1998 JAGUAR X308 partic

the bag securely before opening another bag. Also, replace the bag in its mating part number compartment within the case.
The pre-terminated wiring harness(s) are su pplied with the insulation in one of three colors, red, blue or yellow. The colors
do not apply to any particular circuit but to the harness wire size. See the Relationship Table in the Repair Method section.
Butt splice connectors are also supplied wi th red, blue or yellow coverings, which must be matched to the pre-terminated
wiring harness insulation color.
Pre-Terminated Wiring Harness(s)

The part number of the pre-terminated wiring harness The letter showing the extractor tip which must be used to remove this type of electrical connector terminal Those electrical connector terminals which are gold
Some of the pre-terminated wiring harness( s) have seals installed to the insulation for sealed connector applications. It is
essential for prevention of mo isture ingress that a sealed pre-terminated wiring harness must be used where a sealed
terminal was removed.
CAUTION: Where the repair procedure indica tes that a glue lined heat shrink sleeve should be applied, apply sufficient
heat to the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined
heat shrink sleeve so that the wiring harness insulation becomes damaged.
Two sizes of heat shrink sleeving are supplied in the wiring harn ess repair kit. Each heat shrink sleeve contains a sealant
glue. These must be used when connecting wiring harness(s) or electrical connector terminal(s) at all times. The smaller
diameter heat shrink sleeve is to be used with the red and blue butt splice connectors and the larger di ameter sleeve with
the yellow butt sp lice connectors.
For ease and speed, some of the pre-term inated wiring harness(s) may already have the insulation partly stripped at the
splice end. If the repair requires insula tion to be stripped from the cable, refer to the Relationship Table fo r the correct
length of insulation to be stripped.
The Pre-Terminated Wiring Harness(s) illu stration shows the electrical connector terminal type, the part number of the pre-
terminated wiring harness and the letter of the extractor tip which must be used to extract the electrical connector terminal
from the connector housing. Additionally, those electrical conne ctor terminal(s) which are gold are identified, all others are
therefore, tinned and not gold.
Wiring Harness Cable Identification Sleeves
A selection of colored sleeves are contai ned in the wiring harness repair kit for maintaining the wiring harness cable
identification on the pre-term inated wiring harness. Place the correct colo red sleeve(s) over the pre-terminated wiring
harness insulation as near to the electr ical connector as possible with the main wiring harness cable color nearest to the
electrical connector.
For example, if the original wiring harness cable color is pink with a black trace put the pink wiring harness cable
identification sleeve on the pre-terminated wiring harness first followed by a black sleeve, and slide both along the wiring
harness cable to the electr ical connector terminal.
Extraction Handle and Tips
The extraction handle, in conjunction with th e correct tip, is used to remove a terminal from an elec trical connector. Each tip contained in the wiring harness repair kit is marked with an identification letter, A to K inclusive. Each tip has been special ly
designed to extract a particular ty pe of electrical connector terminal. The use of any other tool is not recommended and is
liable to cause damage to the electrical connector. The tip is fastened to the handle by a screw which holds the tip firmly yet
allows it to be easily replaced.
Extraction Handle and Tips

Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
Description and Operation
Fixed Glass
The 5 mm thick laminated and tinted glas s windshield is supplied with a moulded rubber seal and stainless trim.The inner
face of the glass adjacent to the seal is directly bonded to the windshield aperture flange, to form a stressed member of the
bodyshell. The 4 mm thick toughened and tinted glass backlight which is similarly bonded to the BIW, incorporates a
heating element and a mounting for the high level stop lamp. The 5 mm tempered and tinted glass quarter light which is
supplied as a complete assembly with stainless trim and seals, is directly bonded to the BIW aperture flanges.
Windshield and Backlight Adhesive Application

Key to Adhesive Application Drawing
Door Glass.
The 5 mm tempered and tinted door glass forms part of a fully framed electrically operated system. A switchpack installed
in each door casing provides control of lowering and raising of that particular d oor glass with additional 'one-shot' fast
lowering . The driver's door switchpack also provides for independent control of each passenger door glass and total
isolation of all passenger door glass control. Each door glas s is raised and lowered by an electrically operated scissor
mechanism. All door glass can only be operated wh en the ignition switch is in position I or II.
Door Glass operating Mechanism
1Fitted condition
2Bead application

