Fuel JAGUAR XFR 2010 1.G Workshop Manual

Body Closures - Fuel Filler Door
Removal and Installation

Removal


CAUTION: Do not align the bowl using the hinge arm.


NOTE: Removal steps in this procedure may contain installation details.


1. Published: 11-May-2011
















Installation
















2. CAUTION: Protect the surrounding paintwork to avoid
damage.

Release the clip.

1. To install, reverse the removal procedure. www.JagDocs.com

Body Closures - Fuel Filler Door Assembly
Removal and Installation

Removal


CAUTION: Do not align the bowl using the hinge arm.


NOTE: Removal steps in this procedure may contain installation details. Published: 11-May-2011


1. WARNING: Do not work on or under a vehicle supported only by a jack.
Always support the vehicle on safety stands.
Raise and support the vehicle.

2. Refer to: Fuel Tank Filler Pipe (310-01, Removal and Installation).

3.
4.

1 RH (right-hand) front door handles, latch and motor 2 RH rear door handles, latch and motor 3 Fuel filler door and motor 4 Luggage compartment emergency key barrel 5 Luggage compartment latch and motor 6 LH (left-hand) rear door handles, latch and motor 7 Door emergency key barrel - LH front door only 8 LH front door handles, latch and motor

8 Door latch - RH rear passenger 9 Door ajar switch - RH rear passenger 10 Door latch - LH (left-hand) rear passenger 11 Door ajar switch - LH rear passenger 12 Door module - LH rear passenger 13 Door ajar switch - driver door 14 Door latch - driver door 15 Door module - driver door 16 CJB (central junction box) 17 Central-locking radio-frequency receiver 18 Keyless vehicle module Luggage Compartment Lid and Fuel Filler Door Locking

Note: A = Hardwired; N = Medium speed CAN 1 Battery 2 Megafuse (250 A) 3 RJB 4 Locking motor - fuel door 5 Keylesss vehicle module 6 Emergency key barrel - luggage compartment 7 Release latch - luggage compartment lid 8 Ajar switch - luggage compartment lid 9 Fascia switch - luggage compartment lid 10 Instrument cluster 11 CJB Passive Entry System

door modules.

Locking of the vehicle is performed by pressing one of the buttons located on each exterior door handle, with the Smart Key
within a one meter range of the vehicle. When the door handle button is pressed, the keyless vehicle module transmits a
low-frequency signal via the low-frequency handle antenna to the Smart Key. The Smart Key transmits a radio frequency signal
which is verified by the keyless vehicle module and allows the doors to be locked or double locked and the alarm system to be
armed.

To double lock the vehicle, the button on the exterior door handle must be pressed twice within three seconds, with the Smart
Key within one meter range of the vehicle.

If a door, engine-compartment lid or the luggage compartment lid is ajar when an attempt to lock the vehicle is made, an error
tone is emitted and no locking action will occur.
Refer to: Anti-Theft - Active (419-01A Anti-Theft - Active, Description and Operation).


Engine Compartment Lid Latches Component Description

Two engine-compartment lid latches are located on the front crossmember. An engine-compartment lid release lever is located
below the instrument panel on the left-hand 'A' pillar and is connected with a cable to the latches. An engine-compartment lid
ajar switch is integrated in the engine-compartment lid latch.

Door Latches

The door latches are located at the rear of each door and engage with a striker on the adjacent pillar. Each door latch motor
assembly contains micro-switches for lock, unlock and door ajar. Motors provide for the central door locking and the double
locking feature. The electrical control for the door latch components is provided by the CJB and RJB via the driver's and
passenger door modules.

The interior door handles are connected by a cable to the latch release mechanisms. The interior door handles also incorporate
a locking facility to allow the doors to be locked from inside the vehicle when all the doors are closed. If a door is ajar the
locking feature is inhibited.

Luggage Compartment Lid Latch

The luggage compartment latch is attached to the bottom of the lid. The latch can be released electrically by pressing the
interior release button located on the outboard side of driver's lower knee bolster; a release button is also provided on the
Smart Key. There is also a release switch on the underside of the luggage compartment lid finisher.

On NAS vehicles an emergency release cable is attached to the latch. This allows the latch to be manually opened by pulling a
handle located in the luggage compartment lid interior trim.

Fuel Filler Door

The fuel filler door is electrically locked by a motor located on the fuel door housing. The fuel door is locked when the vehicle
is locked and alarmed. The fuel door can be opened when the vehicle is unlocked or locked:

via an interior handle,
via drive-a-way locking,
via the lock switch on the fascia,
via the external door key barrel. www.JagDocs.com

Published: 18-Mar-2014
Handles, Locks, Latches and Entry Systems - Locks, Latches and Entry Systems
Diagnosis and Testing

Principle of Operation

For a detailed description of the locks, latches and entry systems and operation, refer to the relevant Description and
Operation section of the workshop manual. REFER to: Handles, Locks, Latches and Entry Systems (501-14, Description and
Operation).

