maintenance JAGUAR X308 1998 2.G Workshop Manual

Gener
al specifications (including setting-up information, capacities, lubricants, fluids, sealants and adhesives).
To
r
que specifications.
Description and Operation
A g
eneral illustration and part
s list to identify the components which comp rise a particular system or assembly.
A b
rief description of the system operating characteristics or description of the assembly.
A d

escription of each component and its function.
Diagnosis and Testing
D e
scriptions of how to iden
tify system problems.
Inspection and verifi
cation information.
S
y
mptom charts comprising fault conditions, possible sources and actions.
General Procedures
G e
neral maintenance procedures, including adjustment, alig
nment, bleeding and filling, with illustrated steps and
supporting text.
Tigh te
ning torque specifications, shown in the illustrations.
Removal and Installation
Com p
onent removal and installation maintenance proced
ures, with illustrated steps and supporting text.
Tighte
ning torque specifications, shown in the illustrations.
An i
llustrated tool
chart for each proced
ure requiring the use of special tools.
Disassembly and Assembly
Compon ent disassembly and
assembly
maintenance procedures, with illust rated steps and supporting text.
Tighte
ning torque specifications, shown in the illustrations.
An i
llustrated tool
chart for each proced
ure requiring the use of special tools.
Repairs and Replacem
ents
Wh
en s
ervice parts are required, it is essential that only genuine Jaguar/Daimler replacements are used.
Attention is drawn to the following points concerning repa irs and the fitting of replacement parts and accessories:
Safety feat
ures embodied in the vehicle
may be impaired if other than genuine parts are fitted. In certain territories,
legislation prohibits the fitting of pa rts which are not produced to the vehi cle manufacturer's specification.
Torque wrench setting figures given i
n this manual must be strictly adhered to. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.
O w
ners purchasing accessories
while travelling abroad should ensure that the accessory and its fitted location on the
vehicle conform to mandatory requirements existing in their country of origin.
The vehicle warranty may be invali
dated by the fitting
of other than genuine Ja guar/Daimler parts. All
Jaguar/Daimler replacements have the fu ll backing of the factory warranty.
Jaguar/Daimler dealers are obliged to

supply only genuine service parts.
Thread Locking Devices
P a
tched Fasteners
Two types
of
patched fastener are essentially used on certai
n suspension, steering and other critical components, where
operational movement of the component necessitates positive thread locking. Standard patched fasteners have part
numbers bearing the suffix le tter M. For identification of special patched fa steners, refer to the list of patched fasteners
below, or the relevant component drawings.
Jaguar Specification JFS 02.01.02 patched fasteners incorporate a micro-encapsulated adhesive which is released into the
mating threads during tightening. Following final tightening, the adhesive in this type of patched fastener must be allowed a
period to cure before the component/vehicle is used. On removal, this type of fastener must be discarded and a new

patc
hed fastener of the same specification fitted. All mating th
reads must be thoroughly cleaned prior to fitting of the new
fastener.
Jaguar Specification JFS 02.01.04 patched fasteners incorporat e a plastic/polyester on the thread. Acting as a wedge
between the mating threads, this compound imposes a prevaili ng torque during tightening. Whilst this type of patched
fastener can be re-used, the imposed torq ue diminishes. It is therefore recommended that following third removal, this type
of patched fastener is discarded and a new fast ener of the same specification is fitted.
Special fasteners bearing the following pa rt numbers are of the micro-encapsulated adhesive type and following removal,
must be discarded and replaced by ne w items of the same specification:
CAC 8223
JZB 10060; JZB 10061; JZB 10078.
JZH 100027.
JZS 100082; JZS100087; JZS 100088; JZS 100089; JZS 100090; JZS 100118; JZS 100157; JZS 100164; JZS 100166.
NCA 1451 AA.
Vehicle Specifications

Purchasers are advised th
at th
e specification details set out in this manual apply to a range of vehicles and not to any
specific one. For the specificatio n of a particular vehicle, purchasers should consult their dealer.
The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner
as the Manufacturer thinks fit. Major as well as minor changes may be involved , in accordance with the Manufacturer's
policy of continuous improvement.
Whilst every effort is made to ensure the accuracy of the pa rticulars contained in this manual, neither the Manufacturer nor
the Dealer, by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the
consequences thereof.
Serv
ice Repair Operation Numbering
A
master index of numbered operations has been compiled for
universal application to all vehicles manufactured by Jaguar
Cars Ltd.
Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair
Operation Times schedule. The number consists of six digits arranged in three pairs.
Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the
minimum time, as specified in the Repair Operation Times schedule for this range of vehicles.
Re
ferences to Left- and Right-Hand
R
eferences to the left- or
right-hand side of the vehicle are made as if viewing from the driver's seat.
Ref
erences to Engine Banks
Wi
th the engine installed in the vehicle, the right-hand cylinder
bank is designated Bank A, and the left-hand cylinder bank
is designated Bank B.
Specia
l Tools
Any special too

ls and equipment required
to perform a maintenance procedure, are shown at the beginning of each
maintenance procedure.

