in a contact 5V output signal from the
sensor and no wiper activation. Rain falling on the light sensing area of the wi ndshield results in refraction and diffusion of a
proportion of the projected light with a corresponding imbalance of light received by the photodiode. This results in pulsed
outputs from the sensor, the frequency and duration of which are directly proportional to the number and size of water
droplets respectively. These pulses together with wiper switch position signals are received by the sensor control module
and processed to mimic column switch gear operation. In this recognisable form, signals are input to the body processor
module (BPM) where they are interprete d as normal wiper operation requests.

In
stallation


20
. Remove an
d discard four scrive
ts securing upper section of
air intake to beam.

21 . D
rill out rivets securing uppe
r section of cover to bumper
beam.
22. Withdraw bumper beam from cover.
1. Position beam in cover, ensuring that tangs locate correctly in
beam slots.
2. Using new fir tree fast eners, scrivets and rivets, secure beam
to bumper cover.
3. Install fog lights, direction indicators, and side marker
lamps/reflectors in bumper cover.
4. Fit chrome blades to top of casing locating tangs in slots and fit
and tighten securing screws.
5. Fit powerwash jet assemblies to bumper cover. Refer to
Section 501.16.
6. Fit bumper assembly to vehicle. Refer to operations in this
section.
7. Position splitter vane in air intake and secure by rotating
fasteners 1/4 turn clockwise.
8. Fit number plate and plinth.
9. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.

Installation

air intake to beam.

21. Drill out rivets securing beam to upper section of bumper
cover.
22. Withdraw cover from beam.
1. Position cover over bumper beam and secure with new fir tree
fasteners, scrivets and rivets.
2. Install fog lights, direction indicators, and side marker
lamps/reflectors in bumper cover.
3. Position chrome blades on top of cover, locating tangs in slots
and install securing screws.
4. Install powerwash jet assemblies on bumper cover. Refer to
84.20.08.
5. Position splitter vane in air intake and secure by rotating
fasteners 1/4 turn clockwise.
6. WARNING: ENSURE THAT ALL PERSONNEL AND
EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
Carefully slide bumper assembly onto fender guide blocks.
7. Raise ramp to working height.
8. Install but do not fully tighten bo lts securing bumper to struts.
9. Check clearance between top of bumper and bottom of fender.
If necessary, remove bumper, adjust guide blocks to achieve
correct clearance and refit bumper.
10. Connect harness multiplugs to foglamps, direction indicators
and where fitted side marker lamps.
11. Install harnesses into retaining clips at each side of cover.
12. Install powerwash hoses to jet assemblies and secure with
new plastic clips. Refer to 84.20.08.
13. Install radiator grill and su rround. refer to 76.55.03 and
76.55.15.
14. Check and as necessary adjust bumper cover to fender,
headlamps and radiator grill surround clearances. Refer to
Description and Operation in this section.
15. Fully tighten bumper assembly to strut securing bolts.

The body is pre-treated to ensure high resistance to corrosion and stone chip dama ge. Prior to the first major pre-treatment process, the body shell is high-pressure washed to remove any metal dust and residual oil.
The first major pre-treatment process consists of phosphate and electro-paint deposition, which together with zinc coating,
forms the basis of the corrosion protection. This process includes high pressure knock-off, alkali de-greasing, zinc phosphate
conversion of body steel (dissolving iron and coating with zinc phosphate crystals), trivalent chrome rinsing and
demineralized water rinsing, seal ing all chemicals and impurities.
Both dip and spray techniques are employed and the bodies are submerged to the waistline during the first and third rinses
of the main phosphate clean. Chemical strengths and soluti on temperatures are continuously monitored and accurately
controlled throughout the process.
An 80% water primer is then cathodic elec tro-deposition applied to the thoroughly cleansed bodies in a uniform 'sag-free'
film 18 to 32 micron thick. Optimum durabi lity of the electroprimer is achieved by finally curing in a stoving oven at 165 °C
for a period of 20 minutes.
All underbody seams of the fully primed bo dies are then manually sealed, to prevent water and dust ingress into the vehicle
and to enhance corrosion protection.
An 800 to 1000 g/m2 PVC coating is semi-automatic airless sp ray applied to the underside of the main floor panels, trunk
floor and rear wheel arches (ref. illustration above).
The upper panels of primed and external ly sealed bodyshells are next lightly scuffed to remove imperfections and a PVC
coating is applied to all internal seams by an airless spray technique. A PVC bead seal is also applied to the doors, hood and
trunk clinch joints.
Following anti-corrosion, sealing and primin g treatment, the bodies enter the first stage of 'cosmetic' painting. This consists
of the application of two coats of a highly chip resistant po lyester surfacer, employing high voltage electrostatic 'spinning
bells', to achieve a final film thickness of 35 to 50 micron. Between surfacer coats, a polyurethane coat is automatically
applied to the sills to impart even greater resistance to stone chipping.
All interior panels are then painted us ing a color keyed sealer, wet-on-wet wi th a surfacer material, after which the
bodyshells are stoved at 160 °C for a period of 20 minutes. Further protection agai nst corrosion is provided by a medium
solids black pigmented wax which is airless spray applied to vehicle undersides.
Wax Injected Box Sections
Critical body box-sections are si milarly protected by spray injecting a high solids wax. This is then re-flowed at 70 to 90 °C
to achieve optimum seam/joint penetratio n and form a resilient and durable internal coating (ref. illustration above).
After full wet sanding, rinsing and drying to provide a good su bstrate, a color-keyed semi-matt sealer co at is applied using
electrostatic bells to achieve a film build of 25 to 35 micron . The bodies are then stoved for a further 20 minutes at a
temperature of 145 °C and subjected to a local 'seek-and-find' de -nib operation prior to the final two coat process. The final
top coat finish is achieved by using poly ester base coat colors and an acrylic sag resistant clear coat. This clear over base
(COB) process produces a high gloss, durabl e paint finish with a film thickness of 50 to 65 micron, which is finally cured at a
temperature of 135°C for 20 minutes.
The Munsell three dimensional system of color management is em ployed to achieve highly accurate control of vehicle colors.
This system ensures that paint pigmentations are accurately maintained and facilitates vigorous final checking of finished
vehicles for color match. The hu e of individual panels such as trunk lids, doors and hoods is in some instances adjusted to
offset the effects of differing light angles. Where applicable, coachlines are manually applied and radiant heat cured on the
completed and valeted vehicle prior to hand spray applic ation of a protective wax coat.
Introduction
All repairs, whether structural or cosmetic must return the vehicle to the original manufactured condition with regard to
occupant safety, dimensional accuracy, fi nish and corrosion protection, and ensure continuation of the Paint Surface and
Corrosion warranty where applicable.
Similarly, repaired vehicles must be fu lly checked, and where appropriate reset, with regard to steering, suspension,
braking, and occupant restraint systems.