suspension JAGUAR XFR 2010 1.G Workshop Manual

Installation

1. Install the tie rod end, note the number of turns until adjacent to the
locknut.


2. CAUTION: Make sure that the ball joint ball does not rotate.
Connect the tie-rod end ball joint.
Clean the component mating faces.
Install a new nut and tighten to 133 Nm.

3. Tighten the tie-rod locking nut.
Clean the component mating faces.
Tighten the nut to 55 Nm.

4. Install the front wheel.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

5. Using only four-wheel alignment equipment approved by Jaguar, check
and adjust the wheel alignment.
For additional information, refer to: Four-Wheel Alignment (204-00 Suspension System - General Information, General Procedures).

Item Description 1 Filler cap 2 Vent hose connection 3 Expansion hose connection 4 Level sensor The expansion tank is installed in the engine compartment, on the LH upper suspension housing.
A filler cap and level sensor are incorporated into the expansion tank. A MAX level marking is molded into the interior of the
tank below the filler cap. Cold fill levels are molded onto the exterior of the tank.
The expansion tank provides the following functions:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the filler cap.

The expansion tank has an air space of approximately 0.5 liter (1.06 US pints), above the MAX level, to allow for coolant
expansion. EXPANSION TANK

15 Fuel pump module The fuel tank is a saddle type tank, blow moulded from HDPE (high density polyethylene). The tank is located forward of the
rear suspension and is mounted using two metal straps. The tank is a sealed unit with the only internal access being through
the fuel pump module aperture on the top of the tank.

The fuel pump module flange has a six pin external connector which provides the electrical connections for the fuel pump and
both fuel level sensors. A quick release connector provides for the connection of the fuel feed pipe.

The flange is fitted with a locking ring and seal. The seal locates in a groove on the tank. The locking ring locates and clamps
on the encapsulated ring that is moulded into the fuel tank. The flange has a tag which locates in the top of the tank to
ensure correct orientation.

A carrier within the tank provides for the mounting of the passive side jet pump tube, vent valve, ROV and liquid vapor
separator (LVS), level sensors and passive side drain.

FUEL PUMP MODULE

1 Fuel supply connection 2 Electrical connector 3 Flange locking ring and seal 4 Sucking jet connector 5 Fuel pump module 6 Fuel pick up filter 7 Level sensor float 8 RH level sensor 9 Fuel filter 10 Pressure relief valve 11 Pump supply to flange connection 12 The fuel pump is a variable speed rotary vane type. The pump is energized by the fuel pump relay which is located in the RJB and the FPDM which is located under the RH floor pan above the rear suspension stabilizer bar. The relay and FPDM are controlled by the ECM.
A fine mesh filter is located in the lower section of the pump module. This provides filtration to the fuel as it is drawn into the
module. There is a winged filter on the fuel pump that gives additional protection and a life time fuel filter integrated into the
flange which eliminates the need for an additional filter further downstream in the fuel system.
The RH fuel level sensor is mounted into the pump module housing.
FUEL PUMP DRIVER MODULE (FPDM)



The FPDM is located on a bracket which is integral with the charcoal canister. The module is attached to one end of the canister with a bracket.

The fuel pump operation is regulated by a FPDM which is controlled by the ECM. The FPDM regulates the flow and pressure supplied by controlling the operation of the fuel pump using a PWM (pulse width modulation) output.

The FPDM is powered by a supply from the fuel pump relay in the RJB. The fuel pump relay is energized on opening the driver's door, pressing the start button only or pressing the start button and the footbrake (which initiates engine cranking). The FPDM supplies power to the fuel pump, and adjusts the power to control the speed of the fuel pump and thus the pressure and flow
in the fuel delivery line.

A PWM signal from the ECM tells the FPDM the required speed for the fuel pump. The on time of the PWM signal represents half the fuel pump speed, e.g. if the PWM signal has an on time of 50%, the FPDM drives the pump at 100%.
The FPDM will only energize the fuel pump if it receives a valid PWM signal, with an on time of between 4% and 50%. To switch the fuel pump off, the ECM transmits a PWM signal with an on time of 75%.
The output pressure from the fuel pump will change with changes of engine demand and fuel temperature. The ECM monitors the input from the fuel rail LP sensor and adjusts the speed of the fuel pump as necessary to maintain a nominal output
pressure of 450 kPa (4.5 bar; 65.3 lbf/in.2
), except during engine start-up. At engine start-up the target pressure for the fuel
delivery line is 630 kPa (6.3 bar; 91.4 lbf/in.2
).
If the SRS (supplemental restraint system) outputs a crash signal on the high speed CAN (controller area network), the ECM de-energizes the fuel pump relay to prevent any further fuel being pumped to the engine.

