body JAGUAR X308 1998 2.G Workshop Manual

Key to Plan
Long Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre line of front crossmember rear mount ing at main floor RH longitudinal
4Rearmost hole, transmission mounting at main floor RH longitudinal
5Handbrake rear lever bracket fixings
6Rear Master Datum Plan, rear longitudinal
7Tapped boss, rear suspension 'A' frame mounting bush
8Rear suspension spring-pan damper mounting
9Rear suspension differential strut mounting
10Rear face body-bumper strut/mounting point
11Driveshaft centre bearing mounting

Key to SideView
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmission mountings at the main floor longitudinal
4Handbrake rear lever bracket fixings
5Rear Master Datum Vertical,, rear longitudinal
6Tapped boss, rear suspensi on 'A' frame mounting bush
7Rear suspension spring-pan damper mounting
8Rear suspension differential strut mounting
9Rear face body-bumper strut/mounting point
10Wheel centre to bumper cover face
11Wheelbase
12Wheel Centre to Bumper Cover Face
13Driveshaft centre bearing mounting

ZINC COATED PANELS
Description
Approximately 70% of the 'body in white' (BIW) mass is made up of zinc coated panels.
• NOTE: To maintain the protective qualities of the zinc trea tment, repairs to any damaged coated area must be made as
soon as possible after the damage has occurred.
All exterior skin panels, with the exceptio n of the roof, are double side zinc plated and this coating (nominally 7,5 microns)
provides two way corrosion protection. Should the outer layer of paint become chipped with the zinc coating remain intact,
the zinc will oxidize on contact with air and being impermeable, this coat of oxidation will prevent corrosion damage of the
base metal. If the outer layer of paint and the zinc coating become damaged, the zinc rather than the base metal will react
with the air and 'sacrifice' itself to corrosion as a 'sacrificial anode'.
Welding Preparation
Contamination of the weld with resultant reduction in joint st rength increase and increased electrode tip dressing frequency
will occur zinc coating is not removed. In exceptional cases where the zinc coating must remain intact, the tip pressure and
welding current should be increased by 10 to 20%.
Where 'resistance spot welding' is employed, the zinc coatin g should be lightly abraded away on the mating surfaces and
those in contact with the electrode tips. Do not remove more zinc coating than is absolutely necessary.
Before welding, a weld-through primer or inter-weld sealer should be applied, as detailed in the Body Sealing and
Preservation manual.
Where MIG welding is used as an alternativ e to resistance spot welding for plug and butt welds or due to limited access, the
problems caused by the presence of zinc coating are much the same, with the added complication of increased weld spatter
and nozzle contamination.
Body Fillers
Conventional polyester fillers do not adhere satisfactorily to zinc plated panels, it is ther efore important that only those
products specifically designed for this application are used and the manufacturer's recommendations are followed.
Refinishing
Use only those products approved by Jaguar Cars Ltd and exercise special care on zinc coated panels.
As replacement panels ar e supplied ready primed, the only bare metal that needs to be exposed are those areas prepared
for welding etc, as decribed in 'Welding Preparation. Where any part of a panel is dressed back to the bare surface, it should
be treated with a zinc rich primer compatible with the paint application system.
GENERAL PREPARATION OF PANELS
Removal of Panels and Welds
• NOTE: Where other components must be removed for access, refer to the relevant manual section for guidance. This is
particularly important where steerin g, braking, suspension, electrical and safety systems are affected.
Expose all resistance spot welds, using a ro tary wire brush fitted to an air drill or a hand held wire brush on those that are
not clearly visible (1).
WARNING: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
Cut out spot welds using a Zipcutter or Roto-Bor (2). At this point it may be necessary to cut out the bulk of the panel using

CAVITY WAX INJECTION - APPROVED ADHESIVES, SEALERS AND BODY PROTECTION
SYSTEMS
• NOTE: Cavity wax processes should only be applied on completion of all other refinishing and protection procedures.
Cavity Wax Injection Points - Front
ItemDescription
1.Saw Cut
2.Chisel Cut
3.Cut out Spot Weld
4.Resistance Spot Weld
5.MIG Tack Weld
6.MIG Seam/Butt Weld
7.Braze
8.Gas Weld
9.MIG Plug Weld

