JAGUAR XJ6 1994 2.G Workshop Manual

General Fitting Instructions
I
Fault
Roller wear.
Cause
Marks on track and rollers caused by fine abrasives.
Remedy
Clean all components and housings. Check the seals and
bearings, and renew if leaking, rough or noisy.
Fault
Cracked race.
Cause
Race cracked due to incorrect fitting to shaft, tipping or poor
seating.
Remedy
Renew the bearing and check the condition of the seals.
Fault
Discolouration.
Cause
Discolouration ranging from black to light brown caused by
moisture or incorrect use of lubricants.
Remedy
Reuse bearings if stains can be removed by light polishing
or if no evidence of overheating is apparent. Checkthe seals
and other component part condition. Renew as necessary.
51 060
[pzq-j - ..., .... *au
....... ........ e L. U
1
Fault
Discolouration.
Cause
Heat discolouration ranging from blue to faint yellow,
resulting from overload or incorrect lubricant. As excessive
heat can cause softening of tracks and rollers, check by
drawing a fine
file over a softened area. If faulty, the file will
grab and cut metal. If still hard, the file will skid over the
surface without removing any material.
Remedy
Renewthe bearings and seals if any heat damage is evident.
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6 Fault
Seizure.
Cause
Seizure caused by lack of lubrication, excessive loads or the
ingress of foreign matter.
Remedy
Renew the bearings. Check the seals for wear and ensure
that there is adequate lubrication.
Fault
Etching.
Cause
The bearing surfaces are grey or greyish black, with the
rollers and track material being etched away. This is usually
related to uneven spacing of the rollers.
Remedy - Renew the bearings. Check the seals for wear and ensure
that there is adequate lubrication.
Fault
Rotating track and inner race material removal.
Cause
Removal of material due to slippage. This can be caused by
poor fit, incorrect lubrication, overheating, overloading and
poor assembly.
Remedy
Renew the bearings and clean all related parts. Check the fit
and ensure the replacement bearings are the correct type.
Renew the shaft or housing if damaged.
J51 OS6
Issue 1 August 1994 11 X300 VSM

12

SECTION CON TENTS
Suh-Section Title SRO Page
i Toiii ............ PreliminaryPages ................................................................ i Toiii
A4.1
............. Body Repair, Introduction ............................................................. 1
A4.1.1 ........... Health And Safety .................................................................... 1
A4.1.2 ........... Notification Of Hazards ............................................................... 2
A4.1.3 ........... Potential Risks ....................................................................... \
3
A4.1.3.1
.......... Potential Risks. Paint ................................................................. 3
A4.1.3.2
.......... Potential Risks. Applied Heat (Welding) .................................................. 3
A4.1.3.3 .......... Potential Risks. Metal Repair ........................................................... 3
A4.1.4 ........... Precautions ........................................................................\
. 3
A4.1.4.1 ..........
A4.1.4.2 ..........
A4.1.4.3 ..........
A4.1.5 ...........
A4.1.5.1 ..........
A4.1.6 ...........
A4.1.6.1 ..........
A4.1.6.2 ..........
A4.1.6.3 ..........
A4.1.6.4 ..........
A4.1.6.5 ..........
A4.1.6.6. .........
