1998 JAGUAR X308 Seat

Supplemental Restraint System - Side Impact Sensor
Removal and Installation
Removal
• WARNINGS:
FOLLOWING DISCONNECTION OF THE BA TTERY, A PERIOD OF AT LEAST FIFTEEN MINUTES MUST BE ALLOWED TO
ELAPSE BEFORE DISCONNECTING THE SINGLE-POINT SENSING (SPS) UNIT.
IN THE EVENT OF A FAULT RUPTURING THE 10A BATTER Y SUPPLY FUSE (F4 LOCATED IN THE FUSE-BOX AT THE
DRIVER'S END OF THE FASCIA), THE FUSE MUST NOT BE RENEWED UNTIL THE AIRBAG/SRS SYSTEM HAS BEEN DE-
ACTIVATED. FUSES OF ANY OTHER VALUE MUST NEVER BE USED, AS THIS CAN CAUSE DISARM FAILURE.
Installation


1. Remove battery cover and disconnect ground cable from battery
terminal. Refer to 86.15.19.
2. Remove'B' post trim pa d. Refer to 76.13.08.
3. Remove seat belt upper anchor and seat belt guide. Refer to
76.73.10

4. Slacken and remove two nuts securing sensor unit to lower
section of 'B' post.

5. Lower sensor for access, disco nnect multiplug and remove
sensor.
1. Position sensor at base of 'B' post and connect harness
multiplug.
2. Lift sensor into position and fit and tighten securing bolts.
3. Fit seat belt guide and and seat belt upper anchor. Refer to
76.73.10.
4. Fit 'B' post trim pad. Refer to 76.13.08.
5. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.

Health and Safety
It is the duty of both employer and employee to ensure safe working conditions and practices. Correct safety procedures
and equipment must be applied to any potential hazards that are notified, or identified by an operator.
Employees must observe local legislation go verning working conditions and practices at all times and must always act in a
responsible manner in the workplace. In the event of personal injury resulting from any workshop activity, medical help
should be obtained as soon as poss ible. Self-treatment other than by first aid, should not be attempted.
WARNING: READ AND UNDERSTAND WORKING PRACTICE S CONCERNING CLIMATE CONTROL SYSTEMS, SECTION
412, WITH SPECIAL REGARD TO: REFRIGERANT MUST NEVE R BE DIRECTLY VENTED TO ATMOSPHERE. ALWAYS USE
JAGUAR APPROVED RECOVERY / RECYCLE / RECHARGE EQUI PMENT, WEAR SUITABLE EYE AND SKIN PROTECTION AND
OBSERVE ALL APPLICABLE SAFETY REQUIREMENTS.
With the constant introduction of new materials in the manufacture of vehicles, an awareness of the potential risks and
appropriate precauti ons is important.
Notification of Hazards
Symbols, which convey important information, will be positioned at the beginning of any specific operation or text. Standard symbols will be used where repairs or service procedures ar e detailed. All symbols will conform to standard ANSI Z535.3
(American National Standards Institute). The surround shape of the symbol will indicate the basis of the message to be
conveyed (see top three elements of ?) The icon depicting the message will be within the surrounding shape. Once
nominated the icon will retain its meaning.
POTENTIAL RISKS
Paint
Organic solvents, found in paints, may caus e damage or severe irritation to liver, kidneys, digestive tracts and respiratory
system if inhaled over long pe riods of time. Prolonged exposure to isocyanate s can cause lung sensitization with asthma-like symptoms developing on subsequent exposure to even low concentrations of isocyanates. Solvent inhalation can cause
dizziness or loss of consciousness and inhalation of spray dust and sanding debris may cause lung damage.
Spillage or splashes of solvents, paint ac tivators and additives can cause dermatitis or eye injury. Contact with peroxide or
acid catalysts can cause serious burns.
Applied Heat (Welding)
There is considerable risk of damage to eyes and skin if welding or flame cutting is attempted without using the correct
protective equipment. Many materials or fluids within vehicles are highly flammable and toxic and dangerous fumes may
also be liberated if heat is applied to expanded foam, corr osion protection, trim and seat materials, paints containing
isocyanates, and adhesive and sealing compounds.
When heated to a temperature of 300°C, polyurethane based compounds may liberate small quantities of isocyanate. Many
types of nitrogen containing chemicals ma y be liberated as breakdown products which can contain isocyanates, oxides of
nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases produced when welding include zinc oxide from zinc coated panels, and
ozone gas from the MIG process.
Metal Repair
There is considerable risk of damage to eyes, ears and skin wh en cutting, forming, or dressing metal. Soldering operations
can also be hazardous due to heat generated fumes and the risk of skin contact with hot materials.
PRECAUTIONS

