Door remove JAGUAR X308 1998 2.G Manual PDF

Installation




8. Remove lock link rod from door handle assembly.
1. Fit link rod to handle assembly.
2. Position handle assembly on door.
3. Position mounting bracket on insi de of door and connect lock
link rod.
4. Fit and tighten mounting bracket securing bolts.
5. Reposition PVC inner sheet in door.
6. Check for satisfactory door handle operation.
7. Connect ground cable to battery terminal. Refer to 86.15.15.
8. From driver door check for satisfactory operation of locking
system.
9. Disconnect ground cable from battery terminal. Refer to
86.15.15.
10. Ensure that water shedder contact area of door is clean and
dry.
11. Position water shedder at door and carefully pass harness
through.
12. Fit and firmly seat water shedder on door ensuring
satisfactory adhesion.
13. Fit door casing. Refer to 76.34.01.
14. Fit door casing veneer panel. Refer to 76.47.11.
15. Fit ground cable to battery term inal and fit cover to battery.
Refer to 86.15.15.

Handles, Locks, Latches and Entry Systems - Rear Door Latch
Removal and Installation
Removal
1. Remove battery cover and disco nnect earth cable from battery
terminal. Refer to 86.15.19.
2. Remove rear door casing veneer panel. Refer to 76.47.12.
3. Remove rear door casing. Refer to 76.34.04.

4. Carefully withdraw water shedder passing harness through it
and remove water shedder from door.
5. Place water shedder adhesive face down on clean dry plastic
sheet.

6. Release door lock actuator ha rness multiplug from mounting
bracket and disconnect multiplug.

7. Position PVC inner sheet for access and disconnect door
outer handle operating ro d from lock mechanism.
8. Disconnect inner door lock operating rod from lock
mechanism and remove rod assembly.

Installation

9. Remove door inner cheater finisher.

10. Slacken and remove the door glass guide securing bolts and
position guide for access.

11. Slacken and remove lock mechanism securing bolts.

12. Carefully withdraw lock me chanism from door, remove
cable rear abutment clip and disconnect cable.
13. Remove lock mechan ism from vehicle.

Installation


15. With assistance, support sliding roof assembly and slacken
and remove the remaining securi ng bolt and washer at each
side of frame.

16. With assistance, lower sliding roof assembly and carefully
remove it via the front passenger door.
1. With assistance, carefully pass sliding roof assembly through
front passenger door and position at BIW roof.
2. With assistance fit and hand ti ghten centre bolts and plastic
washers securing sliding roof frame to BIW.
3. Fit and hand tighten remaining securing bolts with plastic
washers.

4. Inserting a 15mm drill shank or similar tool, align circular
apertures in sliding roof fra me and BIW at each side.
5. Finally tighten all sliding roof frame to BIW securing bolts.
6. Position sliding roof rear suppo rt brackets and fit and hand

Supplemental Restraint System - Passenger 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.
1. Remove battery cover and disc onnect ground cable from
terminal. Refer to 86.15.19.
2. Remove glove box. Refer to 76.52.03.

3. Remove deployment door from mounting clips, position for
access and remove and di scard retaining clips..

4. Slacken, remove and discard fo ur nuts and washers securing
air bag module and tether bracket to fascia.
5. Disconnect air bag module multiplug.

Installation
• NOTE: The serial numbers of all supplementary restrain t system components must always be recorded against the VIN of
the vehicle.


6. Withdraw air bag module and remove from vehicle.

7. Slacken, remove and discard two bolts securing air bag tether
bracket to air bag module.

1. Position air bag module on teth er bracket and fit and tighten
two new securing bolts.
2. Position air bag module and deployment door mounting
bracket in fascia.
3. Fit and tighten four new nuts and washers securing air bag

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.

a pneumatic saw (3).
• NOTE: On some panels, before removing the bulk with a pneumatic saw, it may be necessary to remove brazed areas and
MIG welded seams. Separate spot welded joints and remove the panel remnants.
Removal of Panels and Welds

PREPARATION OF PANEL SURFACES
WARNING: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
• NOTE: Observe all appropriate safety procedures.
Remove weld nuggets with a sander and 36 gr it disc and clean all flanges to a bright smooth finish (1). Straighten existing
panel joint edges as required.
Mark off the area of new panel and cut to size leaving approxim ately two inches overlap on the existing panel. Offer up new
panel or section, align with associated pa rts, i.e. new rear fender aligned with door / luggage compartment lid / backlight
aperture and clamp the panel into positi on.Where necessary, cut the new and orig inal panels to form a butt joint.
Release all clamps and remove the new panel. If required, apply inner panel protection and or sound insulation.
Prepare the new panel joint edges, including interior and exterior, for welding by cleaning to bright metal (1).
Apply weld-through primer or in terweld sealer(2) to all surfaces to be resistance spot welded.
Where appropriate, apply metal- to-metal adhesive or sealer (3) in accordance with the manufacturer's instructions.

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