Precautions. Paint .................................................................... 3
Precautions. Applied Heat
............................................................. 3
Precautions. Metal Repair ............................................................. 3
General Repair Notes ................................................................. 4
Welding & Gas Processes. Special Notes ................................................. 4
Plastic Component & Trim Materials. - Table ............................................. 5
Plastics. Explanatory Notes ............................................................ 5
Plastics. Handling Notes .............................................................. 5
Recycled Materials
................................................................... 5
Plastics. Component Location & Type - External. Illustration ................................. 6
Plastics. Component Location
& Type - Internal. Illustration ................................. 7
Plastics. Component Location & Type - Underhood. Illustration .............................. 8
A4.2 ............. Body Structure. ...................................................................... 9
A4.2.1 ........... Body Structure. Introduction ........................................................... 9
A4.2.2.1 .......... Body Alignment. Datum Location ...................................................... 10
A4.2.2.2 .......... Body Alignment. Plan View - Key to Illustration .......................................... 10
A4.2.2.3 .......... Body Alignment. Side View - Key to Illustration .......................................... 12
A4.2.3 ........... Zinc Coated Panels .................................................................. 14
A4.2.3.1 .......... Zinc Coated Panels. Description ....................................................... 14
A4.2.3.2
.......... Zinc Coated Panels. Welding Preparation ............................................... 14
A4.2.3.3
.......... Zinc Coated Panels. Body Fillers ....................................................... 14
A4.2.3.4
.......... Zinc Coated Panels. Refinishing ....................................................... 14
A4.2.4
........... Panels -Associated. Renew ..................................... 77.10.02 ............ 15
A4.2.5
........... Surfaces (Old). Prepare .......................................... 77.10.03 ............ 16
A4.2.5.1 .......... Surfaces (New). Prepare ......................................... 77.10.04 ............ 16
A4.2.5.2 .......... Panels -Align And Weld ........................................ 77.10.05 & 06 ....... 17
A4.2.6 ........... Cutting And Welding Symbols ......................................................... 18
A4.3.1 ........... Adhesive. Sealers and Body Protection - Approved Systems ................................ 19
A4.3.
1 . 1 .......... Body Sealing & Preservation Manual - Section Relevance ................................. 19 A4.3.2 ........... Cavity Wax Injection ................................................................ 19
A4.3.2.1
.......... Cavity Wax Injection Points - Front. Illustration .......................................... 20
A4.3.2.2. ......... Cavity Wax Injection Points - Rear, Illustration ........................................... 21
A4.3.3 ........... Underseal. Application Area .......................................................... 22
A4.3.4
........... Insulation Pads. Location ............................................................. 23
A4.3.5
........... Foamlnjection ..................................................................... 24
A4.4.1 ........... Paint Systems - Approved. Table ...................................................... 25
A4.4.1.1
.......... General Recommendations (Paint Refinishing Manual) .................................... 25
A4.4.1.2
.......... Paint Refinishing Manual. Section Relevance ............................................ 25
A4.4.2
........... ‘Black-Out’ Areas. Illustration ......................................................... 26
A4.4.3 ........... Anti-theft labels .................................................................... 27
A4.4.3.1
.......... Anti-theft labels. Original Components ................................................ 27
A4.4.3.2
.......... Anti-theft Labels. Replacement Components ............................................ 27
A4.4.3.3 .......... Anti-theft Labels. Procurement ........................................................ 27
A4.4.3.4
.......... Anti-theft Labels. Location -Front ..................................................... 28
A4.4.3.5
.......... Anti-theft Labels. Location - Rear ...................................................... 29
A4.4.3.7.
......... Anti-theft Labels. Fitting Process ....................................................... 31
A4.2.1.1
.......... Body Structure.
Constructional Steel Classification - Table .................................. 9
A4.2.2 ........... BodyAlignment ..................................................................... 9
A4.4.3.6 .......... Anti-theft Labels. Location -Power unit & Transmission ................................... 30

Body Systems & Body Repair
Sub-Section Title SRO Page
A4.4.4 ........... Underhood Labels. Location & Tvpe ................................................... 32
A4.4.5
........... Stonechip Protection Area ............................................................ 33
A4.5.1.1
.......... Glass And Body Preparation .......................................................... 34
A4.5.1.2
.......... Glazing Adhesive Application Temperature ............................................. 34
A4.5
............. Glazing ........................................................................\
... 34
A4.5.1
........... Glazing. Special Notes ............................................................... 34
A4.5.1.3
.......... Glazing Adhesive Application ......................................................... 34
A4.5.1.4
.......... Glazing Adhesive Curing ............................................................. 34
A4.6.1
........... Bumpers ........................................................................\
... 35
A4.6.1.2 .......... Bumpers. Features ................................................................... 35
A4.6.1.3
.......... BUmpeN. Service Procedures ......................................................... 37
A4.6.1.4 .......... Bumpers. Fitted Condition - Front ..................................................... 37
A4.6.2
........... BUmpeN. Cover Damage ............................................................. 39
A4.6.1.1
.......... Bumpers.