If the ECM does not detect pressure in the fuel delivery line, it stops, or refuses to start the engine and stores the appropriate DTC (diagnostic trouble code).
The ECM receives a monitoring signal from the FPDM. Any DTC's produced by the FPDM are stored by the ECM.
DTC's can be retrieved from the ECM using an approved Jaguar diagnostic system. The FPDM itself cannot be interrogated by the approved Jaguar diagnostic system.

DTC Description Possible Causes Action U0401-00
Invalid Data Received
From ECM/PCM A - No
sub type information
ECM did not respond
properly to speed control
cancel or auto brake
cancel request
Check ECM for related DTCs and refer to relevant
DTC Index U0401-67
Invalid Data Received
From ECM/PCM A -
Signal incorrect after
event
ECM did not respond
properly to speed control
resume request
Check ECM for related DTCs and refer to relevant
DTC Index U0401-81
Invalid Data Received
From ECM/PCM A -
Invalid serial data
received
Invalid data received
from engine control
module
Bus signal/message
failure
Speed control inhibited
by ECM
Check the Engine Control Module for related DTCs
and refer to relevant DTC Index. If U040181 is
logged as historic but no other DTCs have logged in
the engine control module at the same time and
distance, it may be caused by cranking with low
voltage conditions. Check battery and charging
system according to instructions in the battery care
manual. Install the latest Engine Control Module
software using the manufacturer approved diagnostic
system, contact Dealer Technical Support before
replacing components U0415-53
Invalid Data Received
From Anti-Lock Braking
System (ABS) Control
Module - De-activated
Event information
Deactivated
Check the Anti-Lock Braking System Module for
related DTCs and refer to the relevant DTC index U0415-81
Invalid Data Received
From Anti-lock Brake
System (ABS) Control
Module - Invalid serial
data received
Stability assist fault
Check ABS module for related DTCs and refer to
relevant DTC Index U0417-67
Invalid Data Received
From Park Brake
Control Module - Signal
incorrect after event
Parking brake module did
not respond properly to
apply request
Check parking brake module for related DTCs and
refer to relevant DTC Index U0417-81
Invalid Data Received
From Park Brake
Control Module -
Invalid serial data
received
Speed control inhibited
by parking brake module
Check parking brake module for related DTCs and
refer to relevant DTC Index U0418-68
Invalid Data Received
From Brake System
Control Module - Event
information
Event information
Check the Anti-Lock Braking System Module for
related DTCs and refer to the relevant DTC index U0421-81
Invalid Data Received
From Suspension
Control Module 'A' -
Invalid serial data
received
Invalid serial data
received
Check the Suspension Control Module for related
DTCs and refer to the relevant DTC index U0423-81
Invalid Data Received
From Instrument Panel
Control Module -
Invalid serial data
received
Speed control inhibited
by instrument cluster
Check instrument cluster, CJB and RJB for related
DTCs and refer to relevant DTC Index U1A00-88
Private Communication
Network - Bus off
Bus off
The module setting this code has disabled CAN
transmission. Check for other bus off codes. Check
the module and circuits. Refer to the electrical circuit
diagrams. Clear all DTCs and road test the vehicle. If
the concern reoccurs contact Dealer Technical
Support for further advice. Under no circumstance
should any parts be replaced to overcome this issue U1A14-49
CAN Initialisation
Failure - Internal
electronic failure
Internal electronic failure
Suspect the speed control module. Check and install
a new module as required, refer to the new
module/component installation note at the top of
the DTC Index U2101-00
Control Module
Configuration
Incompatible - No sub
type information
Data sent from RJB is
invalid
Check/amend Car Configuration File using the
manufacturer approved diagnostic system, clear DTC
and re-test. If DTC remains, re-configure RJB using
manufacturer approved diagnostic system, clear DTC
and re-test. If DTC remains check RJB for DTCs and

