located behind the trunk lid badge.
Occupant Restraints
Inertia reel seat belts with electronically controlled pre-tensioners are installed at the front seats. Supplementary occupant
restraint is provided for driver and front seat passenger by front airbags, and side air bags installed in the outer wing of
each front seat. Standard inertia reel type belts are fitted to all three rear seat positions. The front seat belts are provide d
with height adjuster units which are attached one to each of the 'B' posts. Where emergency locking retractor/automatic
locking retractor seat belts are provided, the belts have two operating modes.The inertia reel mode with emergency locking
retractor is for adult passenge r use only and operates to allow the occupant some freedom of tors o movement under normal
travel conditions.. The static reel mode which prevents belt payout and must be used when a ch ild seat is installed, is
activated by fully extending the belt to engage the ratchet me chanism,.then releasing the belt. Operation of the ratchet will
then be felt and the belt w ill become locked in that position. To revert to in ertia reel (adult passenger) mode, pay the belt
back into the reel to th e fully retracted position.
Body Structure
The XJ8 sedan body is produced in monocoque standard and lo ng wheelbase form. 70% of the body panels are zinc coated
to achieve optimum corrosion protection and a further 8% are constructed in high st rength steels to provide high torsional
strength and passenger impact protection.
Doors
Each front and rear door consists of a we lded, mild steel inner frame and an outer panel. The outer panel is welded to the
waist rail and cheater of the inner frame, then bonded and clinched to fo rm the door assembly. Cosmetic PVC bead is
applied to all clinch joints
Hood
The hood consists of one piece inner an d outer panels clinched and bonded toge ther, with cosmetic bead PVC sealant
applied to all clinch joints. The hood pivo ts at the front on two hinges each secured by bolts to the hood front underside and
the BIW front upper crossmember. Two gas struts secured to the hood by pi vot pins and snap-on couplings, support the
hood in the open position.
Trunk
The trunk lid is of similar construction to the hood, consisting of inner and outer panels clinched and bonded together and
PVC bead sealed. The trunk accommodates the spare wheel, the battery, an electrical carrier containing electrical fuses,
relays and modules and where premium ICE is fitted, a compac t disc auto-changer mounted on body bracketry. Carpet
covered trims line the trunk sides and front inner panel and a po lyurethane rear finisher is secured to the rear panel by
spring clips and fir tree fasteners.
B and C Post Reinforcement
the BIW front upper crossmember. Two gas struts secured to the hood by pi vot pins and snap-on couplings, support the
hood in the open position. A full width insulating pad is secured by screws to the underside of the hood. A sponge rubber
tubular seal is mounted transversely to wards the front of the hood underside.
Trunk
The trunk lid is of similar construction to the hood, consisting of inner and outer panels clinched and bonded together and
PVC bead sealed. The trunk accommodates the spare wheel, the battery, an electrical carrier containing electrical fuses,
relays and modules and where premium ICE is fitted, a compac t disc auto-changer mounted on body bracketry. Carpet
covered trims line the trunk and are secured by push-fit fasten ers to the sides and front inner panel. The carpet covered,
two-section, removable trunk floor prov ides access to the spare wheel and wheel changing equipment, the battery and
electrical carrier. The floor board rests on the spare wheel, with the front and rear e dges locating in blocks on the fuel tank
backboard and the rear of the body. The support blocks provide for two floor height settings to accommodate either a space
saver or full size spare wheel.A trunk seal retainer covers the re ar of the trunk below the sill. Finisher panels fitted to the
rear lamp units provide for trunk inte rior access to the lamps. The trunk lid underside is fitted with a removable moulded
liner and two trunk illumination lights. Two gas struts fitted between the inner wheel arches and trunk hinges support the
trunk lid in the open position. For some markets, a warning triangle is attached to a bracket on the trunk lid underside. The
trunk is locked by a central latch and stri ker operated by an adjacent electrical actuator, via the central locking system, or
by key operation of a barrel lock located behind the trunk lid badge.
