wiring JAGUAR XFR 2010 1.G Workshop Manual
[x] Cancel search | Manufacturer: JAGUAR, Model Year: 2010, Model line: XFR, Model: JAGUAR XFR 2010 1.GPages: 3039, PDF Size: 58.49 MB
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Pedestrian Protection System - Pedestrian Protection System
Diagnosis and Testing
Principles of Operation Published: 09-Dec-2013
For a detailed description of the Pedestrian Protection System, refer to the relevant Description and Operation section in the
workshop manual.
REFER to: Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation).
Inspection and Verification
WARNINGS:
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED
BEFORE REPAIRING OR REPLACING ANY PEDESTRIAN PROTECTION SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER
SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT TWO MINUTES. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN PERSONAL INJURY.
Do not use a multimeter to probe the pedestrian protection system actuators. It is possible for the power from the
multimeter battery to trigger the activation of the actuator. Failure to follow this instruction may result in personal injury.
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.
NOTES:
If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the installation of a new module/component.
When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
It is advisable not to use a cellular phone or to have a cellular phone in close proximity when working on the pedestrian
protection system or components
Given the legal implications of a restraints system failure, harness repairs to pedestrian protection system circuits are
not acceptable. Where the text refers to "REPAIR the circuit", this will normally mean the replacement of a harness.
After 5 hood deployment events, a new Pedestrian Protection System Control Module (PPSCM) and wiring harness must be
installed.
1. Verify the customer concern
2. Visually inspect for obvious signs of damage and system integrity
Visual Inspection
Mechanical Electrical
Hood
Hood hinge
Hood deployment controls
Fuses
Wiring harnesses and connectors
Pedestrian Protection System Control Module (PPSCM)
Impact sensors
Hood deployment controls
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
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Cutting out body parts
Depending on how the parts are joined/connected, different tools are suitable for cutting/separating body parts.
NOTES:
All other parts like interior equipment, window glass etc. must be protected against flying sparks.
Make sure that the milling depth is set correctly to prevent the remaining flange from being weakened.
Rod sander
NOTE: Wear protective clothing. Protect any vulnerable body or glass areas against flying sparks. Remove explosive
materials from the vicinity.
Any spot welds that are inaccessible for the spot-weld mill (diameter > 8 mm) should be ground out using a rod sander. The
same applies to MIG spot welds or seams.
Short stroke saw
NOTE: Underlying metal parts, wiring harnesses, hoses etc. must not be damaged - remove them beforehand if
necessary. Spot-weld mill
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- Disadvantage: Scarring and hardening of the surface.
Flattening using a copper electrode.
- Small, sharp dents that face outwards can be worked on with a copper electrode.
Flattening using a flame and body files.
NOTE: When applied correctly, this method can be used with all the attached parts still in place (roof headlining,
wiring harnesses etc.).
- Small, soft dents (only slight stretching): Working at the edges of the dent in an inward spiral pattern, the dent
is heated with an oxyacetylene torch (torch size 1 - 2 mm, excess gas flame) to approx. 250° C.
- Working rapidly with a body file extracts heat from the edge area until the dent is flattened. Preferably alternate
between two files. This increases the amount of heat that can be extracted.
Safety measures
The electronic control modules (ECM) fitted to vehicles make it advisable to follow suitable precautions prior to carrying
out welding repair operations. Harsh conditions of heat and vibration may be generated during these operations which
could cause damage to the modules. In particular, it is essential to follow the appropriate precautions when
disconnecting or removing the airbag RCM.
Do not allow electronic modules or lines to come into contact with the ground connection or the welding electrode.
Seat belt anchorages are a safety critical. When making repairs in these areas, it is essential to follow design
specifications. Note that extra strength low alloy steel may be used for seat belt anchorages. Where possible, the
original production assembly should be used, complete with its seat belt anchorages, or the cut line should be so
arranged that the original seat belt anchorage is not disturbed.
All welds within 250mm (9.842) of seat belt anchorages must be carefully checked for weld quality, including spacing of
spot welds.
Remove the battery before carrying out welding work in its vicinity.
Utmost care must be taken when welding near the fuel tank or other components that contain fuel. If the tank filler
neck or a fuel line must be detached to allow access for welding work, then the fuel tank must be drained and removed.
Never weld, on components of a filled air conditioning system. The same applies if there is a risk of the air conditioning
system heating up.
Connect the ground connection of the electrical welder directly to the part that is to be welded. Make sure that there
are no electrically insulating parts between the ground connection and the welding point.
Adjacent vehicle parts and adjacent vehicles must be shielded against flying sparks and heat.
Pedestrian protection system
The pedestrian protection system is designed to mitigate injuries in a pedestrian collision with the vehicle. It does this by
utilizing a pair of pyrotechnic actuators to lift the hood away from the engine, creating a cushioned impact between the
pedestrian and the vehicle. It is essential that any repair or replacement operations do not affect the safe working of the
system.