Torque Specifications
Torque sp
ecifications are shown in maintenance procedure illustra
tions and also in the torque specifications chart located at
the front of the relevant section.
Disconnecting/Connecting the Battery
Ow ing t
o the electronic components used on the vehicle, it is important that the battery is disconnected when specified in a
maintenance procedure.
When the battery is connected, the specified procedure must be followed, to ensure the correct operation of all vehicle
systems; refer to Section 414-01.
Use of Control Modules
Control modu les may
only be used on the ve
hicle to which they were originally fitted. Do not attempt to use or test a control
module on any other vehicle.
Function
al Test
On
completion of a maintenance procedure, a thorough test should be carried out, to ensu
re that the relevant vehicle
systems are working correctly.
Protecting the Vehicle
Al ways
fit covers to protect
the fenders before commencing work in the engi ne compartment. Cover the seats and carpets,
wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid,
antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water imme diately. Use polythene sheets
in the trunk to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified.
Protect temporarily exposed screw thread s by replacing nuts or fitting caps.
Preparation
Before disassembly, clean the surrounding ar ea
as thoroughly as possible. When co
mponents have been removed, blank off
any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when
separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed
by component removal, with tapered hardw ood plugs or readily visible plastic plugs. Immediately a component is removed,
place it in a suitable container; use a se parate container for each component and its associated pa rts. Before dismantling a
component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the
materials within the component. Clean the bench and obtain ma rking materials, labels, containers and locking wire before
dismantling a component.
Dismantling
O b
serve scrupulous cleanliness when dismantling components,
particularly when parts of the brake, fuel or hydraulic
systems are being worked on. A particle of dirt or a fragment of cloth could caus e a dangerous malfunction if trapped in
these systems. Clean all tapped holes, crev ices, oilways and fluid passages with compressed air. Do not permit compressed
air to enter an open wound. Always use ey e protection when using compressed air.
Ensure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure that
they are replaced as dismantled. Whenever possible use markin g materials which avoid the possibilities of causing distortion
or the initiation of cracks, which could occur if a center pu nch or scriber were used. Wire together mating parts where
necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to
parts requiring further inspection before being passed fo r reassembly. Place labelled parts and other parts for rebuild in
separate containers. Do not disc ard a part which is due for renewal until it ha s been compared with the new part, to ensure
that the correct part has been obtained.

Before inspecting a component for wear or per
forming a dimensional check,
ensure that it is absolutely clean; a slight smear
of grease can conceal an incipient failure. When a component is to be checked dimensionally against figures quoted for it,
use the correct equipment (surface plates, micrometers, dial gauges etc.) in serviceable condition. The use of makeshift
equipment can be dangerous. Reject a component if its dimensio ns are outside the limits quoted, or if damage is apparent.
A part may be refitted if its critical di mension is exactly to the limit size and it is otherwise satisfactory. Use Plastigauge 12
Type PG-1 for checking bearing surface clearance, e.g. big end bearing shell to crank jour nal. Instructions for the use of
Plastigauge and a scale giving bearing clearances in steps of 0.0025 mm (0.0001 in) are supplied with the package.
Safety
Precautions
• WAR
NINGS:
WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE. FUEL
VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM.
ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
DO
NOT SMOKE IN THE WORK AREA.
DISP

LAY 'NO SMOKING' SIGNS AROUND THE AREA.
DISCONNECT TH

E BATTERY BEFORE WORKING ON THE FUEL SYSTEM.
DO NOT CONNEC

T/DISCONNECT ELECTRICAL CIRCUITS
, USE ELECTRICAL EQUIPMENT OR OTHER TOOLS OR
ENGAGE IN WORKING PRACTICES WHICH IN ANY WAY MAY RESULT IN THE PRODUCTION OF SPARKS.
ENS
URE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENS

URE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMP

TY FUEL USING SUITABLE FIRE PROOF EQUIPMENT IN
TO AN AUTHORIZED EXPLOSION PROOF CONTAINER.
DO NOT EMP
TY FUEL WHILE WORKING IN A WORKSHOP OR A PIT.
ENS

