electrical JAGUAR XJ6 1994 2.G Manual PDF

used.
WARNING: FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G.
TRICHLOROETHANE, WHITE SPIRIT, SBPB, METHYLENE CHLORIDE, PERCHLORETHYLENE.
DO NOT SMOKE IN THE VICINITY OF VOLATILE DEGREASING AGENTS.
Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from
naked flames and other sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as
causing damage to protective coatings, there is
a risk of damage from stray heat to electronic equipment and brake
lines. Do not leave tools, equipment, spilt oil etc. around or on work
area. Wear protective overalls and use barrier
cream when necessary.
0 A3.1.1 Used Engine Oils
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dry- ness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause
skin cancer. Washing facilities and adequate means of skin protection should be provided.
A3.1.2 Health Protection Precautions
0 Avoid prolonged and repeated contact with oil; particularly used engine oils.
o Wear protective clothing, including impervious gloves where practicable
0 Do not put oily rags in pockets.
0 Avoid contaminating clothes, particularly underwear, with oil.
0 Overalls must be cleaned regularly. Discard unwashable clothing and footwear which is oil impregnated.
o First Aid treatment should be obtained immediately for open cuts or wounds.
0 Use barrier creams, applying before each work period, to enable easier removal of dirty oil / grease from the
skin.
0 Wash with soap and water to ensure that all oil is removed (skin cleaner and a nail brush will help). The use of
preparations containing lanolin will help to replace the natural skin oils which have been removed.
o Do not use petrol, kerosene, gas oil, thinners or solvents for washing skin.
0 If skin disorders develop, obtain medical advice immediately.
0 Where practicable, degrease components prior to handling.
0 Where there is a risk of fluids coming into contact with the eyes, eye protection should be worn, for example,
goggles or a face shield. An eye wash facility should be provided.
A3.1.3 Environmental Protection Precautions
A3.1 SAFETY PRECAUTIONS
Whenever possible, use a ramp or pit whilst working beneath a car, in preference to jacking. Position chocks at the
wheels as well as applying the handbrake. Never rely on a jack alone to support a car. Use axle stands, or blocks care- fully placed at the jacking points, to provide a rigid location. Checkthat any lifting equipment used has adequate capac- ity and is fully serviceable. Ensure that a suitable form of fire extinguisher is conveniently located.
When using
electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed. Disconnect
the earth (grounded) terminal of the car battery. Do not disconnect any pipes of the air conditioning refrigeration sys-
tem 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. Ensure that adequate ventilation is provided when volatile degreasing agents are being
It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses. The burning of used engine
oil in small space heaters or boilers is not recommended unless emission control equipment is fitted. Dispose of used
oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation trade.
If in doubt, contact the Local Authority for advice on disposal facilities.
X300 VSM 1 Issue 1 August 1994

Body Systems & Body Repair
A4.1.5 GENERAL REPAIR NOTES
The following advice should be noted before ANY repair work is carried out.
0 Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take
note of the reconnection procedures as detailed in Section 15.
0 Where structural parts are straightened or renewed, a body alignment / straightening jig must be used.
0 Where appropriate, structural sections should be straightened by cold processes. Heat, especially excessive
heat, will reduce the strength of steels.
0 Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts
and Jaguar approved materials are used.
0 Tools, procedures and facilities must be right for the job. Do not compromise the quality of the work by using
inappropriate methods.
0 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 sections may contain harnesses, tubes or
foam, see section
A4.3.5.
0 The welding and gas processes detailed in the following sections are the only ones recommended by Jaguar
Cars Ltd.
0 Ensure that you have read and understood the safety related procedures in this and other relevant sections.
WARNING: DO NOT WORK
IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. READ WORKING PRAC- TICES AIR BAG, SECTION 15. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED. PLEASE SEE SECTION
AGE LOCATIONS. 13 FOR IMPORTANT INFORMATION REGARDING 'TEAR LOOP' SEAT BELTS / BUCKLES AND ANCHOR-
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high vottages produced by this process will cause irreparable damage to the electrical control and microprocessor systems.
A4.1.5.1 Welding and Gas Processes Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated,
metal.
The flanges of panels which are to be welded together must be clean, corrosion free and treated as appropriate,
with either weld-through primer or inter-weld sealer; use only materials and processes in accordance with the 'Body Seal-
ing and Preservation Manual' and relevant application areas in section A4.3.1.1.
See 'Zinc Coated Panels' section A4.2.
Generally, the resistance spot welding equipment used in the motor vehicle repair industry does not produce a weld
of equivalent strength to that of the manufacturer. Therefore, the expression 'single row of resistance spot welds'
means that the spots should be spaced on a pitch of
19mm to 25mm. This will usually result in more spot welds than
found in the original factory joint.
To remove resistance spot welds, a resistance spot weld cutter should be used.
If the new joint is to be MIG plug welded, the old resistance spot welds should be cut from the panel which is to be
retained and those holes used for plug welding.
Suitable holes may also be drilled or punched;
8,O mm dia for sections up to 1,6 mm, and 10,O mm dia for thicker sec- tions.
0
0
0
X300 VSM Issue 1 August 1994 4

Body Systems & Body Repair
A4.2.4 PANELS - ASSOCIATED, RENEW
SRO 77.10.02
w: Where other components must be removed to gain access, please referto the relevant manual section for guid- ance. This is critically important with regard to steering, braking, suspension, electrical and safety systems.
. Expose the resistance spot welds, for those spot welds which are not obviously visible, use a rotary wire brush fitted to an air drill or a hand held wire brush (A Fig. 1).
WARM: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
. Cut out the spot welds using a Zipcutter or Roto-Bor (B Fig. 1).
Jhh: On some panels, before removing the bulk of panel with the pneumatic saw, brazed areas and MIG welded
seams should be removed.
= Separate the spot welded joints and remove the panel remnants.
At
this point
it may be necessary to cut out the bulk of the panel using a pneumatic saw (C Fig. 1).
A
C
Fia. 1
B
II I
II I
15 Issue 1 August 1994 X300 VSM