wheel JAGUAR X308 1998 2.G Workshop Manual

1.
WARNING: ENSURE THAT ALL PERSONNEL AND
EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
Carefully slide bumper assembly onto fender guide blocks.
2. Raise ramp to working height.
3. Install but do not fully tighten bo lts securing bumper to struts.
4. Check clearance between top of bumper and bottom of fender.
If necessary, remove bumper, adjust guide blocks to achieve
correct clearance and refit bumper.
5. Connect harness multiplugs to foglamps, direction indicators
and where fitted side marker lamps.
6. Install harnesses in retaining clips at each side of cover.
7. Install powerwash hoses to jet assemblies and secure with new
plastic clips. Refer to Section 501.16.
8. Install radiator grill and su rround. refer to 76.55.03 and
76.55.15.
9. Check and as necessary adjust bumper cover to fender,
headlamps and radiator grill surround clearances. Refer to
Description and Operation in this section.
10. Fully tighten bumper assembly to strut securing bolts.
11. Install wheelarch liners.
12. Install undertray. Refer to 76.22.90.
13. Lower 4-post ramp.
14. Install road wheels and lower wheel-free lifts.

Bumpers - Front Bumper Cover
Removal and Installation
Removal
WARNING: ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
1. Position vehicle on 4-post ramp.
2. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
3. Remove radiator surround and grill. Refer to 76.55.15 and
76.55.03.
4. Raise ramp to working height.
5. Using wheel-free lifts, remove front wheels.
6. Remove wheelarch liners for access.
7. Remove undertray. Refer to 76.22.90.

8. At each side of vehicle:
Disconnect fog lamp, directio n indicator and sidemarker
lamp (where fitted) harness multiplugs.
If headlamp powerwash is fitted, remove and discard
plastic clip from hose and disconnect hose on RH side of
bumper.

9. Remove bolts securing bumper assembly to mounting struts.
10. Lower 4-post ramp.

11. Carefully withdraw bumper casing and beam assembly
forward to clear guide blocks and remove assembly from
vehicle.
12. Remove three bolts securing each fog lamp to bumper cover
and remove both lamps from cover.

16.
Install wheelarch liners.
17. Install undertray. Refer to 76.22.90.
18. Lower 4-post ramp.
19. Install road wheels and lower wheel-free lifts.
20. Position number plate plinth on bumper and install securing
screws.
21. Install number plate.
22. Connect ground cable to batter y terminal and install battery
cover. Refer to 86.15.15.

Safety Belt System - Safety Belt System
Description and Operation
Front Seat Belts

Each front seat belt has three anchorage points, and a height adjuster installed in each 'B' post provides four shoulder strap
positions. The belts are left and right ha nded and have plastic moulding on the r unning loop and tongue. A pyrotechnic pre-
tensioning device installed at the lower mounting point in each 'B' post, removes excess slack from the seat belt in the event
of a heavy frontal impact.
Rear Seat Belts

A standard inertia reel type belt is installed at each rear seat position. Each of these belts has three anchorage points. The
lower end of each outer belt is bolted to the front lower section of the inner wheelarch, whilst the lower end of the centre
belt is bolted to the seat pan. All thr ee inertia reel assemblies are bolted to the upper section of the squab panel. Two
buckle assemblies serving the three belts, are each bolted to the seat pan. A cable mounted single buckle provides for
fastening of the RH outer belt and a twin buckle assembly mounted on two cables serves the centre and LH outer belts.
Pyrotechnic Seatbelt Pre-tensioning

Safety Belt System - Rear Safety Belt Retractor
Removal and Installation
Removal
1. Remove rear seat cushion. Refer to 76.70.37.
2. Remove rear headrests.

3. Slacken and remove bolt securi ng lower anchor to front of
inner wheel arch.

4. Slacken and remove bolt securing belt buckle cable to seat
pan and remove belt buckle assembly from vehicle.

5. Remove escutcheon.
1. Using a flat-bladed screwdriver in the two rectangular apertures, carefully withdraw
escutcheon from top of seat squab.
2. Remove escutcheon from belt via split in moulding.
6. Pass seat belt lower anchor plate and tongue through squab
aperture.

