roof JAGUAR X308 1998 2.G Service Manual

3. Fit and tighten motor securing screws.
4. Connect motor harness multiplug to control module.
5. Using a drive key or screwdriver in the motor gearbox slot,
manually rotate the spindle 1/4 turn counter-clockwise to re-
engage the motor drive.
6. Fit roof console. Refer to 76.13.69.90.
7. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.

Roof Opening Panel - Roof Opening Panel Shield
Removal and Installation
Removal
Installation
1. Turn ignition switch to position II.
2. Open sliding roof to fully tilted position.
3. Turn ignition switch to po sition O and remove key.

4. NOTE: A detent spring is fitt ed at panel front corner for
slider peg engagement.
Pulling trim panel rearwards, release panel front corners from
slider mechanism pegs.

5. Ensure central guide lugs are above mechanism tilt levers.

6. Carefully withdraw trim panel rearwards through roof
aperture.
1. Ensuring central guide lugs are ab ove tilt levers, carefully slide
trim panel into position through roof aperture.
2. Pull trim panel forward and positi on and fully seat front corners
over slider pegs.
3. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.
4. Insert key and turn ignition switch to position II.

5.
Fully close sliding roof, checking that operation is satisfactory
and trim panel remain s correctly fitted.
6. Turn ignition switch to position O.

Roof Opening Panel - Roof Opening Panel Trim
Removal and Installation
Removal
Installation

1.
Remove sliding roof trim panel for access. Refer to 76.82.19.
2. Turn ignition switch to position II.
3. Fully open sliding roof panel.
4. Turn ignition switch to O and remove key.

5. Remove finisher.
1. Exercising care to avoid damaging edge of headlining,
remove aperture trim finisher from flange.
2. Release headlining from BIW aperture flange.
1. Fit edge of headlining over BIW aperture flange.
2. Fit and fully seat trim finisher to flange.
3. Insert key and turn ig nition switch to II.
4. Close sliding roof panel.
5. Turn ignition switch to O.
6. Fit sliding roof trim panel. Refer to 76.82.19.

Roof Opening Panel - Roof Opening Panel Weatherstrip
Removal and Installation
Removal
Installation

1.
Remove sliding roof trim panel for access. Refer to 76.82.19.
2. Remove sliding roof panel fo r access. Refer to 76.82.05.

3. Remove and discard seal fro m roof panel flange and
thoroughly clean flange.
1. Commencing at central rear posi tion, fit and firmly seat new
seal to panel flange.
2. Ensure that the seal is evenly tensioned and free from ripples.
3. Carefully cut off any excess seal and ensure that ends butt
correctly and re main central.
4. Using tool JD 200, crimp seal into position along entire length.
5. Changing commencing position sl ightly, repeat above step to
ensure continuous crimping of seal.
6. Fit sliding roof panel. Refer to 76.82.05.
7. Fit sliding roof trim panel. Refer to 76.82.19.

Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. Ensure
that there is efficient ventilation / extrac tion at all times. Paint spraying should be confined as far as possible to spray
booths. Personnel with a history of asth ma should not be employed in any process involving the use of isocyanates.
Operators working in a spray booth where isocyanate material is present must use air-fed breathing equipment with air
supplied to the visor at the re commended pressure and filtered to remove oil, water, and fumes. Operators involved in
handling mixing or spraying should wear protective clothing including gloves and goggles, to avoid skin and eye contact.
Particle masks or canister type respir atosr should be worn when sanding.
Applied Heat
When welding, flame cutting, brazing etc, the operator shou ld use as appropriate, goggles, mask / fume extractor and
flameproof protective clothing. It is especially important when working with polyurethane compounds to use air-fed
breathing equipment. Appropriat e fire fighting equipment and personnel trai ned in its use must always be available.
Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding. Face
masks or air-fed visors should also be wo rn when sanding or flatting either body solder or fillers. On completion of a
soldering operation, swarf must be re moved from the work area and the operat or must wash his hands thoroughly.
GENERAL REPAIR NOTES
The following advice should be noted before any repair work is carried out.
Disconnect the vehicle battery gr ound lead (disconnect the alternator where electric welding is used) and take note of the
reconnection procedures as detailed in 86.15.15.
Where structural parts are straightened or renewed, a body alignment / straightening jig must be used. The application of
heat, especially excessive heat, reduces the strength of steels, where appropriate therefore, structural sections should be
straightened by cold processes.
Repairs may only be carried out successful ly, and any warranties protected, if genuine Jaguar replacement parts and Jaguar
approved materials are used.
The correct tools, procedures and facilities must always be us ed. The quality of the work must not be compromised by using
inappropriate methods or equipment.
All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel removal /
replacement; this is especially important where hollow sectio ns may contain harnesses, tubes or foam, see section A4.3.5.
WARNING: DO NOT WORK IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. READ WORKING
PRACTICES AIR BAG, SECTION 20. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED.
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high voltages produced by this process will
cause irreparable damage to the electric al control and microprocessor systems.
The following welding and gas processes are the only ones recommended by Jaguar Cars Ltd.
Welding and Gas Processes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated metal.
The flanges of panels to be welded toge ther, must be clean, corrosion free and tr eated as appropriate, with either weld-
through primer or inter-weld sealer. Only materials and processes specified in the 'Body Sealing and Preservation Manual'
should be used in the relevant application areas detailed in this section. Refer to 'Zinc Coated Panels' Section

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

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

FOAM INJECTION
Where any of the sections shown in the illustration are renewed, expanded foam must be introduced into the area on
completion of all other repair / refinishin g / protective processes. Tape should be applied to the areas indicated by arrows to ensure full travel of foam along the holl ow sections.Expanded foam should be introd uced at the points circled. Items such as sliding roof drain tubes and the harness from the rear left-hand bulkhead through to the luggage compartment, must be in
position before the introduction of foam.
Foam Injection Points

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.