On North American specification vehicles, the VIN is marked on all major external panels, certain structural members and
power / transmission units. The labels ca rrying this information are known as 'Label-Anti-theft VIN (USA body panel only)'
or 'Label-Anti-theft-Engine and Gearbo x (U.S.A. only),' drawing reference A .
Replacement Components
Only genuine Jaguar replacement parts must be used in the repair of a vehicle. Furthermore, any new parts replacing items
carrying a VIN label must have either 'Label-Anti-theft Replacement Part (USA body panel only)' or 'Label-Anti-theft
Replacement Part-Engine and Gearbox (U.S.A . only),' drawing reference B , fitted in a different location to the previous
label.
A protective mask used to prevent the replacement part la bel from being damaged or obscured during the refinishing /
protection processes, must be remo ved prior to customer hand-over.
Procurement
Anti-theft labels may only be ordered from Jaguar Cars through :
Product Compliance Dept.,
Jaguar Inc.,
555 MacArthur Blvd.,
Mahwah
NJ 07430

Label Fitting Process
CAUTION: It is a requirement of United States of America federal law th at the protective mask is removed from all
anti-theft labels after performing painting and rustproofing operations. Fail ure to comply with this requirement may render
both the manufacturer and the de aler in violation of the law.
• NOTE: Any attempt to remove an anti-t heft label will destroy that label. Ensure correct location before affixing.
Using a suitable solvent clean the area where the anti-theft label is to be affixed. Peel the backing from the label and
position on the panel. Carry out all refini shing / protection processes. Remove the anti-theft label protective mask prior to
vehicle handover to the customer.

Inset A, shows the 25° - 35°angled cut-away at front edge. The front end of the coachlines should terminate 50mm - 60mm behind the headlamp apertures and the two sides must be symmetrical.
The 1.25mm - 1.75mm wide coachline (inset B), terminates with vertical face and ends 10mm - 20mm forward of tail lamp
aperture.
Inset C shows the upper edge of the coac hline positioned 6mm - 8mm below feature line along the body side. Inset D shows
gap dimensions and lower coachline width.
Details of front end lower coachlines, including position of the lower coachline relative to door mouldings and front wings are
shown in Inset E.
Inset F shows lower coachline rear end detail.
Other Models

Inset A, shows the angled cut-away at 25° - 35° at front edge. The front end of coachlines terminate 50mm - 60mm behind
the headlamp apertures.The two sides must be symmetrical.
The 3mm - 3.5mm wide coachline shown in Inset B, terminates with vertical face and ends 10mm - 20mm forward of tail
lamp aperture.
Inset C shows the upper edge of th e coachline positioned 6mm - 8mm be low the body side feature line.
Paint
Two-pack solid color paint can be applied. Following application of paint by hand brus h or suitable air brush, allow the paint
to dry fully before peeling away the remain ing strips of Striping Tape. The paint takes in excess of 12 hours to air dry and
fully harden, curing can however be accelerated by careful application of heat from infra-red lamps..
• NOTE: Masking tape must only be removed when the paint has hardened.
For the repair of minor damage (cuts, et c.), Paint Touch-up Pens in the colours required, are available via Jaguar Parts
Operations.
Coachline Dimensions
Coachline Colours
• NOTE: The above table refers to water borne paint introduced on 1998MY vehicles. This paint is identified by a four figure
number commencing with a 1. Solvent-based paint is identified by the same succeeding three figures, but this is followed by three different letters. E.G. JBC1712 JHG Westminster Blue is a water-borne paint. JBC712 JFG Westminster Blue is a
solvent-borne paint.
XJ8DAIMLER,SOVEREIGN, EXECUTIVE AND SUPER 8XJ SPORT XJR8
1.5mm Upper3.0mm Upper1.5mm Upper 3.0mm Lower