Fuel Filler Flap
Body Closures - Door
Removal and Installation
Removal
Installation
WARNING: FOLLOWING REPAIR OR RENEWAL OF A FRONT DOOR, IT MUST BE ENSURED THAT A SIDE AIRBAG
WARNING LABEL IS AFFIXED TO THE REAR FACE OF THE DOOR.
• NOTE: The hinges are set during manufacture to achieve correct door fitment. This setting should on ly require adjustment
in the event of damage at the body or door hinge locations. 1.
Remove battery cover, and di sconnect ground cable from
battery terminal. Refer to 86.15.19.
2. Apply protective masking tape to overlap front edge of door.
3. Fully open door, withdraw harness gaiter from 'A' post,
disconnect multiplugs and posi tion them clear of 'A' post
aperture.
4. Remove door.
1. Slacken and remove the two screws securing check
arm to 'A' post and fully retract check arm into
door.
2. Slacken, remove and di scard hinge locking screws.
3. With assistance, lift d oor to clear hinge pins and
remove door from vehicle exercising care to avoid
damaging paintwork.
1. Using a thread chaser or gr ooved slave bolt, remove any
residual thread locking compound from locking screw locations.
2.
Ensure that multiplugs are clea r of door front edge, and check
arm is fully retracted, then with assistance, lift door into
position and locate hinge pins.
3. Fit and fully tighten new hinge locking screws.
4. Position check arm bracket on 'A' post and fit and tighten
securing screws.
5. Fully open door and apply a thin co at of grease to both sides of
check arm.
6. Connect door harness multiplugs and fit and fully seat harness
gaiter in 'A' post.
7. Remove masking tape from front edge of door.
8. Check that door shuts correctly.
9. Wipe any excess grease from check arm.
10. Connect ground cable to batt ery terminal and fit battery
cover. Refer to 86.15.15.
Body Closures - Fuel Filler Door Removal and Installation
Removal
Installation
1.
Remove battery cover and disconnect ground cable from battery
terminal. Refer to Section 86.15.19.
2. Remove fuel filler flap and hinge assembly.
1. Open filler flap
2. Remove fuel filler cap but do not stow on lid.
3. Slacken and remove the two filler flap hinge securing nuts and remove flap assembly from vehicle.
3. Using a flat-bladed screwdriver, carefully ease magnet snap-fit
mounting from filler flap.
4. Depress the filler flap striker retaining tang and remove the striker
assembly.
5. Remove and discard rubber buffer from filler flap.
1. Fit new rubber buffer to filler flap.
2. Fit striker to filler flap.
3. Ensure that magnet location is clean and snap-fit magnet to filler
flap.
4. Locate filler flap studs in hinge plate and fit and tighten securing
nuts.
5. Connect ground cable to battery terminal and fit battery cover.
Refer to Section 86.15.15.
Body Closures - Hood Hinge
Removal and Installation
Removal
Installation
1.
CAUTION: Before slackening hi nge bolts, ensure that the
hood is sufficiently supported to prevent damage to paintwork
and gas support struts.
Remove cover from battery and disconnect ground cable from
battery terminal. Refer to 86.15.19.
2. Open hood and fit fender covers.
3. Remove radiator grille. Refer to 76.55.03.
4. Remove hinge to hood securing bolts.
Note position of ground strap.
Ensuring that the hood is adequately supported,
.slacken and remove bolts se curing hood to hinge and
ground strap to hood.
5. Slacken and remove bolts securi ng hinge to BIW front upper
crossmember and remove hinge from vehicle.
1. Fit and tighten bolts securing hinge to BIW front upper
crossmember.
2. Fit ground strap eyelet to the lower LH bolt (LH hinge only)
securing hinge to hood, then fit but do not tighten bolts.
3. Check and if necessary adjust alignment of hood. Refer to
76.16.02.