DTC Description Possible Cause Action U013900
Lost
Communication
with Suspension
Control Module 'B'
Loss of CAN communication
with adaptive damping module Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check
adaptive damping module for DTCs and refer to the relevant
DTC Index U014000
Lost
Communication
With Body
Control Module
Loss of CAN communication
with CJB Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check CJB for
DTCs and refer to the relevant DTC Index U014200
Lost
Communication
With Body
Control Module
"B"
Loss of CAN communication
with RJB Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check RJB for
DTCs and refer to the relevant DTC Index U015100
Lost
Communication
With Restraints
Control Module
Loss of CAN communication
with RCM Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check RCM for
DTCs and refer to the relevant DTC Index U015600
Lost
Communication
with Information
Centre 'A'
Loss of CAN communication
with information and
entertainment control module Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check
information and entertainment control module for DTCs and
refer to the relevant DTC Index U016400
Lost
Communication
with HVAC
Control Module
Loss of CAN communication
with climate control module Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check climate
control module for DTCs and refer to the relevant DTC Index U019900
Lost
Communication
with Door Control
Module 'A'
Loss of CAN communication
with driver door module (DDM) Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check DDM for
DTCs and refer to the relevant DTC Index U020000
Lost
Communication
with Door Control
Module 'B'
Loss of CAN communication
with passenger door module
(PDM) Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check PDM for
DTCs and refer to the relevant DTC Index U020800
Lost
Communication
with Seat Control
Module 'A'
Loss of CAN communication
with driver seat module (DSM) Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check DSM for
DTCs and refer to the relevant DTC Index U021400
Lost
Communication
with Remote
Function
Actuation
Loss of CAN communication
with keyless vehicle module
(KVM) Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check KVM for
DTCs and refer to the relevant DTC Index U024100
Lost
Communication
with Headlamp
Control Module 'A'
Loss of CAN communication
with headlamp control module Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check
headlamp control module for DTCs and refer to the relevant
DTC Index U025000
Lost
Communication
with Impact
Classification System Module
Loss of CAN communication
with pedestrian protection
module Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check
pedestrian protection module for DTCs and refer to the
relevant DTC Index U025600
Lost
Communication
with Front
Controls Interface
Module 'A'
Loss of CAN communication
with integrated control panel Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Check
integrated control panel for DTCs and refer to the relevant
DTC Index U030000
Internal Control
Module Software
Incompatibility
Invalid configuration message
is received Re-configure the RJB using the manufacturer approved
diagnostic system. Clear the DTC and retest. If the DTC is
still logged suspect the instrument cluster, refer to the new
module/component installation note at the top of the DTC
Index U040268
Invalid data
received from
TCM
Algorithm based failures -
events information Check TCM for DTCs and refer to the relevant DTC Index U200411
Auxiliary Switch
Pack
Auxiliary switch signal circuit -
short to ground Refer to the electrical circuit diagrams and check auxiliary
switch signal circuit for short to ground U200415
Auxiliary Switch
Pack
Auxiliary switch signal circuit -
short to power, open circuit Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check auxiliary switch signal
circuit for short to power, open circuit

Message Other Warnings Reason Action CRUISE NOT
AVAILABLE None Speed control cannot be engaged.
A fault has occurred in the speed
control system. Diagnose fault
using an approved Jaguar Diagnostic System. RADAR SENSOR
BLOCKED None
The adaptive speed control radar
sensor has become dirty or obstructed. Remove obstruction or clean the
radar sensor. FORWARD ALERT
OFF None
Forward alert has been switched off.
No warning will be given for objects in
the vehicles forward direction. None FORWARD ALERT None
Forward alert has been switched on or
the gap settings have changed. None FORWARD ALERT
UNAVAILABLE None
Forward Alert and Emergency Brake
Assist are not available. Use an approved Jaguar
Diagnostic System to diagnose
fault.. Warning/Message Display

Warning and information messages are displayed in the central area of the LCD. When no messages are required, an analogue clock is present on the display. The message display language can be changed by the driver using a selection menu on the
Touch Screen Display (TSD). The following table shows the possible messages which can be displayed, other visual or audible
warnings and a description of the message.

