service JAGUAR XFR 2010 1.G Workshop Manual

Published: 11-May-2011
Roof Sheet Metal Repairs - Roof Panel Vehicles Without: Sliding Roof Opening
Panel
Removal and Installation

Removal


1. NOTE: The roof panel is manufactured from mild steel. The
roof panel is serviced as a separate weld-on panel.



2. The roof panel is replaced in conjunction with:
Headliner
Windshield
Rear window glass

3. 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).

4. Remove both front seats.
For additional information, refer to: Front Seat (501-10 Seating, Removal and Installation).

NOTE: The illustration may indicate either hand of the service panel, the opposite hand will be similar.

Item Description 1 Front fender 2 Front door 3 Rear door 4 Front door skin panel 5 Rear door skin panel 6 Quarter panel 7 Rocker panel 8 Rocker panel front section (cut from rocker panel) 9 Rocker panel rear section (cut from rocker panel) 10 Rocker panel inner reinforcement 11 Rocker panel and b-pillar outer panel 12 B-pillar reinforcement 13 B-pillar inner panel 14 A-pillar outer panel 15 A-pillar reinforcement 16 Fender apron panel 17 Fender apron panel closing panel Time schedules, side panels

The following information shows the total time taken to install single panels and complete assemblies. This time includes
removal of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panels are not included).

The times shown were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide
only.

Single panel times
Panel Description Hours Front fender L/H 8.9 Front fender R/H 9.1 Front door 8.8 Rear door 8.7 Front door skin panel 11.1 Rear door skin panel 10.8 Quarter panel L/H 23.2 Quarter panel R/H 24.2 Rocker panel L/H 19.6 Rocker panel R/H 19.9 Rocker panel front section L/H 18.5 Rocker panel front section R/H 18.8 Rocker panel rear section L/H 16.7 Rocker panel rear section R/H 16.8 Windshield glass remove and install 2.2 Rear window glass remove and install 1.7 Headliner remove and install 3.3 Instrument panel console remove and install 5.3 Combination panel replacement times

The following panel combination times show the total time to remove/install body panels, MET items and paint times based on
Metallic Clear Over Base Paint process, (blends to adjacent panels are not included).

Combination panel times
Panel Description Hours Front fender Front door Total Time L/H 12.7
R/H 12.9 Combination panel times
Panel Description Hours Rear door Quarter panel Rear window glass remove and install Headliner remove and install Total Time L/H 29.0
R/H 30.00

Installation
1. Trim the excess from the upper part of the service panel.
2. Install the riv-nuts into the new rocker panel front section
as indicated.
















3. CAUTION: Care should be taken not to cut through
into the inner panels.


NOTE: Temporarily install the front door and hinges to
aid alignment.

Offer up, align and clamp the new panel into position,
overlapping the old panel remnant. Cut through the new
panel, partially cutting the old panel at the points where
the butt joints are to be made.











4. Remove the front door and hinges and the new A-pillar outer panel. www.JagDocs.com

Side Panel Sheet Metal Repairs - B-Pillar Inner Panel
Removal and Installation

Removal Published: 11-May-2011


1. NOTE: The B-pillar inner panel is manufactured from mild
steel.

The B-pillar inner panel is cut from the bodyside inner front
section service panel.
















2. The B-pillar inner panel is replaced in conjunction with:
Front door
Rear door
Rocker panel and B-pillar outer panel
B-pillar reinforcement
Rocker panel inner reinforcement
Headliner

3. 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).

4. Remove the rocker panel inner reinforcement.
For additional information, refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). www.JagDocs.com

33. Remove the template from the new panel.


34. NOTE: This procedure shows the rocker panel part of the rocker
panel and B-pillar outer panel being installed to its service condition.
The rocker panel lower butt joints could be performed closer to the
B-pillar, dependant on the extent of the damage.

Using the new panel for reference and allowing for an overlap, cut the
old panel at the points indicated.

Interior Trim and Ornamentation, Removal and Installation).

9. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).

10. Remove the B-pillar side impact sensor.
For additional information, refer to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).

11. Remove the C-pillar side impact sensor.
For additional information, refer to: C-Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).

12. Release and position the floor covering to one side.

13. Release and position the inner rocker panel wiring harness to one side.

14. Remove the rocker panel outer moulding.

15. Remove the underfloor splash shield.

16. If the right-hand rocker panel front section is to be repaired, release and
position the underfloor wiring harness to one side.

