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Glass, Frames and Mechanisms: Overview Jaguar XKR I

Windows 39 illustrations ~2306 words

Scheme 1

Scheme 1: Door Window Glass Adjustment
Scheme 1: Door Window Glass Adjustment

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Turn ignition key to position II and motor door glass to fully lowered position.
  2. Turn ignition key to position O.
  3. Remove door switchpack and door casing and disconnect switchpack harness multiplug. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).
  4. Remove door water shedders. Refer to «EXTERIOR DRIVER DOOR HANDLE»(ref-198055-S03616877712005101500000).
  5. Reconnect door glass lift switch lead to glass regulator connector.
  6. Remove door outer waist moulding. Refer to «DOOR WINDOW MOULDING»(ref-198050-S35785254672005101500000).
  7. Using a felt tip pen mark datum lines on glass. Draw a horizontal line across glass 6mm from the top edge on coupe or 9mm down on convertible. Draw a parallel line 6mm from glass leading edge. (Scheme 1): Marking Datum Lines On Glass WARNING: THE FOLLOWING STEPS NECESSITATE WORKING IN THE DOOR INTERIOR WITH THE POWER SUPPLIES CONNECTED. TO AVOID INADVERTENT GLASS OPERATION AND POSSIBLE INJURY, NO OTHER WORK MUST BE CARRIED OUT SIMULTANEOUSLY.
  8. Turn ignition key to position II and motor door glass up until top edge is just below upper seal. (Scheme 2): Positioning Door Glass Below Upper Seal
  9. Adjust gap between glass and outer waist rail flange. Slacken rear guide upper securing screw Move guide to achieve a gap of 9mm and tighten securing screw. (Scheme 3): Adjusting Gap Between Glass And Outer Waist Rail Flange
  10. Using guide runner lower adjusters, laterally align glass top edge with the upper seal. (Scheme 4): Aligning Glass Top Edge With Upper Seal
  11. Remove tape from access hole in PVC secondary water shedder and slacken glass regulator stop adjuster bolt. (Scheme 5): Identifying Glass Regulator Stop Adjuster Bolt
  12. Motor door glass further up until the horizontal datum line aligns with the upper seal. (Scheme 6): Aligning Motor Door Glass Horizontal Datum Line With Upper Seal
  13. Move glass regulator stop to abut quadrant and tighten adjuster bolt. (Scheme 7): Adjusting Glass Regulator Stop
  14. Motor door glass to fully up position, measure any lift adjustment required and re-mark glass in that position.
  15. Motor door glass to partially lowered position.
  16. Slacken glass regulator stop adjuster bolt, move stop required amount and tighten bolt. (Scheme 8): Tightening Glass Regulator Stop Adjuster Bolt
  17. Motor door glass to fully raised position and check glass seating in upper seal. (Scheme 9): Checking Glass Seating In Upper Seal
  18. Repeat operations 14 to 17 as necessary, until door glass seats satisfactorily in upper seal.
  19. With glass in fully raised position, slacken door waist adjuster lock nuts and hand screw adjusters in until they abut the door glass stops. (Scheme 10): Adjusting Door Waist Adjuster
  20. Adjust gap for parallelism between rear edge of door glass and front edge of quarter light. Slacken glass lift regulator channel adjuster lock nut. Move channel to achieve a parallel gap of 8mm on coupe model, 11 mm on convertible. Tighten lock nut. (Scheme 11): Adjusting Door Glass And Front Edge Of Quarter Light Parallelism
  21. Motor door glass fully down and fully up and check all gaps and alignments.
  22. Turn ignition key to position O.
  23. Disconnect and remove door glass lift switch.
  24. Thoroughly clean door glass, removing datum marker lines.
  25. Fit door outer waist moulding.
  26. Fit new tape to access hole in PVC secondary water shedder
  27. Fit water shedders. Refer to «EXTERIOR DRIVER DOOR HANDLE»(ref-198055-S03616877712005101500000).
  28. Fit door switchpack to door casing, connect multiplug and fit casing. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).

