2. Secure the suppression module positive cable and
main positive cable to the generator positive
terminal.
3. Fit the boot to the terminal.
4. Reconnect the generator harness multi-plug.
4. Refit the air intake ducting to the generator. The upper section
is retained by two screws to the sump body assembly and the
lower (horizontal) section is retained by one screw.
5. Lower the vehicle on the ramp ; refer to Section 100-02.
6. Fully tighten the generator upper mounting bolt, to 18-24 Nm.
7. Refit the drive belt to the generator.
1. Pass the drive belt around the idler pulley.
2. Using spanner )Churchill JD-230 or Snap On XDHM 1415) on the centre bolt of the belt tensioner idler
pulley, rotate the adjuster against spring tension.
3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and
check that it is correctly located on the other pulleys.
Release the tensioner slowly and remove the
spanner. Check the alignment of the belt.
8. Refit the fan and motor assembly ; refer to Operation 26.25.12.
9. Refit the air cleaner assembly; refer to Operation 19.10.05.
10. Reconnect the battery ground cable and fit the battery cover.
Reset the radio inform ation and the clock.
1. Disconnect the harness multi-plug.
2. Remove the protective boot from the positive
terminal, remove the termin al nut and disconnect the
cable from the terminal.
11. Remove the lower mounting bolt and reposition the harness
mounting bracket.
12. From above the vehicle, reposi tion the supercharger water
pump for access.
1. Reposition the pump harness multiplug from the
retaining bracket.
2. Remove the two nuts which secure the U-bracket around the pump.
3. Remove the U-bracket from the pump.
4. Reposition the pump to al low access for removing the
generator.
13. Remove the upper securing bolt and withdraw the generator
from the mounting bracket.
14. Carefully, manoeuvre the ge nerator forward towards the
radiator.
2. Fit the lower mounting bolt and nut, tighten to 38-48
Nm.
3. Connect the harness.
1. Secure the main positive cable to the generator positive terminal.
2. Fit the boot to the terminal.
3. Reconnect the generator harness multi-plug.
4. Refit the air intake ducting to the generator. The upper section
is retained by two screws to the sump body assembly and the
lower (horizontal) section is retained by one screw.
5. Lower the vehicle on the ramp ; refer to Section 100-02.
6. Fully tighten the generator upper mounting bolt, to 18-24 Nm.
7. Reposition the superc harger water pump.
1. Reposition the pump to the mounting bracket.
2. Fit the U-bracket to the pump.
3. Fit the two nuts which secure the U-bracket around the pump.
4. Reposition the pump harness multiplug to the retaining bracket.
8. Refit the drive belt to the generator.
1. Pass the drive belt around the idler pulley.
2. Using spanner )Churchill JD-230 or Snap On XDHM
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