Paint
The inhalation of sprays, fumes, or dust during paint application or sanding processes should always be avoided. Ensure
that there is efficient ventilation / extrac tion at all times. Paint spraying should be confined as far as possible to spray
booths. Personnel with a history of asth ma should not be employed in any process involving the use of isocyanates.
Operators working in a spray booth where isocyanate material is present must use air-fed breathing equipment with air
supplied to the visor at the re commended pressure and filtered to remove oil, water, and fumes. Operators involved in
handling mixing or spraying should wear protective clothing including gloves and goggles, to avoid skin and eye contact.
Particle masks or canister type respir atosr should be worn when sanding.
Applied Heat
When welding, flame cutting, brazing etc, the operator shou ld 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. Appropriat e fire fighting equipment and personnel trai ned in its use must always be available.
Metal Repair
Appropriate eye and hand protection should be worn when sanding, drilling, cutting, chiselling, flatting or welding. Face
masks or air-fed visors should also be wo rn when sanding or flatting either body solder or fillers. On completion of a
soldering operation, swarf must be re moved from the work area and the operat or must wash his hands thoroughly.
GENERAL REPAIR NOTES
The following advice should be noted before any repair work is carried out.
Disconnect the vehicle battery gr ound lead (disconnect the alternator where electric welding is used) and take note of the
reconnection procedures as detailed in 86.15.15.
Where structural parts are straightened or renewed, a body alignment / straightening jig must be used. The application of
heat, especially excessive heat, reduces the strength of steels, where appropriate therefore, structural sections should be
straightened by cold processes.
Repairs may only be carried out successful ly, and any warranties protected, if genuine Jaguar replacement parts and Jaguar
approved materials are used.
The correct tools, procedures and facilities must always be us ed. The quality of the work must not be compromised by using
inappropriate methods or equipment.
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 sectio ns may contain harnesses, tubes or foam, see section A4.3.5.
WARNING: DO NOT WORK IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. READ WORKING
PRACTICES AIR BAG, SECTION 20. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED.
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high voltages produced by this process will
cause irreparable damage to the electric al control and microprocessor systems.
The following welding and gas processes are the only ones recommended by Jaguar Cars Ltd.
Welding and Gas Processes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated metal.
The flanges of panels to be welded toge ther, must be clean, corrosion free and tr eated as appropriate, with either weld-
through primer or inter-weld sealer. Only materials and processes specified in the 'Body Sealing and Preservation Manual'
should be used in the relevant application areas detailed in this section. Refer to 'Zinc Coated Panels' Section

Generally, resistance spot welding equipment used in the motor vehicle repair industry does not produce welds of equivalent strength to those achieved during manufactu re. The expression 'single row of resistance spot welds' indicates that the spots
should be spaced on a pitch of 19mm to 25mm, which normally results in mo re spot welds than those produced in the
original factory joint.
Resistance spot welds should be removed using a resistance spot weld cutter. If the new joint is to be MIG plug welded, old
resistance spot welds should be cut from the panel to be reta ined and the resulting holes used for plug welding. Suitable
holes may also be drilled or punched; 8,0 mm dia for sect ions up to 1,6 mm, and 10,0 mm dia for thicker sections.
PLASTICS-EXPLANATORY NOTES
Plastic component and trim materials
This table, in conjunction with the illu strations on the following pages will enable rapid identification of the particular
material of any major plastic part.
• NOTE: Only those components suitable for economic reclamation are identified.
Plastics - Handling Notes
The exterior panel temperature of a vehicle must not exceed 95°C at any time and may only be held at this level for a
maximum of two hours. Similarly, interior vehicle temperatur e must be limited to 86°C for a maximum duration of two
hours. Exposure to temperatures above those specified may result in distorted or permanently damaged components. If
there is doubt concerning temperature limitations, components that may be adversel y affected by exposure to heat should
be removed from the vehicle.
Plastic components that become greasy may be clea ned with an 'SBP 3' spirit wipe, or equivalent.
Recycled Materials
Any of the materials listed in this section, may be recycled provided that they ar e not contaminated by other incompatible
plastics or metals. For instan ce, the air conditioning unit case, manufactur ed from PP (polypropylene), must be separated
from the heater matrix, evaporator, contro l devices (electronic and mechanical) and all fixings before it can be considered
for recycling. After removal, the case mu st only be placed for disposal with materials of the same generic type. Bumper
cover assemblies similarly have side arma tures of dissimilar materials rivetted to them, these together with their fixings
must be removed prior to recy cling. Components manufactured from 'blended' materials must not be recycled with pure
materials. For example do not mix PC/ABS (wheel trim) with ABS ('B' pillar upper trim).
Plastics, Component Location and Type - External
TermMaterial Name
absAcrylonitrile Butadiene Styrene
abs / paAcrylonitrile Butadiene Styrene and Polyamide (nylon) blend
abs / pcAcrylonitrile Butadiene Styrene and Polycarbonate blend
ABS / PBTAcrylonitrile Styrene Acrylate and Polybutylene Terephthalate
paPolyamide (nylon)
pcPolycarbonate
pePolyethylene
pmmaPolymethyl Methacrylate
pomPolyoxymethylene (acetal)
ppPolypropylene
ppoModified Polyphenylene Oxide
purPolyurethane
pvcPolyvinylchloride
SMAStyrene Maleic Anhydride