Major Components ......................................................... 35
A4.6.1.5 .......... Bumpers. Fitted Condition -Rear ...................................................... 38
A4.6.2.1
.......... Bumpers. Damage Assessment ........................................................ 39
A4.6.2.2
.......... Bumpers. Repair Materials ............................................................ 39
A4.6.3 ........... Bumpers. Refinishing ................................................................ 40
A4.6.3.1
.......... Bumpers. Refinishing - Original ....................................................... 40
A4.6.3.2
.......... Bumpers. Refinishing - New .......................................................... 40
A4.6.3.3
.......... Bumpers. Refinishing - All ............................................................ 40
A4.6.4
........... Bumpers. Replacement Covers ........................................................ 40
A4.6.5
........... Recycled Materials. General Note ..................................................... 40
A4.6.6.1
.......... Body-side Moulding, Introduction ..................................................... 41
A4.6.6.2
.......... Body-side Moulding. Fitted Condition - Illustration ....................................... 41
A4.6.6.3
.......... Body-side Moulding. Fitting Process ................................................... 41
A4.6.7
........... Finisher, Door Frame - Fitted Condition ................................................ 42
A4.6.8
........... Finisher, Roof Drip Rail - Fitted Condition .............................................. 42
A4.7.1
........... Body Exterior Clearances & Alignments ................................................. 43
A4.7.1.1
.......... Body Exterior Clearances & Alignments. Introduction ..................................... 43
A4.6.6
........... Body-side
Moulding ................................................................. 41
A4.7.1.2
.......... Body Exterior Clearances & Alignments. Criteria - Clearances ............................. 43
A4.7.1.3
.......... Body Exterior Clearances & Alignments. Criteria - Alignment .............................. 43
A4.7.1.4
.......... Body Exterior Clearances & Alignments. Criteria - Exterior Fitments ........................ 43
A4.7.1.5
.......... Body Exterior Clearances & Alignments. Illustrations (Specifications) ........................ 43
A4.7.2
........... DOON ........................................................................\
..... 47
A4.7.2.1
.......... DOON. Features ..................................................................... 47
A4.7.2.2
.......... DOON. Removal .................................................................... 47
A4.7.2.3
.......... DOON. Fitting ....................................................................... \
47
A4.7.2.4
.......... DOON. Alignment ................................................................... 47
A4.7.2.5
.......... Door Seals. Table ................................................................... 48
A4.7.2.6 .......... Door Seals - Typical Sections. Illustration ............................................... 48
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Body Systems Body Repair
A4.1 BODY REPAIR
Introduction
This section contains information, specifications and procedures for body repair and rectification of the Jaguar sedan
range (with standard wheelbase).
All repairs, whether structural or cosmetic, must ensure the continuance of the Paint Surface and Corrosion warranty,
where applicable.
Following repair or rectification, the vehicle must be returned to the original manufactured condition with regard to
occupant safety, dimensional accuracy, finish and corrosion protection.
Similarly, repaired vehicles must be fully checked, and where appropriate reset, with regard to steering, suspension,
restraint and
braking systems.
A4.1.1 Health and Safety
(Please Read The
Fol/owing Notes Carethlly)
Where legislation governing working conditions and practises is applicable, you should observe it. Do not forget that
you have a duty, to yourself and those around you, to act in a responsible manner in the workplace.
In the United Kingdom the Health and Safety
at Work Act (1974) places a duty on employers and employees to ensure,
whenever possible, safe working conditions and practices. Wherever a potential hazard is notified to, or identified by
the operator, he must employ the correct safety procedures and equipment.
Should
a personal injury occur as a result of any workshop activity, seek medical help as soon as possible and do not
attempt self-treatment other than by the application of first aid.
With the constant introduction of new materials in the manufacture of vehicles,
it is important that potential risks are
identified and precautions made known.
