1994 JAGUAR XJ6 transmission

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
Location
Centre line of the front crossmember rear mounting, at the
main floor
RH longitudinal
A4.2.2.1 Datum location, Example
The FRONT MASTER DATUM (front crossmember rear mounting at the inner face ofthe main floor RH longitudi- nal) is nominally 359,5mm to the right-hand side of the body center line. The LH side front datum is measured 717,0/ 721,Omm from the RH. Please refer to the illustration on the following page.
Expressed as
a true position in three planes, the front master datum is:
Position
X 300,O
Y 359.5 Z -50.0
0
Datum
Front Master Datum
Plan
A4.2.2.2 Key, Plan View
Please refer to the illustration on the opposite page.
Key Location
1
2
3
4
5 Driveshaft centre bearing fixings
6
7
8
9
10 Front
face body
- bumper strut / mounting point
Rearmost hole, Vee
-mount to crush tube
Front Master Datum Plan, centre line
of the front crossmember rear mounting at the main floor RH longi-
tudinal
Rearmost hole, transmission mounting
at the main floor RH longitudinal
Rear Master Datum Plan, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear suspension differential strut mounting
Rear face body
- bumper strut / mounting point
X300 VSM Issue 1 August 1994 10

E 12
Rear face bodv - bumDer strut / mountina Doint
Body Systems
I
& Body
side vww
the illustration on the opposite page.
Repair
Location
Front face body - bumper strut / mounting point
Front Master Datum Vertical. centre line of the front crossmember rear mountina
Front
face body - bumper strut / mounting point
Front Master Datum Vertical, centre line of the front crossmember rear mounting
Transmission mountings
at the main floor longitudinal
Driveshaft centre bearing fixings
Rear Master Datum
Vertical, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear suspension differential strut mounting
Rear face body
- bumper strut / mounting point
Transmission
mountings
at the main floor longitudinal
Driveshaft centre bearing fixings
Rear Master Datum
Vertical, rear longitudinal
Tapped boss, rear suspension
'A' frame mounting bush
Rear suspension spring
-pan damper mounting
Rear
susoension differential strut mounting
Wheel centre to
bummr cover face I
Wheel base I
Wheel centre to bumper cover face
Body Systems & Body Repair
A4.2.2.3 Key, Side Vww
Please refer to the illustration on the opposite page.
0
0
0
X300 VSM Issue 1 August 1994 12

in the same location as the previous label, see location illustrations.
A protective mask is used to prevent the replacement part label from being damaged or obscured
during the refinishing / protection processes. This protective mask MUST be removed prior to customer hand-over.
m: All service panels are supplied in electrocoat primer and where appropriate MUST have an anti-theft label in the correct location.
A4.4.3.3 Procurement
Anti-theft labels may only be ordered from Jaguar Cars through:
Product Compliance Dept.,
Jaguar Inc.,
555 MacArthur Blvd.,
Mahwah
NJ
07430
A4.4.3 ANTI-THEFT LABELS, (NORTH AMERICAN MARKET ONLY)
A4.4.3.1 Original Components
North American specification vehicles have the VIN marked on all major external panels, certain structural members
and power/transmission units. The labelswhichcarry this information are known as 'Label -anti-theftVIN (USA body
panel only)' or 'Label - anti-theft - engine and gearbox (U.S.A. only)' (A Fig. I), see location illustrations.
A4.4.3.2 Replacement Components
When a vehicle suffers damage, only genuine Jaguar replacement panels / units should be used in the repair; further, if any parts originally carried a VIN label then a different type of label MUST be affixed 'Label - anti-theft replacement
part (USA body panel only)' or 'Label - anti-theft replacement part - engine and gearbox (U.S.A. only)' (B Fig. 11, NOT
A B
i f *
JAGUAR CARS VEH. IDENT. NO.
+ &
R DOT
JAGUAR
J76-IOL I
Fig. 1
issue 1 August 1994 27 X300 VSM