wheel JAGUAR X308 1998 2.G Workshop Manual

Generally, resistance spot welding equipment used in the motor vehicle repair industry does not produce welds of equivalent strength to those achieved during manufactu re. The expression 'single row of resistance spot welds' indicates that the spots
should be spaced on a pitch of 19mm to 25mm, which normally results in mo re spot welds than those produced in the
original factory joint.
Resistance spot welds should be removed using a resistance spot weld cutter. If the new joint is to be MIG plug welded, old
resistance spot welds should be cut from the panel to be reta ined and the resulting holes used for plug welding. Suitable
holes may also be drilled or punched; 8,0 mm dia for sect ions up to 1,6 mm, and 10,0 mm dia for thicker sections.
PLASTICS-EXPLANATORY NOTES
Plastic component and trim materials
This table, in conjunction with the illu strations on the following pages will enable rapid identification of the particular
material of any major plastic part.
• NOTE: Only those components suitable for economic reclamation are identified.
Plastics - Handling Notes
The exterior panel temperature of a vehicle must not exceed 95°C at any time and may only be held at this level for a
maximum of two hours. Similarly, interior vehicle temperatur e must be limited to 86°C for a maximum duration of two
hours. Exposure to temperatures above those specified may result in distorted or permanently damaged components. If
there is doubt concerning temperature limitations, components that may be adversel y affected by exposure to heat should
be removed from the vehicle.
Plastic components that become greasy may be clea ned with an 'SBP 3' spirit wipe, or equivalent.
Recycled Materials
Any of the materials listed in this section, may be recycled provided that they ar e not contaminated by other incompatible
plastics or metals. For instan ce, the air conditioning unit case, manufactur ed from PP (polypropylene), must be separated
from the heater matrix, evaporator, contro l devices (electronic and mechanical) and all fixings before it can be considered
for recycling. After removal, the case mu st only be placed for disposal with materials of the same generic type. Bumper
cover assemblies similarly have side arma tures of dissimilar materials rivetted to them, these together with their fixings
must be removed prior to recy cling. Components manufactured from 'blended' materials must not be recycled with pure
materials. For example do not mix PC/ABS (wheel trim) with ABS ('B' pillar upper trim).
Plastics, Component Location and Type - External
TermMaterial Name
absAcrylonitrile Butadiene Styrene
abs / paAcrylonitrile Butadiene Styrene and Polyamide (nylon) blend
abs / pcAcrylonitrile Butadiene Styrene and Polycarbonate blend
ABS / PBTAcrylonitrile Styrene Acrylate and Polybutylene Terephthalate
paPolyamide (nylon)
pcPolycarbonate
pePolyethylene
pmmaPolymethyl Methacrylate
pomPolyoxymethylene (acetal)
ppPolypropylene
ppoModified Polyphenylene Oxide
purPolyurethane
pvcPolyvinylchloride
SMAStyrene Maleic Anhydride

Body Structure
Introduction
The standard wheelbase Jaguar sedan has a unit construction monocoque body structure with bolt-on front fenders and
welded rear fenders. The doors feature lif t-off hinges and welded drop-glass frames.
Constructional Steel Classification
BODY ALIGNMENT
The Body Dimensions Plan, and Body Dimensions Side View, provide specified BIW dimensions to facilitate damage
assessment and location of replacemen t parts. These dimensions must be strictly applied when used for damage
assessment, component location or post repair verification.
• NOTE: The right-hand side is always looking towards the front, from the rear of the vehicle.
The nominated plan view master datums are on the right-hand side of the body with the left-hand datums dimensioned
from them. Right-hand datums must therefore be known to be correct before any other cross-car dimensions are checked.
Datum location, Example
The Front Master Datum (front crossmember rear mounting at the inner face of the main floor RH longitudinal) is nominally
359,5mm to the right-hand side of the body center line. The LH side fron t datum is measured 717,0 / 721,0mm from the
RH. Refer to the Body Dimensions Plan.
Expressed as a true posi tion in three planes, the front master datum is:
Standard Wheelbase Bo dy Dimensions-Plan
MaterialApplication
High strength low alloy
(HLSA).Impact prone areas, ie. seat frame and bumper mountings.
Double sided zinc plated mild steel.Exterior body panels subject to severe cond itions such as stone chipping and weather
exposure (excluding roof panel).
Boron steelDoor intrusion beams
Mild steel.Internal brackets, fill ets and strengtheners.
DatumLocationPosition
Front Master Datum
PlanCentre line of the front crossmember rear mounting, at the main floor RH
longitudinalX
300,0
Y 359,5 Z -50,0

Key to Plan
Standard 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 li ne 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
Long Wheelbase Body Dimensions-Plan
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

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

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

8. Remove generator front cooling duct.
Remove bolt.
Move duct rearwards to rele ase tang from undertray.
Release front duct from rear vertical duct.

9. Remove scrivets or screws se curing undertray to bumper
cover. Discard scrivets.

10. Remove and discard tiestrap securing undertray to body
brace.

11. At each side of vehicle, remo ve and discard scrivet securing undertray to wheelarch liner.
12. Remove undertray from vehicle.
13. Remove both front road wheels. Refer to Section 100-02.
14. Remove both front road springs. Refer to 60. 20.02.
15. Disconnect wheel speed sensor harness connectors.

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.

30. Connect steering harness.
Route harness connector to body front location.
Connect steering ha rness connector.
Install connector in body retaining clip.

31. Connect wheel speed sensor harness.
1. Connect wheel speed sensor harness to sensor.
2. Using new tiestraps secure wheel speed sensor harness to upper wishbone.
Repeat procedure to connect opposite side wheel speed
sensor.

32. Install brake calipers.
1. Install caliper on carrier.
2. Install guide pins.
3. Install guide pin dust caps.
4. Install caliper spring clip.
Repeat procedure to install opposite side front brake
caliper.
33. Install both front road sp rings. Refer to 60. 20.02.
34. Using screws or new scrivets , secure undertray to front
bumper cover.