length JAGUAR X308 1998 2.G Owner's Manual

Belt tension is achieved by an automatic tensioner; neither the belt nor the tensioner require service apart from checking
the belt wear indicators at each normal service interval.
The minimum service life of the drive belt is 100,000 miles.
Never apply oil to the belt or to the belt tensioner.


ItemDescription
1New Belt - Minimum Length
2New Belt - Maximum Length
3Replace the Belt

Installation


13. Move the spacing bush rearward s slightly in the generator
mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a
tubular spacer or socket spanner, fit a nut and
tighten the assembly to move the bush slightly.
Remove the nut, bolt and spacer.

1. Fit the generator to the engine.
1. From above, position th e generator and fit the upper
mounting bolt and nut, but do not fully tighten.

2. Fit the generator lower mounting.
1. From below, reposition an d align the harness clip to
the generator lower mounting.
2. Fit the lower mounting bolt and nut, tighten to 38-48
Nm.
3. Connect the harness.
1. Reposition the suppres sion module harness and
connect the negative cable to the generator negative
terminal. Fit and tighten the terminal nut.

Installation


15. Change the position of the ge nerator and remove it upwards
between the engine and the radiator.

16. Move the spacing bush rearward s slightly in the generator
mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a
tubular spacer or socket spanner, fit a nut and
tighten the assembly to move the bush slightly.
Remove the nut, bolt and spacer.

1. Fit the generator to the engine.
1. From above, position th e generator and fit the upper
mounting bolt and nut, but do not fully tighten.
2. Fit the generator lower mounting.
1. From below, reposition an d align the harness clip to
the generator lower mounting.

The part number of the pre-terminated wiring harness The letter showing the extractor tip which must be used to remove this type of electrical connector terminal Those electrical connector terminals which are gold
Some of the pre-terminated wiring harness( s) have seals installed to the insulation for sealed connector applications. It is
essential for prevention of mo isture ingress that a sealed pre-terminated wiring harness must be used where a sealed
terminal was removed.
CAUTION: Where the repair procedure indica tes that a glue lined heat shrink sleeve should be applied, apply sufficient
heat to the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined
heat shrink sleeve so that the wiring harness insulation becomes damaged.
Two sizes of heat shrink sleeving are supplied in the wiring harn ess repair kit. Each heat shrink sleeve contains a sealant
glue. These must be used when connecting wiring harness(s) or electrical connector terminal(s) at all times. The smaller
diameter heat shrink sleeve is to be used with the red and blue butt splice connectors and the larger di ameter sleeve with
the yellow butt sp lice connectors.
For ease and speed, some of the pre-term inated wiring harness(s) may already have the insulation partly stripped at the
splice end. If the repair requires insula tion to be stripped from the cable, refer to the Relationship Table fo r the correct
length of insulation to be stripped.
The Pre-Terminated Wiring Harness(s) illu stration shows the electrical connector terminal type, the part number of the pre-
terminated wiring harness and the letter of the extractor tip which must be used to extract the electrical connector terminal
from the connector housing. Additionally, those electrical conne ctor terminal(s) which are gold are identified, all others are
therefore, tinned and not gold.
Wiring Harness Cable Identification Sleeves
A selection of colored sleeves are contai ned in the wiring harness repair kit for maintaining the wiring harness cable
identification on the pre-term inated wiring harness. Place the correct colo red sleeve(s) over the pre-terminated wiring
harness insulation as near to the electr ical connector as possible with the main wiring harness cable color nearest to the
electrical connector.
For example, if the original wiring harness cable color is pink with a black trace put the pink wiring harness cable
identification sleeve on the pre-terminated wiring harness first followed by a black sleeve, and slide both along the wiring
harness cable to the electr ical connector terminal.
Extraction Handle and Tips
The extraction handle, in conjunction with th e correct tip, is used to remove a terminal from an elec trical connector. Each tip contained in the wiring harness repair kit is marked with an identification letter, A to K inclusive. Each tip has been special ly
designed to extract a particular ty pe of electrical connector terminal. The use of any other tool is not recommended and is
liable to cause damage to the electrical connector. The tip is fastened to the handle by a screw which holds the tip firmly yet
allows it to be easily replaced.
Extraction Handle and Tips

By pressing the outer edges of the wiring harness cable length stop together the adjuster can be slid up or down the jaw.
This decreases or increases the length by which the wiring harn ess cable insulation will be stripped from the pre-terminated
wiring harness or wiring harness wire. The adjuster has a position indicator to align with a graduated scale and this sets the
correct length in millimet res, of insulation to be strippe d. The amount of insulation to be stripped is shown in the
Relationship Table.
The illustration shows the insulation stri pper tool and a wiring harness correctly gripped in the jaws. A wire cutter is
provided on the outer side of the fixed jaw.
Cable Correctly Grippe d in Stripper Blades