GLAZING
In order that the design condition of the vehicle is preserved when direct glazing repairs are carried out, it is essential that
only approved materials an d processes are employed.
Glass and Body Preparation
Betaseal HV3 System methods an d materials, are used on all Jaguar vehicles . Ease of working and extended process time
can however be gained by ensuring that the vehicle body and replacement glass are at a minimum room temperature of 20°
C prior to adhesive a pplication and fitting.
In the event of damage to the body flange finish, rectify as appropriate with the full paint refinishing process as described in
the Paint Refinishing Manual.
Adhesive Application Temperature
The specified adhesive has a high viscosity and is not easily applied at 'room te mperature' using conventional methods.
When the adhesive is applied it chills ra pidly on contact with the body and reverts to the hard condition, providing retention
strength with in minutes.
Raising the temperature of the adhesive will reduce viscosity an d speed up the flow. It is recommended that the adhesive is
pre-warmed in a heated cabinet for a mini mum of twenty minutes and applied with an extrusion gun incorporating integral
heating elements.
Adhesive Application
CAUTION: The glass will not bond to the body if the time taken to apply the adhesive and position the glass, exceeds
the stated limit.
It is recommended that the be ad of adhesive conforms to the shape and dimensions shown in the Adhesive Application
Vehicle ColourXJ8Daimler, Sovereign, Executive, and Super
8XJ Sport and XJR8
JBC1712 JHG Westminster BlueJSC156 Mid BlueJSC156 Mid BlueJSC156 Mid Blue
JBC1732 NEE SpindriftJBC 851 LGA greyJBC 851 LGA greyJSC158 Black
Cherry
JBC1753 HGD British Racing
GreenJSC155 Light GreenJSC155 Light GreenJSC155 Light Green
JBC1806 JHE Sapphire BlueJSC154 Light BlueJSC154 Light BlueJSC154 Light Blue
JBC1807 PEC BlackJBC 851 GreyJBC 851 Grey
JBC1810 LGL TitaniumJSC156 Mid BlueJSC156 Mid BlueJSC156 Mid Blue
JBC1811 CGG CarnivalJSC153 Light BeigeJSC153 Light BeigeJSC153 Light Beige
JBC1820 SEC TopazJSC158 Black
CherryJSC158 Black CherryJSC158 Black
Cherry
JBC1823 HGL SpruceJSC155 Light GreenJSC155 Light GreenJSC155 Light Green
JBC1835 HGE SherwoodJSC153 Light BeigeJSC153 Light BeigeJSC153 Light Beige
JBC1839 JHF AquamarineJSC155 Light GreenJSC155 Light GreenJSC155 Light Green
JBC1840 JHH AntiguaJSC154 Light BlueJSC154 Light BlueJSC154 Light Blue
JBC1859 PED AnthraciteJBC851 LGA GreyJBC851 LGA GreyJBC851 LGA Grey
JBC1860 MDV SeafrostJSC158 Black
CherryJSC158 Black CherryJSC158 Black
Cherry
JBC1861 JHJ MistralJBC851 LGA GreyJBC851 LGA GreyJBC851 LGA Grey
JBC1862 KDK AmaranthJBC851 LGA GreyJBC851 LGA GreyJBC851 LGA Grey
JBC1881 CGH MadeiraJSC153 Light BeigeJSC153 Light BeigeJSC153 Light Beige
JBC1911 MDX MeteoriteJSC153 Light BeigeJSC153 Light BeigeJSC153 Light Beige
Temperature EffectTemperature RangeApplication time - including positioning
Optimum60°C - 70°C4 minutes
Maximum75°C4 minutes
Minimum35°CWill not bond

illustration and is positioned along the edge of the rubber.
• NOTE: The depth of the glass and thus the thickness of the ad hesive, is controlled by the screen rubber contacting the
body flange.
Adhesive Application

Key to Adhesive Application Drawing
Adhesive Curing
The specified adhesive cures by exposure to moisture (not by heat). Cure times may vary considerably dependent upon
ambient humidity levels. Initial 'chill off' will occur within 1 to 4 minutes ( dependent upon the application temperature and
rate of cooling), after which the screen must not be moved.
BUMPER REPAIR\RENEWAL
Bumper Description
Each bumper comprises a beam mounte d to the body via two strut assemblies and a moulded polypropylene cover
incorporating side armatures and chrome plated plastic upper trims. The front bumper cover which is moulded to form a
lower air intake for the cooling pack, also incorporates twin fog lamps, brake cooling ducts and side marker lamps or
reflectors (dependent upon market). A plastic undertray secured to the lower edge of the front bumper and the BIW
improves airflow and minimises the ingres s of road grime in that area. Standard bumpers have glass mat thermoplastic
(GMT) beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy
absorbing struts.
Bumper Cover Repair
1Fitted condition
2Bead application

Replacement bumper cover assemblies includer side armatures, which should be removed from discarded bumper
assemblies and rout ed for recycling.
BODY SIDE MOULDINGS
Description
Two types of moulding are fitted to the standard wheelbase sedan. The lower mouldings are positioned on the body / door
lower feature lines. Where applicable, the upper mouldings are positioned using the lower mouldings as data. Replacement
lower mouldings are supplied in a primed condition and must be finished as detailed in this section.
Side Moulding Positions

Body Closures
Clearances and Alignments
When any panel, closure or body component is renewed, refitted or reset, the specified clearances and alignments must be
restored. This ensures that vehicle appearance and operation fully satisfy design intent and the customer.
Clearances
Gaps should be uniform around body panel contours and must be parallel to within 1mm in a 400mm linear measurement.
LocationFinishApplicationFixing method
UpperPolished stainless steelDaimler / VDPSelf adhesive
LowerBody colorAll modelsSelf adhesive
1Adhesive tape
2Moulding, Daimler/VDP
3Moulding all models