JAGUAR XFR 2010 1.G Manual PDF

General Information - Solvents, Sealants and Adhesives
Description and Operation Published: 11-May-2011

WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off
fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt about any substance,
particularly a solvent, DO NOT use it.


CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the
manufacturer of the product for information regarding storage, handling and application.

The Solvents, Sealers and Adhesives subsection refers to some commonly used chemicals and materials, hazards associated
with their use, and safety measures to be taken.

Adhesives and Sealers

Highly flammable, flammable, combustible – observe No Smoking policy.

Generally should be stored in No Smoking' areas. Cleanliness and tidiness in use should be observed e.g. disposable paper
covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be
labelled appropriately.

Solvent - based Adhesives/Sealers - See Solvents

Follow manufacturer's instructions.

Water - based Adhesives/Sealers

Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin
and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation
of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut - out and adequate extraction.

Resin - based Adhesives/Sealers e.g. Epoxide and Formaldehyde Resin - based

Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals
through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.

Anaerobic, Cyanoacrylate (Super - glues) and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin and/or respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean
moist pad and seek immediate medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors
can cause irritation to the nose and eyes.
For two - pack systems see Resin - based and Isocyanate Adhesives/Sealers.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin - based Adhesives

Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions
can occur.

Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous
system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapor concentrations
may result in adverse health effects.
Prolonged contact with the skin may lead to skin irritation and, in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the
breathing zone.
Wear appropriate gloves, eye and respiratory protection.

General Information - Standard Workshop Practices
Description and Operation

Protecting the Vehicle Published: 04-Jul-2014

Always install covers to protect the fenders before commencing work in the engine compartment. Always install the interior
protection kit, wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic
fluid, antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use polythene
sheets in the luggage compartment to protect carpets. Always use the recommended service tool, or a satisfactory equivalent,
where specified. Protect temporarily exposed screw threads by replacing nuts or installing caps.

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards
If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed
There is adequate room to jack up the vehicle and remove the wheels, if necessary
Fender covers are always installed if any work is to be carried out in the engine compartment
The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up


CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a
surge of current causing damage to the internal components of the generator.
If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap
or die impairs the strength and fit of the threads and is not recommended.
NOTES:

During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this
is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and
thread is used.


New Taptite bolts when used cut their own threads on the first application.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts
having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the
repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread
locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque
reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or
faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages,
these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve
tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.
Where it is stated that bolts and screws may be reused, the following procedures must be carried out:
Check that threads are undamaged.
Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.
Make sure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Supplementary Restraint System (SRS) Precautions

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The following
guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the importance of
ensuring the integrity of the SRS components installed to the vehicle.


WARNING: The following precautions MUST be adhered to when working on the SRS system:
The correct procedures must always be used when working on SRS components.
Persons working on the SRS system must be fully trained and have been issued with the safety guidelines.
The airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids or heavy
metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contact with electricity
before the unit has been deployed.
Always replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing
shows signs of fraying.
Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with an SRS
system.


CAUTION: Do not expose airbag modules or seat belt pre-tensioners to temperatures exceeding 85° C (185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The same
care should be exercised when working on ancillary systems and components located in the vicinity of SRS components; these
include but are not limited to:

Steering wheel airbag, rotary coupler.
Passenger front airbag.
Head airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.
Side (thorax) air bags.
Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the following
operations:

Remove the ignition key.
Disconnect battery, earth lead first.
Wait 2 minutes for the SRS power circuit to discharge before commencing work.


NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure under
crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to avoid the risk of
accidental deployment.
Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is
ready for effective operation in the event of a collision. Carefully inspect SRS components before installation. Do not install a
part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.


WARNING: The integrity of the SRS systems is critical for safety reasons. Make sure the following precautions are always
adhered to:
Do not install accessories or other objects to trim panels which cover ITS airbags.
Never install used SRS components from another vehicle or attempt to repair an SRS component.
When repairing an SRS system, only use genuine new parts.
Never apply electrical power to an SRS component unless instructed to do so as part of an approved test
procedure.
Special fixings are necessary for installing an airbag module – do not use other fixings and make sure that all
fixings are tightened to the correct torque.
Always use new fixings when replacing an SRS component.

CAUTIONS:
Take care not to trap airbag modules when installing interior trim components.
Make sure SRS components are not contaminated by oil or grease.
NOTES:


Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but will need to

be replaced as soon as possible to make sure full SRS protection.


If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following :


WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only approved JLR
diagnostic equipment to diagnose system faults.




WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the SRS components,
it may cause accidental deployment and injury.
Handling and storage

Always observe the following precautions when handling SRS components:



Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and must be
handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to a strong shock.
Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the cover
uppermost and the base away from your body.
Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle. Always use the
luggage compartment of the vehicle for carrying airbag modules and seat belt pre-tensioner units.
Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow anything to
rest on top of an airbag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
Always store an airbag module with the deployment side uppermost. If it is stored deployment side down, accidental
deployment will propel the airbag module with sufficient force to cause serious injury.
Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the empty
packaging for carriage.

WARNINGS:


When handling an inflatable tubular structure (ITS) airbag module, hold by the gas generator housing, DO NOT hold by
the airbag. Do not wrap the thumb around the gas generator while holding. Do not drape airbag over shoulder or around neck.
For seat buckle type pre-tensioners, hold by the piston tube, with the open end of the piston tube pointing towards the ground
and the buckle facing away from your body. Do not cover the end of the piston tube. DO NOT hold buckle type pre-tensioners
by the bracket assembly or cable. Never point the piston tube towards your body or other people.


Airbag modules and seat belt pre-tensioners are classed as explosive devices. For overnight and longer term storage,
they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has been registered
with the local authority.


Store airbag modules or seat belt pre-tensioners in a designated storage area. If there is no designated storage area
available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.