Crimping Pliers
Crimping Pliers

Items can be ordered from:
SPX United Kingdom Limited
Ironstone Way
Brixworth
Northants
NN6 9UD
United Kingdom
Telephone: +44 (0) 1327 704461
Fax: +44 (0) 1327 706632
Repair Methods
CAUTION: Several different types and sizes of terminal may be found in a single electrical connector
housing.
It is necessary to identify:
The conductor (wire) size of the affected wiring harness The electrical connector range from which the damaged wiring harness is to be removed The terminal type
Use of the approved diagnostic tool will greatly assist in th e quick identification of electrical connectors and faulty pin
terminal(s).
Reference can also be made to the vehicle Electrical Guides, he ld by Dealers, to identify wiring harness(s) and electrical
connector(s).
By using the Relationship Table, the wiring harness conductor (wire) size can be related to a suitable pre-terminated wiring
harness by the color of the insulation. Also , the correct length of insulation to be stripped from the wiring harness lead is
identified.
Relationship Table
Electrical Connector Terminal Extraction
Tip G418-1241
Tip H418-1251
Tip I418-1261
Tip J418-1271
Tip K418-1281
Sleeve Identification Pa ck – for Red insulation418-112500
Sleeve Identification Pack – for Blue insulation 418-113500
Sleeve Identification Pack – for Yellow insulation 418-114500
Instruction Manual JTP 5931
Crimping Pliers YRW5000101
Wire Stripping Tool 418-1171
CABLE RANGE SPLICE STRIP LENGTH
0.35 mm² to 1.50 mm²RED6.00 to 7.00 mm
1.00 mm² to 2.50 mm²BLUE6.00 to 7.00 mm
4.00 mm² to 6.00 mm²YELLOW9.00 to 9.50 mm

Repair Procedure
• CAUTIONS: Do not use crimping pliers, insulation strippers, butt splice connectors, heat sh rink sleeves or pre-terminated wiring
harness(s) that are not supplied with the Jagu ar wiring harness repair kit. Each part has been designed to be used only with
the other parts in this wiri ng harness repair kit.
Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to
the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not
over heat the glue lined heat shrink sleeve so that the wiring harness insulation becomes damaged.
It is not correct to make more than five repair joints on the wiring harness to any electrical connector and if more damage is
found at the same electrical connector then a new wiring harness must be installed.
Remove the faulty terminal from the elec trical connector using the extractor tool and correct tip. Make sure that any
anti-backout device is released befo re trying to remove the terminal.
CAUTION: : A number of electrical connector terminals ar e gold plated or gold flashed. When defective, they
must be installed with a gold pre-terminated wiring harnes s(s) from the wiring harness repair kit. It is not always
easy to identify the female as gold but the male pins are visually easier, therefore always check both male and
female terminals to identify those which are gold. Under no circumstances are gold and tin terminals to be mixed as
this will lead to early failur e of the electrical contact.
• NOTE: Never use a harness lead with a smalle r diameter than the original harness lead.
Select the correct size and ty pe of pre-terminated wiring harness and butt splice connector from the wiring harness
repair kit.
Using the wire cutter on the stripping tool, cut the pre-terminated wiring harness and the harness cable to the
required length.
• NOTE: See illustration: Stripping Insulation
From the Relationship Table, find the correct length of insulation to be stripped from the pre-terminated wiring
harness and set the adjustable cable length stop to the correct length. Place the pre-terminated wiring harness in
the wire stripper and remove the insulation.
Put the cable identification sleeve(s) on to the wiring harness with the main cable colour nearest to the terminal. During this next step do not overtighten. Place the selected butt splice connector in the crimping tool, matching the
aperture and the butt connector colours. Make sure that the window indentation in the butt connector is resting over
the guide bar on the lower jaw. Partially close the grip until the butt connec tor is securely held in the aperture. This
will give support to the butt conn ector while the pre-terminated wiring harness is inserted into it.
• NOTE: See illustration: Spice Correctly Located
Insert the pre-terminated wiring harnes s into the butt connector and make sure that the wire is against the wire
stop. Close the grip firmly, crimping the lead to the butt connector. When the handles have been completely closed
the butt connector will be fre ed from the tool as the handles are released. If the handles have not been completely
closed then the jaws will hold the butt connector and it cannot be removed from the tool until the crimp is fully made
by closing the handles completely. Make sure that the harness cable has been squarely cut and the correct length of insulation removed. If more than
one splice is needed the butt connectors must be not be crimped to the wiring harness at the same distance from
the connector. The splices must be staggered to prevent a bulk of splices in the same area of the wiring harness.
It is preferable to cover the butt splice joint with heat shrink sleeve. This is desirable not essential, except where the
electrical connector is a sealed electrical connector. Use the smaller diameter sleeve for red and blue pre-terminated
wiring harness(s) and the large diameter sleeve for the yellow pre-terminated wiring harnes s(s). It is advisable to
place the heat shrink over the completed joint but in some instances the sleeve will not pass over the terminal.
Check, and if required, place the correct size sleeve onto the harness cable or pre-terminated wiring harness before
crimping the butt splice to the wiring harness.
Place the harness cable into the butt splice with the spli ce window over the guide bar. Make sure that the cable
harness wire is agains t the stop in the butt splice, crimp the butt splice connector to the wiring harness.
Gently pull the harness cables each side of the butt sp lice to make sure that a secure joint has been made.
AMP 6.3 flatDD
Econoseal III 250 seriesBF