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

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 hinges and welded drop-glass frames.
Constructional Steel Classification
BODY ALIGNMENT
The Body Dimensions Plan, and Body Dimensions Side View, provide specified BIW dimensions to facilitate damage
assessment and location of replacemen t parts. These dimensions must be strictly applied when used for damage
assessment, component location or post repair verification.
• NOTE: The right-hand side is always looking towards the front, from the rear of the vehicle.
The nominated plan view master datums are on the right-hand side of the body with the left-hand datums dimensioned
from them. Right-hand datums must therefore be known to be correct before any other cross-car dimensions are checked.
Datum location, Example
The Front Master Datum (front crossmember rear mounting at the inner face of the main floor RH longitudinal) is nominally
359,5mm to the right-hand side of the body center line. The LH side fron t datum is measured 717,0 / 721,0mm from the
RH. Refer to the Body Dimensions Plan.
Expressed as a true posi tion in three planes, the front master datum is:
Standard Wheelbase Bo dy Dimensions-Plan
MaterialApplication
High strength low alloy
(HLSA).Impact prone areas, ie. seat frame and bumper mountings.
Double sided zinc plated mild steel.Exterior body panels subject to severe cond itions such as stone chipping and weather
exposure (excluding roof panel).
Boron steelDoor intrusion beams
Mild steel.Internal brackets, fill ets and strengtheners.
DatumLocationPosition
Front Master Datum
PlanCentre line of the front crossmember rear mounting, at the main floor RH
longitudinalX
300,0
Y 359,5 Z -50,0

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

Installation

Repeat procedure to remove wishbone securing nuts from
opposite side.

47. Remove upper wishbone fu lcrum shaft securing nut.
Repeat procedure to remove securing nut from opposite
side fulcrum shaft .
48. Remove wire temporarily supporting hub assembly.

49. Remove wishbone/hub assembly from crossbeam.
Supporting hub assembly, wi thdraw lower wishbone
eccentric bolts.
Supporting hub assembly, wi thdraw fulcrum shaft from
upper wishbone.
Remove wishbone/hub assembly from crossbeam.
Repeat procedure to remove wishbone/hub assembly on
opposite side.

50. Remove crossbeam front mountings.
Remove front mounting heatshield.
Remove four bolts securing mounting to crossbeam.
Repeat procedure to remove mounting on opposite side.
1. Install front mounting brackets.
Position and fully seat mounting bracket on crossbeam.

Position stabilizer bar on crossbeam.
Install and tighten bolts to 30-40Nm.
Repeat procedure at opposite end of stabilizer bar.

6. Tighten link arm to stabilizer bar securing nut to 60-80Nm.
Repeat procedure at opposite end of stabilizer bar.

7. Install steering rack on crossbeam.
Ensure that bushes are correct ly positioned on steering
rack.
Position steering rack on crossbeam.
Position support brac kets over bushes.
Install mounting bracket bolt s and tighten to 40-54Nm.

8. Install tie rods on steering arms.
Position and fully seat tie rod ball joint taper pin on
steering arm.
Install tie rod ball joint nu t and tighten to 71-85Nm.
Repeat procedure to install opposite side tie rod ball joint.
9. Install harness on suspension turret.
Noting positions marked during removal, tape new
securing clips to st eering harness.
Install securing clips/harness on LH turret.

10. With assistance position crossbeam/suspension assembly on
jack with protective wood under.
11. Traverse assembly into position below vehicle.
12. Ensure steering harn ess connector is positioned to avoid
damage during crossbeam lift .

13. NOTE: It may be necessary to use a hammer and drift to
finally align new mounting with body location.
Carefully raise crossbeam assembly into position.
Ensure that dowels of both crossbeam mountings are
correctly seated in body locations.

14. Ensure that both engine hydram ounts are correctly seated in
crossbeam locations.

15. Install crossbeam rear mountings.
Align rear mounting rubber with body location.
Install rear mounting securing bolt and nut and tighten
nut to 131-185 Nm.
Repeat procedure to install opposite side rear mounting
bolt and nut.
16. From engine compartment, install but do not tighten
crossbeam front RH bolts.