For additional information, refer to: Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation).
Resistance spot welding
Where resistance spot welds have been used in production, they must be reproduced with new spot welds in replacement
where possible. All such reproduction spot welds should be spaced 25 to 30mm apart.
Setting up the equipment and co-ordinating the welding parameters.
Equipment:
- Follow the equipment manufacturer's instructions for the equipment settings.
- Select the correct electrode arms (as short as possible).
- Align the electrode arms and tips exactly.
- Electrode tips should be convex (rough shaping with a file, fine shaping with a sanding block).
Body:
- Make sure that the flanges to be joined lie perfectly flat to one another.
- Prepare a bare metal joint surface (inside and outside).
Notes on technique/method:
- Carry out a test weld on a sample piece of the material coated in welding paste.
- If any metal parts are located between the electrode arms then there will be a loss of induction and therefore
power (adjust current setting).
- The power needs to be adjusted for high-strength low alloy steel.
- Repeated welding on old welding points often leads to poor quality welds.
- Keep the electrode tips as near as possible to an angle of 90° to the contact surface.
- Keep the pressure on the electrodes for a short period after finishing the weld.
- The electrodes work best if their shape is convex. Clean the contact surface of the electrodes regularly.
Resistance spot welding panels where the total thickness is 3 mm or more
For all repairs to modern Jaguar vehicles, spot-welding equipment should be suitable for reliable welding of zinc-plated,
high-strength and high-tensile steels in three or more layers, up to 5 mm total thickness. If these requirements are not
fulfilled, plug welding must be used for safety reasons. The electrical specifications (current, resistance, heat) of the
spot-welding equipment have different validity, depending upon the type of equipment. Therefore, it is essential that the
manufacturer's instructions are observed with regard to the actual welding performance.
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Published: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Panel Closing Panel
Removal and Installation
Removal
1. NOTE: The fender apron panel closing panel is
manufactured from mild steel.
The fender apron panel closing panel is serviced as a
separate weld-on panel.
2. The fender apron panel closing panel is replaced in conjunction with:
Front bumper cover
Front fender
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 front fender.
For additional information, refer to: Front Fender (501-27 Front End Sheet Metal Repairs, Removal and Installation).
5. Disconnect the generator electrical connectors.
6. Remove the pedestrian protection hood actuator.
For additional information, refer to: Pedestrian Protection Hood Actuator LH (501-20C Pedestrian Protection System, Removal and Installation) / Pedestrian Protection Hood Actuator RH (501-20C Pedestrian Protection System, Removal and Installation).
7. Remove the secondary bulkhead panel.
For additional information, refer to: Secondary Bulkhead Panel LH - 3.0L NA V6 - AJ27 (501-02 Front End Body Panels, Removal and Installation) / Secondary Bulkhead Panel RH - 3.0L NA V6 - AJ27 (501-02 Front End Body Panels, Removal and Installation).
8. Remove the pedestrian protection actuator bracket.
9. Release and position the fuse box to one side.
10. Release and position the wiring harness to one side.
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Front End Sheet Metal Repairs - Front Fender Support Bracket
Removal and Installation
Removal Published: 11-May-2011
1. NOTE: The front fender support bracket is
manufactured from mild steel.
The front fender support bracket is serviced as a separate
weld-on panel.
2. The front fender support bracket is replaced in conjunction with:
Front bumper cover
Front fender
Hood latch panel
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 hood latch panel.
For additional information, refer to: Hood Latch Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
5. Disconnect the generator electrical connectors.
6. If the left-hand front fender support bracket is to be repaired, remove
the air conditioning (A/C) pipe.
7. Release and position the front fender support bracket wiring harness to
one side.
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Transmission (307-01A Automatic Transmission/Transaxle - V6 3.0L Petrol, Removal) /
Transmission - 4.2L (307-01, Removal) /
Transmission - V8 5.0L Petrol/V8 S/C 5.0L Petrol (307-01B Automatic Transmission/Transaxle - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L
Petrol, Removal) /
Front Shock Absorber (204-01 Front Suspension, Removal and Installation) /
Front Subframe - 2.7L Diesel (502-00, Removal and Installation) /
Front Subframe - V6 3.0L Petrol (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation) /
Front Subframe - 4.2L, Vehicles Without: Supercharger (502-00, Removal
and Installation) /
Front Subframe - 4.2L, Vehicles With: Supercharger (502-00, Removal
and Installation).
8. Remove the pedestrian protection hood actuator.
For additional information, refer to: Pedestrian Protection Hood Actuator LH (501-20C Pedestrian Protection System, Removal and Installation) / Pedestrian Protection Hood Actuator RH (501-20C Pedestrian Protection System, Removal and Installation).
9. If the drivers side front side member and suspension top mount is to be
repaired, remove the brake master cylinder and reservoir.