WARNING: Do not use a naked flame in areas where fuel or oil have been spilt. Clean the area of residual oil
and fuel and wait un til the fuel spill has fully evaporated.
• CAUTIONS:
When using a heat source make sure that it is localised and caus es no damage to surrounding materials.
Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient
heat to the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue
lined heat shrink sleeve so that the wi ring harness insulation becomes damaged.
Using a suitable heat source, shrink the sleeve over the butt splice.
If further pre-terminated wiri ng harness(s) are to be installed to the sa me electrical connector, make sure that the
lead is cut at a different length to the previous joint. This makes sure that the splices will, where possible, be
staggered on the wiring ha rness and prevent a bulk of splices in one area.
When all of the splices have been made, fit the terminal(s) to the electrical connector, taking care that the terminals
are correctly orientated.
Install the wiring harness cove r and secure with adhesive electrical tape. Do not cove r the wiring harness right to the electrical connector as the terminals must have a little movement and no t be firmly bound to the electrical connector or wiring harness. Make sure that the cable identification sleeve(s) are showing at the wiring harness electrical
connector.
Stripping Insulation
Spice Correctly Located

Exterior Trim and Ornamentation - Door Moulding
Removal and Installation
Removal
Installation

1.
Apply suitable protecti ve tape to immediately adjacent areas of
paintwork.
2. Using a hand-held heat gun, appply heat uniformly along
moulding length.
3. Applying local heat at one end and using a suitable thin lever
to avoid damaging paintwork, progressively ease moulding
away from door panel.
4. Discard moulding and remove protective tape.
5. Remove any residual adhesive and thoroughly clean area using
white spirit.
1. NOTE: Optimum adhesion is achi eved by warming body panel
and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and
de-greased.
2. Remove protective backing tape from moulding.
3. NOTE: Do not allow moulding to contact the body panel until it
is correctly aligned.
Heat moulding and moun ting area to 65degC.)
4. Aligning with adjacent mouldings or to match opposite side of
vehicle, press new moulding firmly onto body panel.
5. Apply hand pressure along moulding length to ensure
satisfactory adhesion.
6. Allow moulding and door panel to cool , then thoroughly clean
both using white spirit.
7. Apply a coat of suitab le polish to moulding and body panel.

Exterior Trim and Ornamentation - Front Fender Moulding
Removal and Installation
Removal
Installation

1.
Apply suitable protecti ve tape to immediately adjacent areas of
paintwork.
2. Using a hand-held heat gun, appply heat uniformly along
moulding length.
3. Applying local heat at one end and using a suitable thin lever
to avoid damaging paintwork, progressively ease moulding
away from fender.
4. Discard moulding and remove protective tape.
5. Remove any residual adhesive and thoroughly clean area using
white spirit.
1. NOTE: Optimum adhesion is achi eved by warming body panel
and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and
de-greased.
2. Remove protective backing tape from moulding.
3. NOTE: Do not allow moulding to contact the fender until it is
correctly aligned.
Heat moulding and mounting area to 65deg C.
4. Aligning with adjacent mouldings or to match opposite side of
vehicle, press new mouldi ng firmly onto fender.
5. Apply hand pressure along moulding length to ensure
satisfactory adhesion.
6. Allow moulding and fender to cool , then thoroughly clean both
using white spirit.
7. Apply a coat of suitable poli sh to moulding and fender.