WARNING: READ AND UNDERSTAND WORKING PRACTICES CLIMATE CONTROL SYSTEMS, SECTION 14, WITH SPECIAL REFERENCE TO
ERY
/ RECYCLE / RECHARGE EQUIPMENT.
WEAR SUITABLE EYE AND SKIN PROTECTION.
OBSERVE ALL APPLICABLE SAFETY REQUIREMENTS.
DO
NOT VENT REFRIGERANT DIRECTLY TO ATMOSPHERE, ALWAYS USE JAGUAR APPROVED RECOV
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Issue 1 August 1994 1 X300 VSM

A4.1.2 Notification Of Hazards
Symbols, which convey important information, will be posi- tioned at the beginning of any specific operation or text.
Standard symbols will be used where repairs or service pro
- cedures are detailed.
All symbols will conform to standard
ANSl 2535.3 (Ameri- can National Standards Institute).
0 The surround shape of the symbol will indicate the
basis of the message to be conveyed (see top three el-
ements of Fig. l)
0 The icon depicting the message will be within the sur- rounding shape.
0 Once nominated the icon will retain its meaning. Hazard
A
Information
0
Jn-136
Flammable
Explosion
Poison
Eye protection
A ,774s
m-l*
A
m I.
Ear protection
@
@
Respiratory protection
(a i r-f ed 1
Respiratory protection
(self contained)
Hand protection
Extinguisher
Fia.
1 Svmbols
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X300 VSM Issue 1 August 1994 2

Systems Repair Body & Body -
A4.1.3. POTENTIAL RISKS I
A4.1.3. Paint
Organic solvents, found in paints, may cause damage or severe irritation to liver, kidneys, digestive tracts and respira- tory system if inhaled over long periods of time.
Prolonged exposure to isocyanates may cause lung sensitization. Asthma
-like symptoms may develop with subse-
quent exposure to very low concentrations of isocyanates.
Solvent inhalation can cause dizziness or loss of consciousness.
Splashes of solvents, paint activators and additives can cause damage to the eyes and may cause dermatitis. Peroxide
and acid catalysts may cause burns.
Inhalation of
spray dust and sanding debris may cause lung damage.
I
A4.1.3.2 Applied Heat (Welding)
There is considerable risk of damage to eyes and skin when welding or flame cutting.
Fire is a serious danger and many materials or fluids within the vehicle are highly flammable.
Toxic and dangerous fumes may be liberated when any of the following are subjected to heat:
0 Expanded foam
0 Corrosion protection
0 Trim and seat materials
0 Paints which contain isocyanates
0 Adhesive and sealing compounds
When heated to a temperature of 3OO0C, polyurethane based compounds may liberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products; these chemicals can contain
isocyanates, oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases are produced by welding, for example; zinc oxide with zinc coated
panels, and ozone gas from the MIG process.
A4.1.3.3 Metal Repair
There is considerable risk of damage to eyes, ears and skin when metal cutting, forming, or dressing is being carried
out.
Soldering may be hazardous because of heat generated fumes and skin contact with the materials.
A4.1.4. PRECAUTIONS
A4.1.4.1 Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. En- sure that there is efficient ventilation / extraction at all times. Paint spraying should be confined as far as possible to
spray booths. Personnel with a history of asthma should not be engaged in any process which involves the use of
isocyanates. Any operator working inside
a spray booth where isocyanate material is present must use air-fed breath- ing equipment. Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water,
and fumes. Operators involved in handling mixing or spraying should wear protective clothing - gloves and goggles,
to avoid skin and eye contact.
A particle mask or canister type respirator should be worn when sanding.
A4.1.4.2 Applied Heat
When welding, flame cutting, brazing etc, the operator should 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.
Ensure that
at all times the appropriate fire fighting equipment is available and that personnel are trained in its use.
A4.1.4.3 Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding.
Operators should wear
a face mask or air-fed visor when sanding or flatting either body solder or fillers.
When
a soldering operation has been completed, swarf must be removed from the work area and the operator must
wash his hands thoroughly.
X300 VSM 3 Issue 1 August 1994