4. Fully tighten hinge to hood securing bolts.
5. Fit radiator grill. Refer to 76.55.03.
6. Close hood and remove fender covers.
7. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.
Interior Trim and Ornamentation - Interior Trim
Description and Operation
Carpets
The passenger compartment carpet is a one piece moulded constr uction with integral sound deadening material, heel mats
and driver's footrest. The carpet is attach ed to the vehicle floor by plastic clips fitted below the door treadplates. Removal of the carpet necessitates re moval of the front seats, lifting of the centre console rear extens ion and removal of the heelboard
carpet.
Fascia
The full width, slush moulded, soft feel PVC fascia is mounted on an injection moulded armature and is faced with wood
veneer. In addition to the air conditioning and central, outer and demisting vents, it accepts instrument packs dedicated to
market requirements and a centrally mounted analogue clock.
Doors
The one-piece door casings are trimmed in UEV to match the seating, with wood veneer at the waistline and a carpet insert
at the front lower corner. Each casing is secured to the door inner panel by fir tree press fast eners along the lower section,
two armrest fixings at the centre and vene er panel dowels and fixings at the top. The armrests which are common to front
and rear doors, are trimmed in matching leather or UEV according to specification. The door switchpacks, dedicated to
driver and front or rear passenger, are in corporated in the armrests. A speaker is in stalled in the lower section of each door
and a tweeter is incorporated behind each interior door handle escutcheon. Where premium ICE is fitted, the front tweeters
are installed in the upper A posts.
A, B, C and D Posts
On each side,a grained UEV finisher trimmed to match the headlining is secured to the 'A' post and cantrail by fir tree
fasteners locating in BIW apertures. The upper 'D' post finisher is trimmed and secured in the same manner. The single
piece'B/C' post finishers, also finished in grained matching UEV, each have a front se at belt exit aperture and are secured to
the BIW by four spring clips and two fir tree fasteners.
Headlining
The one-piece headlining consists of a 6mm thick polyurethane foam membrane covered with suede effect knitted polyester. The headlining is secured to the BIW roof by body tangs, the roof console, sun visors, combined grab handles and coat
hooks, the cantrail finishers and where fitt ed, the sliding roof finisher and clips.
Trunk
Carpet covered trims line the trunk and are secured by fir tr ee fasteners to the sides and front inner panel. The carpet
covered, two-section, removable trunk fl oor provides access to the spare wheel and wheel changing equipment, the battery
and electrical carrier. The floor board rests on the spare wheel, with the front and rear edges locating in blocks on the fuel
tank backboard and the rear of the body. The support blocks provide for two floor he ight settings to accommodate either a
space saver or full size spare wheel.A moulded finisher covering the rear of the trunk below the sill is secured to the rear
panel by tabs and fir tree fasteners. Finish er panels fitted to the rear lamp units provide trunk interior access to the lamps.
The trunk lid underside is fitted with a removabl e moulded liner and two trunk illumination lights.
Interior Trim and Ornamentation - Floor Covering
Removal and Installation
Removal
1. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
2. Remove rear seat cushion. Refer to 76.70.37.
3. Remove front seats. Refer to 76.70.01
4. Remove 'J' gate surroun d. Refer to 76.25.24.
5. Remove centre console finish er veneer panel. Refer to
76.47.26.
6. Remove fascia centre veneer panel. Refer to 76.47.06.
7. Remove centre console assembly. Refer to 76.25.01.
8. Remove 'A' post lower trim pads. Refer to 76.13.30.
9. Remove 'B' post trim pads. Refer to operations in this section.
10. Slacken and remove centre console heater ducting securing
screw and remove ducting from vehicle..
11. Rotate heelboard fasteners 1/4 turn and remove both
heelboards from vehicle.
12. Remove front sill treadplates. Refer to operations in this
section.
13. Remove rear sill treadplates. Refer to operations in this
section.
14. Release the carpet retainers fro m BIW flanges at each side.
15. Release the two carpet rear retainers from BIW brackets.