Message Other Warnings Reason Action DSC ON
DSC warning indicator
flashes for a short time. Displayed for a short time when the DSC
switch is operated to activate the DSC system. None DSC OFF
DSC warning indicator
illuminated. Displayed for a short time when the DSC
switch is operated to de-activate the
DSC system. None TRAC DSC
DSC warning indicator
illuminated. Displayed for a short time when the DSC
switch is operated to activate the TRAC
DSC system. None DSC NOT
AVAILABLE DSC warning indicator
illuminated. A fault is present in the DSC system.
A fault has occurred in the DSC
system. Interrogate ABS (anti-lock
brake system) module for faults and
diagnose fault using an approved Jaguar Diagnostic System. BRAKE FLUID
LOW
Brake warning
indicator
illuminated.
Red warning triangle
illuminated in LCD. Brake fluid level has become low and
activated low level switch. Investigate fluid loss and check brake
system for leaks. Repair system as
required and replenish brake fluid
reservoir. ABS FAULT
ABS warning indicator
illuminated.
Amber warning
triangle illuminated
in LCD. A fault is present in the ABS system. Braking system will operate but ABS will not be available. A fault has occurred in the ABS system. Interrogate ABS module for faults and diagnose fault using an approved
Jaguar Diagnostic System. BRAKE ASSIST
FAULT Amber warning triangle
illuminated in LCD. A fault is present in the braking system
preventing brake assist operation.
Braking system will operate but brake
assist will not be available and
increased effort on the brake pedal may
be required. A fault has occurred in the brake assist
system. Interrogate ABS module for faults and diagnose fault using an
approved Jaguar Diagnostic System. EBD FAULT
Red warning triangle
illuminated in LCD. A fault is present in the braking system
preventing EBD operation. Braking
system will operate but EBD will not be
available. A fault has occurred in the EBD
system. Interrogate ABS module for faults and diagnose fault using an approved Jaguar Diagnostic System. ADAPTIVE
DYNAMICS FAULT Amber warning triangle
illuminated in LCD. A fault is present in the Computer
Active Technology Suspension (CATS) or
the Adaptive Dynamic Suspension
system. Suspension will default to the
'hard' setting. A fault has occurred in the CATS
system. Interrogate the CATS or
adaptive damping module for faults
and diagnose using an approved Jaguar Diagnostic System. PARK BRAKE
APPLIED None
Parking brake has been applied when
the vehicle moving at a speed 5 km/h (3 mph) or above. None PARK BRAKE
FAULT
Brake warning
indicator
illuminated.
Red warning triangle
illuminated in LCD. A fault is present in the parking brake
system. A fault has occurred in the parking
brake system. Interrogate the parking
brake module for faults and diagnose
using an approved Jaguar Diagnostic
System.

The lighting system has an 'auto' lights function which is controlled by the CJB on receipt of signals from the rain/light sensor located at the top of the windscreen. The exterior lights are turned on or off in response to ambient light signals from the
rain/light sensor on a LIN (local interconnect network) bus connection to the CJB . The auto lights can also be activated when the windshield wipers are activated by signals from the rain sensor, which is located at the top of the windshield or when the
driver activates the wipers in the fast wipe position.

Two levels of headlamp specification are available; halogen or xenon. In certain markets the headlamps feature a cornering
lamp or a static bending lamp which illuminates the area at the side of the vehicle when turning into driveways for example.
North American Specification (NAS) vehicles have a side marker lamp installed in the headlamp assembly. Replacement of any
of the headlamp bulbs requires removal of the headlamp assembly.

The tail lamp comprises two separate lamp assemblies. The turn signal indicator, side and stop lamps and reverse lamps are
located in each rear fender tail lamp assembly. The rear fog lamps are located in separate units attached to the luggage
compartment lid. A side marker lamp is fitted to the rear fender tail lamp assembly and is fitted in all markets.

Two systems of headlamp leveling are available; manual leveling which is only available on halogen headlamps and static
dynamic leveling which is available on xenon headlamps. The manual system uses a thumbwheel rheostat to adjust the
vertical alignment of the headlamps to compensate for differing vehicle loading. The static dynamic system uses height
sensors fitted to the front and rear suspension and a headlamp leveling module which periodically monitors the vehicle
attitude and adjusts the headlamp vertical alignment accordingly.

dependant on a particular ignition mode status. The side lamps will also be illuminated when the lighting control switch is in
the AUTO position and a 'lights on' signal is received by the CJB from the rain/light sensor Side Marker Lamps (NAS only)

The side marker lamp is located in the outer part of the headlamp assembly. The side marker lamp uses a W5W wedge fitting
bulb. The bulb is fitted into a holder which connects with contacts in the headlamp housing. The holder is fitted into an
aperture which connects with contacts in the headlamp housing. The side marker lamp is active at all times when the side
lamps are active.

AUTOMATIC HEADLAMP OPERATION

The automatic headlamp function is a driver assistance system. The driver can override the system operation by selection of
side lamp or headlamp on if the ambient light conditions require front and rear lighting to be active. The automatic headlamp
system uses a light sensor and the CJB, which are connected via a LIN (local interconnect network) bus to control the headlamp functionality. The light sensor is incorporated in the rain/light sensor located on the inside of the windshield, below
the rear view mirror. The wiper system also uses the rain/light sensor for automatic wiper operation.

