JAGUAR XFR 2010 1.G Workshop Manual

37.
38.
39. Drill out the spot welds as indicated.



































Drill out the spot welds as indicated.



















NOTE: The spot welds indicated should be drilled from
inside the engine compartment, to allow spot welding on
installation.
Drill out the spot welds as indicated.

40. NOTES:


Remove the NVH (noise, vibration and harshness)
sound deadening material to expose the spot welds.


The spot welds indicated should be drilled from inside
and right through, to allow MAG plug welding on
installation.
Drill out the spot welds as indicated.











41. CAUTION: This step requires the aid of another technician as the
removed panel will be heavy.
Separate the joints and remove the old panel.

Installation

1. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.


2. NOTE: To avoid overlapping MAG plug welds, the original
removal holes must be marked so that they can be
avoided when drilling the adjacent MAG plug holes.

Mark the position of the drilled holes as indicated, on the
new panel.















3. Remove the new panel.

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12.
13.
14. MAG plug weld at the points indicated.


























NOTE: A MAG weld run replaces the original two spot
welds as there is no access to install spot welds or MAG
plug welds in this area. The MAG weld run should be
performed avoiding the area of adhesive.
Perform a MAG weld run, of approx 30mm as indicated.













NOTE: Spot welds must be installed 5mm away from
the originals and in the same quantities, whenever this is
possible. Where this is not possible, spot welds should be
installed adjacent to the original. Where there is adhesive
in the original joint, spot welds should be installed through
the original.
Spot weld.








15.
Dress all welded joints.

16. Make sure any remaining areas of bare metal created during this
procedure are treated with a zinc primer prior to the installation of outer
panels.

17. Install the NVH sound deadening material in the areas
indicated.




















18. NOTE: Make sure all underbody joints are fully sealed following this
repair procedure.

The installation of associated panels and components is the reversal of
removal procedure.

Published: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member Closing Panel
Removal and Installation

Removal


1. NOTE: The front side member closing panel is
manufactured from High Strength Low Alloy Steel, 350MPa,
(HSLA350).

The front side member closing panel is serviced as a
separate weld-on panel.









2. In this procedure, to ensure the vehicle is correctly aligned, it must be
placed on an approved alignment jig.

3. The front side member closing panel is replaced in conjunction with:
Front bumper cover
Front bumper
Front bumper mounting
Hood
Hood latch panel
Front fender support bracket
Front fender support bracket mounting
Front wheelhouse section
Front side member
Engine, transmission / transaxle, front subframe and front
suspension, as an assembly

4. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).


5. NOTE: This procedure assumes that if the front side member closing
panel is damaged, the front side member will also be damaged.
Therefore, the replacement procedure for the front side member closing
panel is combined within the front side member procedure.
Remove the front side member.
For additional information, refer to: Front Side Member (501-27 Front End Sheet Metal Repairs, Removal and Installation).

Installation

1. The installation of associated panels and components is the reversal of
removal procedure.

(100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).


5. NOTE: This procedure assumes that if the front side member closing
panel section is damaged, the front side member section will also be
damaged. Therefore the removal procedure for the front side member
closing panel section is combined within the front side member section
procedure.
Remove the front side member section.
For additional information, refer to: Front Side Member Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).

Installation

1. The installation of associated panels and components is the reversal of
removal procedure.

Front End Sheet Metal Repairs - Front Side Member Section
Removal and Installation

Removal Published: 11-May-2011


1. NOTE: The front side member section is manufactured from
High Strength Low Alloy Steel, 350MPa, (HSLA350).

The front side member section is cut from the front side
member service panel, which includes the hood latch panel
mounting bracket.









2. In this procedure, to make sure that the vehicle is correctly aligned, it
must be placed on an approved alignment jig.


3. NOTE: This procedure assumes that the front side member closing
panel section is damaged. Therefore, the procedure combines the repair
of the front side member section and the front side member closing
panel section.

The front side member section is replaced in conjunction with:
Front bumper cover
Front bumper
Front bumper mounting
Hood
Hood latch panel
Front side member closing panel section
For additional information, refer to: Front Side Member Closing Panel Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).

4. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

5. Remove the hood.
For additional information, refer to: Hood (501-02 Front End Body Panels, Removal and Installation).

6. Remove the front bumper mounting.
For additional information, refer to: Front Bumper Mounting (501-27 Front End Sheet Metal Repairs, Removal and Installation).

7. Disconnect the generator electrical connectors. www.JagDocs.com