Identifying Door Glass Operating Mechanism. Scheme 12

Scheme 12: Identifying Door Glass Operating Mechanism
Scheme 12: Identifying Door Glass Operating Mechanism

The windshield, which is of 5 mm laminated glass with a black obscuration band and has the interior mirror fitted, is common to the coupe and convertible. The windshield finisher is a one-piece, single color unit with seal. The backlight is 4 mm tempered glass, green tinted and heated. The windshield, backlight and quarter lights, except for the convertible model, are direct glazed to the body.

The windshield and coupe backlight are supplied as assemblies complete with trim which is secured to the glass by clips and is fully demountable when the assembly is bonded to the vehicle.

The convertible backlight and outer seal are conventionally glazed to the inner seal, which is stitched and bonded to the top. On both models, the heated backlight remains on for 21 minutes after being switched on unless it is manually switched off before the time delay expires. Some backlights are fitted with a security antenna. A fine wire heated windshield offered as an option on some markets, is controlled from the air conditioning panel.

The door glass on both models is a frameless system with 5 mm green tempered glass. The window glass is operated electrically and raised and lowered by a scissor mechanism.

Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or lowered, closing when either the door is shut or the top is fully raised and latched in position. The door glass can be closed via the remote control unit. Glass operation is internally controlled from switchpacks located in the driver and passenger arm rests via the driver and passenger door modules. The switchpacks are illuminated when the sidelights are on.

One-touch up operation causes the door glass to fully close unless an object is detected or if the glass is already within 45 mm of top of travel when the door is opened. On detection of an object, the glass will drop fully open or to 200 mm below the obstruction. All door glass operates with the ignition switch in either position I or II and after ignition is switched off, until either door is opened.

Before commencing work within a door interior, all Warnings and Notes within the appropriate Removal and Installation procedures must be read and fully understood.

Identifying Rear Quarter Glass Operating Mechanism. Scheme 13

Scheme 13: Identifying Rear Quarter Glass Operating Mechanism
Scheme 13: Identifying Rear Quarter Glass Operating Mechanism

The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit direct glazed to the tonneau. The rear quarter glass of the convertible is 5 mm, tempered, semi-flush and green tinted. A drum and wire lowering and raising system provides automatic full glass drop when the top is lowered. Rear glass control is incorporated in the convertible top switch and operation of the rear quarters is as follows.

General Operation

The rear quarters are operated automatically up or down respectively when raising or lowering the convertible top. When the top is raised, with the door glass at the top of its travel, the glass will be powered down 12 mm and the rear quarters will be powered to the bottom of their travel. When the top is fully raised all glass will be powered up to close, forming a seal with the top.

If the front glass has been either fully or partially lowered manually, the rear quarters only will be powered up. If the power supply to the driver or passenger door module is disconnected (battery disconnected, module unplugged or fuse removed) then the glass/system must re-learn the glass operating characteristics. The last known glass position is regarded as top of travel by one touch operation until re-learning has taken place. One touch down, manual up and down control and the automatic lowering of the glass for door opening are unaffected.

To re-learn the glass operating characteristics, the associated door must be closed (door ajar switch inactive). The glass must then be driven fully down and held stalled at the bottom of its travel for a minimum of one second. The glass is finally driven to the fully up position and held stalled for a minimum of one second. The re-learning procedure must also be accomplished to regain the automatic glass closing sequence.