For additional information, refer to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation) /
Brake Fluid Reservoir (206-06 Hydraulic Brake Actuation, Removal and Installation).
10. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the fuel supply and return lines.
11. Release and position the front side member wiring harness to one side.
12. Remove any remaining miscellaneous components from the repair area.
13. NOTE: Retain the front fender support bracket
mounting if it is to be reused. If the front fender support
bracket mounting is to be renewed, it is not necessary to
remove or retain it.
Drill out the spot welds to remove the front fender support
bracket mounting.
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Actuation, Removal and Installation).
12. Remove the left-hand and right-hand front seats.
For additional information, refer to: Front Seat (501-10 Seating, Removal and Installation).
13. Remove the heater core and evaporator core housing.
For additional information, refer to: Heater Core and Evaporator Core Housing (412-01 Climate Control, Removal and Installation).
14. Remove the front safety belt retractor.
For additional information, refer to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
15. 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).
16. Remove the left-hand and right-hand front floor covering.
17. Remove the rear floor covering.
18. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the left-hand rear foot well duct.
19. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the right-hand rear foot well duct.
20. If the drivers side front side member and suspension top mount is being
repaired, remove the pedal box.
21. Release and position the insulating material at the inner bulkhead to
one side.
22. Release and position the inner bulkhead and floor panel wiring harness
to one side.
23. Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
24. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the left-hand under shield.
25. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the right-hand under shield.
26. If the left-hand front side member and suspension top mount assembly
is to be repaired, remove the fuel supply and return pipes.
27. For diesel engine vehicles only, if the left-hand front side member and
suspension top mount assembly is to be repaired, remove the fuel
cooler.
28. If the right-hand front side member and suspension top mount assembly
is to be repaired, release and position the underfloor wiring harness to
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one side.
29. If the right-hand front side member and suspension top mount assembly
is to be repaired, remove the front to rear brake pipes.
30. Remove the exhaust heat shields.
31. Release and position the front side member and suspension top mount
wiring harness to one side.
32. Remove any remaining miscellaneous components from the repair area
as necessary.
33. NOTE: Remove the sealer to expose the spot welds.
Drill out the spot welds as indicated.
34. NOTES:
Remove the sealer to expose the spot welds.
Use a belt sander where there is no access to drill. The three spot
welds at the rocker panel should be drilled from outside and right
through, to allow MAG plug welding on installation
Drill out the spot welds as indicated. www.JagDocs.com
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Lighting, Removal and Installation).
7. Remove the condenser core.
For additional information, refer to: Condenser Core - 2.7L Diesel
(412-03, Removal and Installation) /
Condenser Core - V6 3.0L Petrol (412-03 Air Conditioning, Removal and Installation) /
Condenser Core - 4.2L, Vehicles Without: Supercharger (412-03, Removal
and Installation) /
Condenser Core - 4.2L, Vehicles With: Supercharger (412-03, Removal
and Installation).
8. Remove the radiator.
For additional information, refer to: Radiator (303-03A, Removal and
Installation) /
Radiator (303-03B Engine Cooling - V6 3.0L Petrol, Removal and Installation) /
Radiator - Vehicles With: Supercharger (303-03C, Removal and
Installation) /
Radiator - Vehicles Without: Supercharger (303-03C, Removal and
Installation).
9. Remove the both hood latch panel braces.
10. Remove the cooling fan upper shroud.
11. Remove both crash sensors.
For additional information, refer to: Crash Sensor (501-20B Supplemental Restraint System, Removal and Installation).
12. Remove the both hood latches.
13. Remove the hood safety hook guide.
14. Remove both hood latch panel buffers.
15. Release and lay aside the hood latch panel wiring harness.
16. Remove the old panel.
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(414-01 Battery, Mounting and Cables, General Procedures).
6. Disconnect the generator electrical connectors.
7. Remove the windshield glass.
For additional information, refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
8. Remove the rear window glass.
For additional information, refer to: Rear Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
9. Remove the roof opening panel frame.
For additional information, refer to: Roof Opening Panel Frame (501-17 Roof Opening Panel, Removal and Installation).
10. Remove the driver and passenger side front scuff plate trim panels.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
11. Remove the driver and passenger side rear scuff plate trim panels.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
12. Remove the driver and passenger side air curtain modules.
For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).
13. Remove the rear seat backrest.
14. Remove the driver and passenger side rear safety belt retractors.
For additional information, refer to: Rear Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
15. Remove the rear center safety belt retractor.
For additional information, refer to: Rear Center Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
16. Remove the driver and passenger side RF filters.
17. Remove the diversity antenna module.
18. Remove the antenna.
For additional information, refer to: Navigation System Antenna (419-07 Navigation System, Removal and Installation).
19. Release and position the roof wiring harnesses to one side
20. Position the roof opening panel front and rear drain hoses to one side.
21. Remove the driver and passenger side roof mouldings.
22. Drill out the spot welds.
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