The light sensor measures the ambient light around the vehicle in a vertical direction and also the angular light level from the
front of the vehicle. The rain/light sensor uses vehicle speed signals, wiper switch position and the park position of the front
wipers to control the system. The automatic headlamp operation uses ambient light levels which are monitored by photodiode
incorporated in the rain/light sensor. The rain/light sensor sends a lights on/off request to the CJB on the LIN bus, which responds by switching on the low beam headlamps, front side lamps and rear tail lamps. The automatic headlamps are
activated under the following conditions:

Twilight
Darkness
Rain
Snow
Tunnels
Underground or multistoried car parks.

Operation of the automatic headlamps requires the ignition to be in ignition mode 6, the lighting control switch to be in the
'AUTO' position and a lights on request signal from the light sensor. If the rain sensor signal activates the fast speed wipers,
the low beam headlamps are activated, providing the lighting control switch is in the 'AUTO' position.

HEADLAMP LEVELING

Headlamp leveling provides for the adjustment of the vertical aim of the headlamps. The leveling system is primarily required
to minimise glare to other road users when a heavy load is in the rear of the vehicle. Two systems of headlamp leveling are
available; manual and static dynamic.
Manual Headlamp Leveling

The manual system uses a thumbwheel rheostat to adjust the vertical alignment of the headlamps to compensate for differing
vehicle loading. The rotary thumbwheel is located on the auxiliary lighting switch, adjacent to the illumination dimmer
thumbwheel. Three positions are available to adjust the headlamps to a position to prevent glare to other road users.
Static Dynamic Headlamp Leveling
The static dynamic headlamp leveling system uses the following components:
Front and rear vehicle height sensors
Two headlamp leveling, vertical adjustment motors
Headlamp leveling module
Ignition in mode 6
Vehicle speed information from ABS module.
The static dynamic system uses height sensors fitted to the front and rear suspension and a headlamp leveling module which
periodically monitors the vehicle attitude and adjusts the headlamp vertical alignment accordingly.

Static dynamic headlamp leveling is controlled by a headlamp leveling module located in the lower instrument panel, behind
the glovebox.

The height sensors are both located on the RH side of the vehicle. The front sensor is attached to the front suspension lower arm with a strap and to the front sub frame with a bracket and 2 bolts. The rear sensor is attached to the rear suspension
upper control arm with a cable tied clip and to the rear sub frame with a bracket and 2 bolts. Each sensor has 3 connections to
the headlamp leveling module; power, ground and signal.

DAYTIME RUNNING LAMPS (DRL)

Refer to DRL section for details. Refer to: Daytime Running Lamps (DRL) (417-04 Daytime Running Lamps (DRL), Description and Operation).
REAR LAMP ASSEMBLY

The rear lamp assembly is a 2 piece unit, with one part located in the rear quarter panel and the second part attached to the
luggage compartment lid. The outer rear lamp assembly is located in a recess in the vehicle body. The lamp is secured with 2
studs inboard studs on the lamp body which are secured to the vehicle body with 2 nuts. A third outboard stud and nut secures

Cooper Pegler

Burgess Hill
Sussex
RH 15 9LA
Telephone (014446) 42526

Sika Ltd

Watchmead
Welwyn Garden City
Hertfordshire
AL7 1BQ
Telephone (01707) 394444
www.sika.co.uk
SATA Spray Equipment

Minden Industrial equipment
16 Greyfriars Road
Moreton Hall
Bury St Edmunds
Suffolk
IP32 7DX
Telephone (01284) 760791
www.sata.com
Henkel Loctite Adhesives Limited

Technologies House
Wood Lane End
Hemel Hempstead
Hertfordshire
HP2 4RQ
Telephone (01442) 278000
www.loctite.co.uk
Teroson

Henkel Ltd
Apollo Court
2 Bishops Square Business Park
Hatfield
Hertfordshire
AL10 9EY
Telephone (01707) 635000
www.henkel.co.uk
Underbody sealer

Under floor areas and the front part of the spare wheel well are treated with a plastisol PVC underbody sealer. This material is
not suitable for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing adheres soundly to the
panel.

Apply new underbody sealer between primer and surface paint operations. Apply seam sealer as necessary before application
of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax injection) are fitted
before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in repair with the aid of a hot air
blower, or replace with rubber grommets


CAUTION: Ensure that suspension units, wheels, tires, power unit, drive shafts, exhaust and brakes, (including all
mounting points), are shielded prior to application of fresh underbody sealer. www.JagDocs.com