Scheme 14

Scheme 14: Removal
Scheme 14: Removal

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Turn ignition key to position II.
  2. Motor door glass to fully raised position.
  3. Turn ignition key to position O.
  4. Remove battery cover and disconnect ground cable from battery terminal. Refer to «BATTERY DISCONNECTION PROCEDURE»(ref-171253-S19302448882005020100000).
  5. Remove door casing for access. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).
  6. Remove door primary water shedder. Refer to «EXTERIOR DRIVER DOOR HANDLE»(ref-198055-S03616877712005101500000).
  7. Position PVC secondary water shedder for access.
  8. Remove door latch assembly from vehicle. Refer to «DOOR LOCK ACTUATOR»(ref-198055-S33215644292005101500000).
  9. Slacken and remove latch assembly cover securing screw. (Scheme 14): Removing Latch Assembly Cover Securing Screw
  10. Release cover to latch inner locating boss and remove cover. (Scheme 15): Releasing Cover To Latch Inner Locating Boss
  11. Release door glass drop switch securing tangs and remove switch from latch assembly. (Scheme 16): Releasing Door Glass Drop Switch Securing Tangs And Removing Switch From Latch Assembly
  12. Remove and discard switch harness securing tape
  13. Remove harness multiplug pin protector and using special tool MS.1540, release switch terminal pins from multipug.

Scheme 17

Scheme 17: Installation
Scheme 17: Installation

Scheme 18

Scheme 18
Scheme 18
  1. Fit and fully seat switch terminal pins in harness multiplug and fit terminal pin protector.
  2. Fit door glass drop switch to latch assembly, ensuring that both tangs are fully seated. (Scheme 17): Fitting Door Glass Drop Switch To Latch Assembly
  3. Secure switch harness with suitable tape.
  4. Fit cover to latch assembly. Position cover over latch assembly, ensuring that internal boss locates correctly in latch housing. Fit and tighten cover securing screw. (Scheme 18): Fitting Cover To Latch Assembly
  5. Fit latch assembly to door. Refer to «DOOR LOCK ACTUATOR»(ref-198055-S33215644292005101500000).
  6. Connect ground cable to battery terminal. Refer to «BATTERY RECONNECTION PROCEDURE»(ref-171253-S14708357522005020100000).

Scheme 19

Scheme 19: Removal
Scheme 19: Removal

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25
  1. With door open, turn ignition key to position II.
  2. Motor door glass to fully raised position.
  3. Turn ignition key to position O.
  4. Remove battery cover and disconnect ground cable from battery terminal. Refer to «BATTERY DISCONNECTION PROCEDURE»(ref-171253-S19302448882005020100000).
  5. Remove door casing for access. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).
  6. Remove speaker.
  7. Remove main water shedder and position secondary shedder clear of regulator assembly. Refer to «EXTERIOR DRIVER DOOR HANDLE»(ref-198055-S03616877712005101500000).
  8. Slacken and remove glass rear guide runner upper retaining screw. (Scheme 19): Removing Glass Rear Guide Runner Upper Retaining Screw
  9. Slacken and remove rear guide runner lower adjuster and securing screws and position guide runner clear of glass guide. (Scheme 20): Removing Rear Guide Runner Lower Adjuster And Securing Screws
  10. Reconnect door glass operating switch.
  11. Connect ground cable to battery terminal. Refer to «BATTERY RECONNECTION PROCEDURE»(ref-171253-S14708357522005020100000).
  12. Motor door glass to 50mm from bottom position.
  13. Remove ground cable from battery terminal. Refer to «BATTERY DISCONNECTION PROCEDURE»(ref-171253-S19302448882005020100000).
  14. Remove door inner waist seal. Refer to «DOOR WINDOW GLASS WEATHERSTRIP»(ref-198053-S31268443042005101500000).
  15. Remove door outer waist rail moulding. Refer to «DOOR WINDOW MOULDING»(ref-198050-S35785254672005101500000).
  16. Slacken and remove screw securing door glass guide to front guide runner retaining bracket and remove bracket. (Scheme 21): Removing Front Guide Runner Retaining Bracket
  17. Remove clips from nylon fixings and retain for re-use. (Scheme 22): Removing Clips From Nylon Fixings
  18. Release glass regulator assembly from nylon fixings. (Scheme 23): Releasing Glass Regulator Assembly
  19. Lift glass upwards, tilt rear end outwards pass upwards between top adjuster screws and remove glass from door. (Scheme 24): Removing Glass From Door
  20. Remove nylon fixings from lower channel and refit clips to fixings. (Scheme 25): Removing Nylon Fixings From Lower Channel