URE THAT WORKING AREA IS WELL VENTILATED.
ENS

URE THAT ANY WORK ON THE FUEL SYSTEM IS ON
LY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED
MAINTENANCE PERSONNEL.
ENS
URE THAT FUME EXTRACTION EQUIPMENT IS USED WHERE APPROPRIATE.
FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE,
WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHY LENE. DO NOT SMOKE IN THE VICINITY OF VOLATILE
DEGREASING AGENTS.
General workshop practices:
Disc
onnect the grounded termin
al of the vehicle battery.
D
o not apply heat in an attempt to free seized nuts or fitt
ings; as well as causing damage to protective coatings,
there is a risk of damage from stray heat to electronic equipment and brake lines.
Keep oils and solven
ts away from naked flames and other sour
ces of ignition.
Adhere str
ictly to handling and safety inst
ructions given on containers and labels.
E
nsure that a suitab
le form of fire extinguisher is conveniently located.
Wh
en using electrical tools and equipment, inspect the power
lead for damage and check that it is properly earthed.
D
o not leave tools, equipment, spilt oil etc. around the work area.
Working beneath a vehicle:
Wh
enever possible, use a ramp or
pit in preference to jacking.
Posit
ion chocks at the wheels as we
ll as applying the parking brake.
N
ever rely on a jack alone to support a
vehicle; use axle stands, or blocks care fully placed at the jacking points, to
provide a rigid location.
Ch
eck that any lifting equipment used has adeq
uate capacity and is fully serviceable.
Working on air conditioning systems:
D
o not disconnect any pipes of the refrigeration system
unless you are trained and instructed to do so; a refrigerant
is used which can cause blindness if allowed to come into contact with the eyes.
Health Protection

P

rolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness,


In
spection

WARNING: NEVER USE A CFC 12 ANALYZ
ER OR NAKED FLAME TYPE.
Leak tests should be carried out with a UV spot lamp or an electronic analyzer which is dedicated to HFC 134A refrigerant.
Handling Lubricati
ng Oil
Av
oid breathing lubricant mist; it can cau
s
e irritation to the respiratory system.
Always use fresh oil from a sealed containe r and do not leave oil exposed to the atmosphere for any reason other than to fill
or empty a system. PAG oil is very hygr oscopic (absorbs water) and will rapidly become contaminated by atmospheric
moisture.

PAG oil is NOT compatible with previously used mineral based oi ls and must NEVER be mixed. Do not re-use oil when it has
been separated from refrigerant, following a re covery cycle. Dispose of used oil safely.
System Maintenance
Plug pipes an
d units immediatel
y after disconnection an d do not remove the plugs until immediately before making the
connection. Do not leave the system open to atmosphere.
The receiver drier must be renewed if the compressor has failed or if it is susp ected that debris may be present in the
system.
It is not always necessary to renew th e receiver drier if the correct procedur es have been followed. However, if a
component or part of the system is left dismantled for more than five minutes, it may be advisable to renew the receiver
drier. This guidance is based on UK average humidity levels; lo cations with lower humidity levels will be less critical to
moisture contamination. It must be stressed however th at there is not a safe period for work to be carried out in.
Do not use any replacement parts su pplied without transit plugs and seals - return them to the supplier.
Diagnostic equipment for pres sure, mass and volume should be calibrated regularly and certified by a third party
organization.
Use extreme care when handling and securi ng aluminum fittings; always use a backing spanner and take special care when
handling the evaporator.
Use only the correct or re commended tools for the job and apply the manufacturer's torque specifications.
Graph - High S
ide Pressure against Ambient Temperature

Battery, Mounting and Cables - Battery and Cables Description and Operation
The battery has been designed specifically for Jaguar. It provides the high output which is required for this vehicle, but with a
substantial saving in weight. It is a low maintenance battery, located on the right ha nd side of the luggage compartment floor.
The negative (Ground) lead is connected to the vehicle body. The positive lead is connected to a high power protection module; from
here power is connected to the starter motor an d distributed to other systems on the vehicle.
The high power protection module comprises three fuses, each of 250A capacity. Two fuses are connected in parallel to provide
protection for the starter circuit. Th e third one provides high level protection for fusebox supply circuits .
PDU is unable to diagnose the overall condition of the battery - only that it is present and supplying battery voltage to the system.
To test the battery, follow the test procedure described in Section 414-02 Generator and Regulator of this Manual.
Although these tests will not actually test the battery, they will confirm that the generator, regulator and connecting cables are
working correctly and that conseq uently, the battery may be at fault. Alternatively, the tests may indicate that the fault lies in the
generator, regulator or wiring and not in the battery.
Battery

Parts List


ItemPart NumberDescription
1—Battery
2—Positive Lead
3—Battery Hold-Down Clamp
4—Negative (Ground) Lead
5—High Power Protection Module (Fuses)