Installation



7. Remove seat squab for access using extension of undisturbed
belts to achieve clearance from inertia reels. Refer to 76.70.38.

8. Slacken and remove two bolts and washer securing inertia reel
assembly to top of squab panel and remove belt assembly from
vehicle.
1. Position inertia reel assembly at top of squab panel and fit and
tighten securing bolts.
2. Pass belt tongue and lower anchor plate through aperture at
top of seat.
3. Fit escutcheon over seat belt an d fit and firmly seat in squab
aperture.
4. Position lower anchor plate at inner wheelarch (seat pan for
centre seat belt) and fit and tighte n securing bolt.
5. Position buckle assembly (and lo wer anchor plate if centre belt)
on seat pan and fit and tighten cable securing bolt.
6. Position and secure rear se at squab. Refer to 76.70.38.
7. Fit rear seat cushion. Refer to 76.70.37

Supplemental Restraint System - Air Bag Supplemental Restraint System
(SRS)
Description and Operation
Supplementary Restraint Air Bag System

Airbag/SRS units provided for driver and fro nt seat passemger protection, are installed in the center of the steering wheel,
the passenger side fascia and the oute r wing of each front seat. A single point sensing unit (SPS) mounted on the
transmission tunnel, below the ra dio, provides fully electronic impact sensing, control and diagnostics for the front airbags
Deployment of each side airbag is initia ted by a side impact sensing module (SISM) installed in the adjacent 'B' post. Each
SISM senses and electronically processes a crash pulse and if this exceeds the 'must fire' threshold, transmits a fire signal
to the SPS unit. The SPS unit monitors wh ole vehicle motion and on confirmation of a crash condition, transmits a firing
current pulse to the appropriate airbags. In the event of a side only impact, the SPS will send a current pulse to the airbag
on the struck only. Neither th e non-struck side airbag nor the frontal restraint system will be deployed under these
conditions. The airbag system can only be activated wh en the ignition switch is in position II or III.
Side Air Bags

Supplemental Restraint System - Driver Air Bag Module
Removal and Installation
Removal
• WARNINGS:
FOLLOWING DISCONNECTION OF THE BATTERY, A PERIOD OF AT LEAST ONE MINUTE MUST BE ALLOWED TO ELAPSE
BEFORE ANY WORK IS CARRIED OUT ON AN AIR BAG MODULE.
FOLLOWING TEN YEARS IN SERVICE, AN AIR BAG MO DULE MUST BE REMOVED AND DISPOSED OF IN THE
APPROVED MANNER, AND A NEW AIR BAG MUST BE FITTED.
AIR BAGS CONTAIN A CHEMICAL IRRITANT. IF AN AIR BAG IS RENEWED, THE ORIGINAL UNIT MUST BE DISPOSED
OF IN ACCORDANCE WITH CURRENT SAFETY PROCEDURES.
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTERY SUPPLY FUSE (F4 LOCATED IN THE FUSE-BOX AT THE
DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-
ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
Installation
1. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.

2. Remove air bag module securing bolts.
1. Turn steering wheel 90 degrees to the left to
provide access to module LH securing bolt.
2. Fully slacken captive securing bolt
Turn steering whee l 180 degrees to the right to provide
access to module RH securing bolt.
Fully slacken captive securing bolt.

3. Remove air bag module from steering wheel.
1. Carefully withdraw airbag module from steering wheel
and position for access.
2. Release air bag harness mu ltiplug from retaining clip
and disconnect multiplug.
1. Position air bag module and connect harness multiplug.
2. Fit multiplug onto retaining clip.
3. Carefully install airbag mo dule in steering wheel.
4. Turn steering wheel 90 degrees to right an d partially tighten
module RH securing bolt.

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.