steering JAGUAR X308 1998 2.G Workshop Manual

5.
Turn steering wheel 90 degrees to left and partially tighten
module LH securing bolt.
6. Repeat steps 3 and 4 to fully ti ghten securing bolts and return
steering wheel to central position.
7. Fit ground cable to battery terminal. Refer to 86.15.15.

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.

1. Sever and discard tiestraps securing front wheel
speed sensor harness to upper wishbone.
2. Disconnect harness connector from sensor.
Repeat procedure to disconnect opposite side wheel speed
sensor harness.

16. CAUTION: Do not suspend caliper from brake hose as
this will damage the hose.
Remove brake calipers from carriers.
1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension mounting bracket.
Repeat procedure to remove opposite side front brake
caliper.

17. Remove filler cap from power steering fluid reservoir.

18. Disconnect steering rack transducer harness front connector.
Release harness connector from body retaining clip.
Disconnect connector.
19. Sever and discard tiestrap secu ring return pipe, harness (RHD
only) and rubber support to steering rack.

20. RHD vehicles. Sever and discard tiestrap securing harness to
steering rack.
21. Route harness from behind steering return pipe.
22. Position a drain receptacle below pinion housing.

23. Remove pipe retaining plate secu ring bolt and withdraw plate.

24. Drain power steering fluid.
Disconnect pipes and al low fluid to drain.
Remove and discard 'O'-ring seals from pipe connectors.
Fit blanking plugs to pipe connectors and pinion housing
ports.
25. Remove drain receptacle.
26. Remove pipe support from steering rack.
Release return pipe from support.

Remove support from rack.
27. Ensure that steering is in central position.

28. Release lower steering column from pinion shaft.
1. Remove lower steering co lumn securing nut and bolt.
Move column upwards to release it from pinion shaft.

29. Support weight of crossbeam.
Position a jack under crossbeam.
Place a piece of wood between jack and crossbeam.
Raise jack to just support crossbeam.

30. From engine compartment, remove crossbeam front RH
securing bolts.
31. Remove power steering fl uid reservoir for access.
Remove reservoir securing nuts and bolts.
Position reservoir for access.

36. Ensure that steering transducer harness is clear of return pipe and LH side body.
37. Lower and traverse front suspension assembly clear of
vehicle.
38. With assistance, lift front suspension as sembly onto bench.

39. Remove nut securing each tie ro d outer ball joint to steering
arm.

40. Release tie rod ball joint from steering arm.
1. Install special tool 211-098 on tie rod outer ball joint.

2. Tighten tool bolt to re lease ball joint taper pin.
3. Remove tool and release tie rod from steering arm.
Repeat procedure to release opposite side tie rod ball
joint.

41. Remove steering harness fr om LH suspension turret.
Release harness securing clip s from suspension turret.
Mark position of clips on harness.
Remove tape securing clips to harness and discard clips.
42. Disconnect and remove steering harness.

Disconnect harness connector from transducer.
Remove harness from suspension assembly.

43. Remove steering rack from crossbeam.
1. Remove steering rack securing bolts.
2. Remove steering rack and mounting brackets.

44. Release stabilizer bar from link arms.
Remove link arm to stabil izer bar securing nut.
Release link arm from stabilizer bar.
Repeat procedure to release opposite end of stabilizer bar
from link arm.

45. Remove stabilizer bar from crossbeam.
Remove stabilizer bar securing bolts.
Remove stabilizer bar mountin g brackets and remove bar
from crossbeam.
46. Remove wishbone securing nuts.
1. Remove lower wishbone front arm eccentric bolt
securing nut.
2. Remove lower wishbone rear arm eccentric bolt
securing nut.

Position stabilizer bar on crossbeam.
Install and tighten bolts to 30-40Nm.
Repeat procedure at opposite end of stabilizer bar.

6. Tighten link arm to stabilizer bar securing nut to 60-80Nm.
Repeat procedure at opposite end of stabilizer bar.

7. Install steering rack on crossbeam.
Ensure that bushes are correct ly positioned on steering
rack.
Position steering rack on crossbeam.
Position support brac kets over bushes.
Install mounting bracket bolt s and tighten to 40-54Nm.

8. Install tie rods on steering arms.
Position and fully seat tie rod ball joint taper pin on
steering arm.
Install tie rod ball joint nu t and tighten to 71-85Nm.
Repeat procedure to install opposite side tie rod ball joint.
9. Install harness on suspension turret.
Noting positions marked during removal, tape new
securing clips to st eering harness.
Install securing clips/harness on LH turret.

10. With assistance position crossbeam/suspension assembly on
jack with protective wood under.
11. Traverse assembly into position below vehicle.
12. Ensure steering harn ess connector is positioned to avoid
damage during crossbeam lift .

13. NOTE: It may be necessary to use a hammer and drift to
finally align new mounting with body location.
Carefully raise crossbeam assembly into position.
Ensure that dowels of both crossbeam mountings are
correctly seated in body locations.

14. Ensure that both engine hydram ounts are correctly seated in
crossbeam locations.

15. Install crossbeam rear mountings.
Align rear mounting rubber with body location.
Install rear mounting securing bolt and nut and tighten
nut to 131-185 Nm.
Repeat procedure to install opposite side rear mounting
bolt and nut.
16. From engine compartment, install but do not tighten
crossbeam front RH bolts.

17. From engine compartment, install crossbeam front LH bolts
and tighten to 22-28Nm..

18. Install power steering fluid reservoir.
Position reservoir on mounting bracket.
Install reservoir securi ng nuts and bolts.

19. From engine compartment, tighten crossbeam front RH bolts
to 22-28Nm.
20. Install shock absorber on lower wishbone.
Lift lower wishbone to align shock absorber lower
mounting.
Install bolt and nut and ti ghten nut to 43-57Nm.