Scheme 26

Scheme 26: Installation
Scheme 26: Installation

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33
  1. Lubricate glass lower channel and fit nylon fixings ensuring that looped ends of clips face outwards. (Scheme 26): Fitting Nylon Fixings In Lower Channel
  2. Position glass in door aperture and fit front guide onto guide runner. (Scheme 27): Installing Glass From Door
  3. Check that the three buffers are fitted to outer waist reinforcer. (Scheme 28): Identifying Buffers Fitted To Outer Waist Reinforcer
  4. Fit and align glass front guide retaining bracket and tighten securing screw. (Scheme 29): Installing Glass Front Guide Retaining Bracket
  5. Fit glass regulator assembly onto nylon fixings and fit and fully seat retaining clips. (Scheme 30): Installing Glass Regulator Assembly Onto Nylon Fixings
  6. Connect ground cable to battery terminal. Refer to «BATTERY RECONNECTION PROCEDURE»(ref-171253-S14708357522005020100000).
  7. Motor glass to 25mm from fully raised position
  8. Disconnect ground cable from battery terminal.
  9. Fit rear guide runner to glass guide. (Scheme 31): Installing Rear Guide Runner To Glass Guide
  10. Fit and tighten rear guide runner adjuster securing screws. (Scheme 32): Tightening Rear Guide Runner Adjuster Screws
  11. Fit and tighten rear guide runner upper securing screw ensuring that a clearance of 9mm is maintained between glass and outer waist rail flange inner face. (Scheme 33): Installing And Tightening Rear Guide Runner Upper Securing Screw
  12. Fit ground cable to battery terminal and fit battery cover. Refer to «BATTERY RECONNECTION PROCEDURE»(ref-171253-S14708357522005020100000).
  13. Motor glass to fully lowered position.
  14. Disconnect and remove door switchpack.
  15. Fit door outer waist rail moulding. Refer to «DOOR WINDOW MOULDING»(ref-198050-S35785254672005101500000).
  16. Fit door inner waist seal. Refer to «DOOR WINDOW GLASS WEATHERSTRIP»(ref-198053-S31268443042005101500000).
  17. Adjust door glass as required. Refer to «DOOR WINDOW GLASS ADJUSTMENT»(ref-198053-S28950493502005101500000).
  18. Fit speaker.
  19. Fit secondary and main water shedders. Refer to «EXTERIOR DRIVER DOOR HANDLE»(ref-198055-S03616877712005101500000).
  20. Fit door casing. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).

Scheme 34

Scheme 34: Removal
Scheme 34: Removal
  1. Remove door casing for access. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).
  2. Commencing at door release button recess, carefully use a thin blade to ease inner waist seal from rear of door waist flange. (Scheme 34): Removing Inner Waist Seal
  3. Working from rear, and exercising care to avoid distortion, progressively remove seal from waist flange.

Scheme 35

Scheme 35: Installation
Scheme 35: Installation

Scheme 36

Scheme 36
Scheme 36
  1. Ensure that top edge of PVC water shedder is correctly positioned on door waist flange. (Scheme 35): Positioning Top Edge Of PVC Water Shedder
  2. Commencing at front and ensuring that end of seal aligns with front of door waist flange, fit and fully seat seal on door. (Scheme 36): Installing Inner Waist Seal
  3. Fit door casing. Refer to «DOOR TRIM PANEL»(ref-198049-S08318676492005101500000).

Scheme 37

Scheme 37: Removal
Scheme 37: Removal

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39
  1. Partially lower convertible top.
  2. Remove two screws securing front of seal to header rail. (Scheme 37): Removing Screws Securing Front Of Seal To Header Rail
  3. Remove seal from carrier. (Scheme 38): Removing Seal From Carrier
  4. Clean carrier seal locating channel and apply a thin film of Johnson KY Jelly or equivalent. (Scheme 39): Identifying Carrier Seal Locating Channel

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