CAUTION: Improper handling or storage can internally damage the airbag module making it inoperative. If you suspect
the airbag module has been damaged, install a new module and refer to the deployment/disposal procedures for disposal of
the damaged module.
SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:



Never attempt to modify, splice or repair SRS wiring.
Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in such a
way that it could generate electrical interference in the airbag harness. Seek specialist advice when installing such
equipment.


NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used). www.JagDocs.com

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS wiring.




WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses. Look for
possible chafing points.
Side impact crash sensor inspection

After any degree of side body damage, inspect the side impact crash sensors. Replace a crash sensor if there is any sign of
damage.


CAUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the crash sensors. Avoid direct
exposure of the crash sensors or link harnesses to heat guns, welding or spraying equipment. Take care not to damage sensor
or harness when reinstalling components.
Rotary coupler


CAUTION: Always follow the procedure for installing and checking the rotary coupler as instructed in the SRS repairs
section. Comply with all safety and installation procedures to make sure the system functions correctly. Observe the following
precautions:

Do not unlock and rotate the rotary coupler when it is removed from the vehicle.
Do not turn the road wheels when the rotary coupler is removed from the vehicle.
Always make sure the rotary coupler is removed and installed in its central position and with the front road wheels in
the straight ahead position - refer to SRS repair section for the correct removal and installation procedure.
If a new rotary coupler is being installed, make sure the locking tab holding the coupler's rotational position is not
broken; units with a broken locking tab must not be used.
Airbag location labels

WAITING AIRBAG LOCATION AND DESIGN LABELS - DUE MARCH - NEIL HARRISON 46404

Airbag and pre-tensioner deployment


WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes after
deployment before touching the airbag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who have
undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The following
precautions must be complied with:
Only use deployment equipment approved for the intended purpose.
Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been designated
for the purpose.
Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner units.
When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away from the
deployment zone.
Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of this
manual. In particular, make sure deployment tool is NOT connected to battery supply before connecting to airbag
module connector.
When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and seal
deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be replaced.
DO NOT reuse or salvage any parts of the SRS system.
Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this case
airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its correct mounting
position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped,
deploy the module outside of the vehicle.

SRS Component Replacement Policy

CAUTIONS:


The Restraints Control Module (RCM) will log a crash fault after every impact which is severe enough to cause airbag
deployment. It is possible to have three crashes/impacts logged after one event where, for example, a front, side and
rollover has occurred. After the third fault is logged, the SRS warning lamp will be illuminated and the RCM must be
installed. After any airbag deployment a new RCM must be installed.


The SRS side impact sensor must be replaced if there are any signs of physical damage or if the restraints control module
(RCM) is registering a fault.
The following information details the policy for replacement of SRS components as a result of a vehicle accident.

Impacts which do not deploy the airbags or pre-tensioners

Check for structural damage in the area of the impact paying particular attention to bumper armatures, longitudinals and
bracketry.
Impacts which deploy the airbags or pre-tensioners

The replacement and inspection policy is dependent on the type and severity of the crash condition. The following guidelines
are the minimum that should be exercised as a result of the deployment of specific SRS components.

Check for structural damage in the area of impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Front Airbag Deployment - Driver and Passenger

CAUTION: If the front airbags are deployed, the following components must be replaced:
Driver airbag module
Passenger airbag module
Fly leads (where applicable) connecting front airbag modules to SRS harness
Front seat belt buckle pre-tensioner
Rear seat belt pre-tensioners - if installed
Driver's seat belt retractor - if installed
Rotary coupler
Any front impact sensors that have been physically damaged or if a fault is being registered
Restraints control module (RCM) if the three crashes/impacts have been stored
Additionally, the following items must be inspected for damage and replaced as necessary:

Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
Fascia moulding adjacent to passenger airbag module
Steering wheel
Front seat frames and head restraints
Steering column - if adjustment is lost or if there are signs of collapse
Seat belt height adjusters

Rear seat belts

Side Air Bags


CAUTION: If the side (thorax) air bags are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:
Side (thorax) airbag
Any side impact sensors that have been physically damaged or if a fault is being registered
Restraints Control Module (RCM) if the three crashes/impacts have been stored
Additionally, the following items must be inspected for damage and replaced as necessary:

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Front seat frame and head restraints
Door trim casing
Seat belt height adjusters
Rear seat belts
Head airbag modules


CAUTION: If the head airbag modules are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:
Head airbag modules
Link lead between airbag gas generator and restraints control module (RCM) harness
Airbag retaining clips
Internal trim finisher
Front seat belt buckle pre-tensioners
Any side impact sensors that have been physically damaged or if a fault is being registered
Restraints Control Module (RCM) if the three crashes/impacts have been stored
Additionally, the following items must be inspected for damage and replaced as necessary:

Headlining
Component mounting brackets
Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Seat belt height adjusters

Rear impacts

CAUTION: If the seat belt pre-tensioners are deployed during a rear impact, the following components must be replaced:
Seat belt pre-tensioners
Front and rear seat belt retractors used during the impact
Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:
Seat belt height adjusters
Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

1 - Minor component movement clockwise/counterclockwise 2 - Major component movement clockwise/counterclockwise 3 - Component movement to the left/right/up/down 4 - Component movement towards/away 5 - 3 dimensional component movement 6 - 2 dimensional component movement 7
3 dimensional component rotation 8
3 dimensional component cycling

1
Turn the component clockwise through 45° 2
Turn the component counterclockwise through 45° 3
Turn the component clockwise through 90° 4
Turn the component counterclockwise through 90° 5
Turn the component clockwise through 180° 6
Turn the component counterclockwise through 180° 7
Turn the component clockwise through 2 complete turns 8
Turn the component counterclockwise through 2 complete turns www.JagDocs.com