17. Remove the front fender.
For additional information, refer to: Front Fender (501-27 Front End Sheet Metal Repairs, Removal and Installation).

18. Remove the front door.
For additional information, refer to: Front Door (501-03 Body Closures, Removal and Installation).

19. Remove the rear door.
For additional information, refer to: Rear Door (501-03 Body Closures, Removal and Installation).

20. Cut the new rocker panel front section from the new rocker panel service
panel.

For additional information, refer to: Rear Door (501-03 Body Closures, Removal and Installation).

21. Cut the new rocker panel rear section from the new rocker panel service
panel.




22. CAUTION: Care should be taken not to cut through into the inner
panels.

Using the new panel for reference and allowing for an overlap, cut the
old panel at the points indicated.

NOTE: The illustration may indicate either hand of the service panel, the opposite hand will be similar.

Item Description 1 Luggage compartment lid 2 Rear bumper cover 3 Rear bumper 4 Back panel 5 Rear bumper mounting L/H 6 Rear bumper mounting R/H 7 Quarter panel 8 Quarter panel lower extension 9 Rear wheelhouse outer 10 Spare wheel well 11 Rear floor side extension 12 Rear side member section 13 Rear side member closing panel section Time schedules, rear end

The following information shows the total time taken to replace single panels and complete assemblies. This time includes
removal of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panels are not included)

The times shown were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide
only.

Single panel times
Panel Description Hours Luggage compartment lid 7.5 Rear bumper cover 6.6 Back panel 9.4 Quarter panel L/H 23.2 Quarter panel R/H 24.2 Headliner remove and install 3.3 Rear window glass remove and install 1.7 Rear subframe and rear suspension remove and install 5.2 Combination panel replacement times

The following panel combination times show the total time to remove/install body panels, MET items and paint times based on
Metallic Clear Over Base Paint process, (blends to adjacent panels are not included).

Combination panel times
Panel Description Hours Luggage compartment lid Rear bumper cover Rear bumper Quarter panel Back panel Headliner remove and install Rear window glass remove and install Total Time L/H 35.2
R/H 35.9 Combination panel times
Panel Description Hours Luggage compartment lid Rear bumper cover Rear bumper Quarter panel L/H and R/H Back panel Headliner remove and install Rear window glass remove and install Total Time 44.7 Combination panel times
Panel Description Hours Luggage compartment lid Rear bumper cover Rear bumper Quarter panel Back panel Rear wheelhouse outer Rear side member section

Rear End Sheet Metal Repairs - Back Panel
Removal and Installation
Removal Published: 11-May-2011


1. NOTE: The back panel is manufactured from mild
steel.

The back panel is serviced as a separate weld-on panel, it
includes the back panel inner, right-hand and left-hand rear
bumper mountings, it also includes its weld studs.









2. The back panel is replaced in conjunction with:
Rear bumper cover
Rear bumper

3. For additional information relating to this repair procedure please see
the following: Health and Safety Precautions / 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).

4. Remove the rear bumper.
For additional information, refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).

5. Remove the battery.
For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

6. Remove the battery tray.

7. Disconnect the generator electrical connectors.

8. Remove the loadspace left-hand trim panel.
For additional information, refer to: Loadspace Trim Panel LH (501-05 Interior Trim and Ornamentation, Removal and Installation).

9. Remove any electrical components in the local area of repair to prevent
damage.

10. Remove the auxiliary junction box (AJB).
For additional information, refer to: Auxiliary Junction Box (AJB) (418-00 Module Communications Network, Removal and Installation).

11. Release the external back panel wiring harness and pull through into the
loadspace.

33.

















34. NOTE: The upper butt joint must be performed below
the 4 metal thickness parts of the door and rear window
apertures, (to enable spot welding back).

Cut the old panel at the points illustrated, allowing for
overlap, ensuring the final cut is performed below the 4
metal thickness parts of the door and rear window aperture.












NOTE: This procedure assumes that the door striker
reinforcement panel is undamaged. In this case, the
original remains on the vehicle and the new door striker
reinforcement panel is removed from the quarter panel
service panel and discarded.
Drill out the spot weld.









35. NOTE: Use a belt sander where there is no access to drill.
Drill out the spot welds.