1998 JAGUAR X308 body

radiator cap coolant temperature climate control turn signal bonnet engine oil capacity

Page 2383 of 2490

JAGUAR X308 1998 2.G Workshop Manual 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 sp

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

Page 2386 of 2490

JAGUAR X308 1998 2.G Workshop Manual Body Structure
Introduction
The standard wheelbase Jaguar sedan has a unit construction monocoque body structure with bolt-on front fenders and
welded rear fenders. The doors feature lif t-off hing

Page 2387 of 2490

JAGUAR X308 1998 2.G Workshop Manual
Key to Plan
Standard Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre li ne of

Page 2388 of 2490

JAGUAR X308 1998 2.G Workshop Manual
Key to SideView
Long Wheelbase Body Dimensions-Plan
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmiss

Page 2389 of 2490

JAGUAR X308 1998 2.G Workshop Manual
Key to Plan
Long Wheelbase Body Dimensions- Side View
KeyLocation
1Front face body-bumper strut/mounting point
2Rearmost hole, vee-mount to crush tube
3Front Master Datum Plan, centre line of fron

Page 2390 of 2490

JAGUAR X308 1998 2.G Workshop Manual
Key to SideView
KeyLocation
1Front face body-bumper strut/mounting point
2Front Master Datum Vertical, centre line of front crossmember rear mounting
3Transmission mountings at the main floor longi

Page 2391 of 2490

JAGUAR X308 1998 2.G Workshop Manual 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 t

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

Page 2395 of 2490

JAGUAR X308 1998 2.G Workshop Manual CAVITY WAX INJECTION - APPROVED ADHESIVES, SEALERS AND BODY PROTECTION
SYSTEMS
• NOTE: Cavity wax processes should only be applied on completion of all other refinishing and protection procedures.

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