ZINC COATED PANELS
Description
Approximately 70% of the 'body in white' (BIW) mass is made up of zinc coated panels.
• NOTE: To maintain the protective qualities of the zinc trea tment, repairs to any damaged coated area must be made as
soon as possible after the damage has occurred.
All exterior skin panels, with the exceptio n of the roof, are double side zinc plated and this coating (nominally 7,5 microns)
provides two way corrosion protection. Should the outer layer of paint become chipped with the zinc coating remain intact,
the zinc will oxidize on contact with air and being impermeable, this coat of oxidation will prevent corrosion damage of the
base metal. If the outer layer of paint and the zinc coating become damaged, the zinc rather than the base metal will react
with the air and 'sacrifice' itself to corrosion as a 'sacrificial anode'.
Welding Preparation
Contamination of the weld with resultant reduction in joint st rength increase and increased electrode tip dressing frequency
will occur zinc coating is not removed. In exceptional cases where the zinc coating must remain intact, the tip pressure and
welding current should be increased by 10 to 20%.
Where 'resistance spot welding' is employed, the zinc coatin g should be lightly abraded away on the mating surfaces and
those in contact with the electrode tips. Do not remove more zinc coating than is absolutely necessary.
Before welding, a weld-through primer or inter-weld sealer should be applied, as detailed in the Body Sealing and
Preservation manual.
Where MIG welding is used as an alternativ e to resistance spot welding for plug and butt welds or due to limited access, the
problems caused by the presence of zinc coating are much the same, with the added complication of increased weld spatter
and nozzle contamination.
Body Fillers
Conventional polyester fillers do not adhere satisfactorily to zinc plated panels, it is ther efore important that only those
products specifically designed for this application are used and the manufacturer's recommendations are followed.
Refinishing
Use only those products approved by Jaguar Cars Ltd and exercise special care on zinc coated panels.
As replacement panels ar e supplied ready primed, the only bare metal that needs to be exposed are those areas prepared
for welding etc, as decribed in 'Welding Preparation. Where any part of a panel is dressed back to the bare surface, it should
be treated with a zinc rich primer compatible with the paint application system.
GENERAL PREPARATION OF PANELS
Removal of Panels and Welds
• NOTE: Where other components must be removed for access, refer to the relevant manual section for guidance. This is
particularly important where steerin g, braking, suspension, electrical and safety systems are affected.
Expose all resistance spot welds, using a ro tary wire brush fitted to an air drill or a hand held wire brush on those that are
not clearly visible (1).
WARNING: DO NOT BURN UNDERSEAL OFF. USE A 'HOT KNIFE' OR SUITABLE SOLVENT.
Cut out spot welds using a Zipcutter or Roto-Bor (2). At this point it may be necessary to cut out the bulk of the panel using

For coachline specifications, see page? .
Tape Application
Apply a suitable length of 3M "Fine Line Striping Tape" to the panel. Having suitably applied the tape, which is slit into 8
strips, each 3mm wide, the appr opriate strip may then be peeled away to expose the lacquer coat below (Refer to
Application of Striping Tape Drawing). The paint may then be applied by hand brush or a suitable air-brush. The remaining
tape provides masking during paint applicat ion and drying. Careful positioning of the masking tape is necessary, particularly
when the repair is confined to a single panel and the newly painted coachline mu st conform to coachlines on adjacent
panels.
Where it is necessary to match an existing 1.5mm coachline, two tec hniques are available:
Proceed as above, to expose a 3mm strip of lacquer coat. Using either a standard masking tape, or a 3M "Fine Line Masking
Tape" applied over the striping tape, reduce the width of the exposed strip to 1.5mm.
Use a suitable combination of standard mask ing tape, together with 3M "Fine Line Striping Tape" if desired, to achieve an
unmasked strip 1.5mm wide in the correct position on the panel.
After application of the tape, use a fine-g rit wet-and-dry paper to lightly 'flat' the exposed surface, before application of
paint.
Application of Striping Tape

Coachline Locations
The coachline locations on the side of XJ Sport and supercharged models are illustrated below, for all other models refer to
the drawing under 'Other Models'.
XJ Sport and XJR8

Panels centered between two adjacent panels must have equal gaps on either side. For exceptions to this, refer to the
appropriate specification. Gaps between ad jacent panels or components must not expose harnesses, labels, brackets or
visually poor joint or assembly conditions.
• NOTE: Sliding roof panel clearances are specified without the edge seal installed.
Areas of particular concern are, fuel filler flap, trunk lid to fenders and saddle panels, hood to fenders, grill and headlamps,
sliding roof to main roof panel, door gaps at fenders, B\C posts, roof drip rail an d rocker panel, and bumper cover to fenders
and cross car assemblies
Alignment
Panels must be correctly profiled to maintain cosmetic appearance, and ensure co rrect seating of seals with minimal wind
noise. Areas of particular concern are hood to fenders, trunk lid to fenders and saddle panels, doors to apertures, doors to
fenders and adjacent doors and relationship of the sliding roof panel leading and trailing edges to the main roof panel.
Exterior Fitments
Bezels, trims and lamps must be concentric with apertu res and have equal clearances with adjacent panels.
Areas of particular concern are headlamp to hood, fender and trim panel, exhaust tailpipe trim to bumper cover cut-out,
rear lamp assembly to trunk lid, fender and bumper cover trim, and side feature lines including body side mouldings, fender
to door and door to door.
Exterior Clearances and Alignments-Front