Inspection and Verification


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 checked and/or the donor vehicle


NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests

1. Verify the customer concern, to be sure the correct issue is investigated
2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical Electrical
Incorrectly aligned door(s), hood or tailgate
Fuel filler door lock actuator
Hood release handle
Hood release cables
Hood latch(es)
Exterior door handle(s)
Interior door handle(s)
Cable(s)
Tailgate release switch
Rear window release switch
Fuses
Wiring harness
Wiring connector(s)
Door lock actuator(s)
Remote transmitter (key-fob or smart key)
Central locking switches
Controller Area Network (CAN) circuits
Radio frequency (RF) receiver
Central junction box (CJB)
Loose or corroded connections
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
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index
Symptom Chart


NOTE: Complete the diagnostic steps below to confirm any concern prior to replacing any component

Symptom Possible Causes Action The message center indicates that the
hood, the luggage compartment is
open when it appears to be closed
Incorrect striker
alignment/adjustment
Ajar switch circuit short circuit to
ground
Ajar switch failure
Check/adjust the strikers as
necessary
Check for DTCs indicating an ajar
switch fault. Refer to the DTC index Vehicle indicates a miss-lock when the
hood, luggage compartment appear to
be closed Fuel flap does not lock/unlock
Fuel flap cable detached from body
Fuel flap actuator detached from
mounting bracket
Fuel flap actuator disconnected
Fuel flap actuator failure
Check the condition and installation
of the fuel flap cable
Check the security of the fuel flap
actuator and bracket
Check the security of the actuator
electrical connector
Check for DTCs indicating a fuel flap
actuator fault. Refer to the DTC
index Door(s) will not unlatch/open when
using outside door handle
Exterior door handle
condition/installation
Exterior release cable disconnected
from exterior door handle or door
latch
Check the exterior door handle
condition and installation
Check the condition and security of
the exterior release cable
Single door will not open from the

Driver Passenger Applicable Pretensioner Driver airbag Passenger airbag Fastened - -
Fired at pretensioner
threshold Fired at belt fastened
threshold - Unfastened - - Not fired
Fired at belt unfastened
threshold - - Fastened Occupied allow
Fired at pretensioner
threshold -
Fired at belt fastened
threshold - Fastened
Unoccupied inhibit/empty Fired at pretensioner
threshold - Not fired - Unfastened Occupied allow Not fired -
Fired at belt unfastened
threshold Unfastened
Unoccupied inhibit/empty Not fired - Not fired The battery disconnect unit is fired:

At driver and passenger airbag belt fastened threshold in a frontal impact
At the driver and passenger side impact threshold in a side impact
At the rear impact threshold in a rear impact.

Crash Signal

When the RCM outputs any of the fire signals it also outputs a crash signal to the RJB and the ECM (engine control module) on the high speed CAN. The crash signal is also hardwired to the ECM and the RJB. The instrument cluster picks up the crash signal from the high speed CAN and gateways it to the LCM (lighting control module). On receipt of the crash signal, the RJB goes into a crash mode and the ECM cuts the power supply to the fuel pump relay. In the crash mode, the RJB: Activates all of the unlock signals of the vehicle locking system, even if the vehicle is already unlocked.
Ignores all locking/superlocking inputs until it receives an unlock input, when it returns the locking system to normal
operation.
Activates the interior lamps. The interior lamps remain on permanently until they are manually switched off at the lamp
unit, or the RJB crash mode is switched off and they return to normal operation. Disables the rear window child lock input until the crash mode is switched off.
Sends a crash message to the LCM, to activate the hazard flashers. The hazard flashers remain on until cancelled by the hazard warning switch or the crash mode is switched off.
The RJB crash mode is switched off by a valid locking and unlocking cycle of the locking system.


Restraints Control Module Component Description



The RCM is installed on the top of the transmission tunnel, in line with the B pillars, and controls operation of the SRS (supplemental restraint system). The main functions of the RCM include:
Crash detection and recording
airbag and pre-tensioner firing
Self-test and system monitoring, with status indication via the airbag warning lamp and non-volatile storage of fault
information.
The RCM determines which elements of the SRS are to be deployed by using two internal areas:

1 Bodyshell High Strength Steels

Most modern vehicles are constructed from a number of different steels, partly to obtain an optimised body (collision, safety,
rigidity, fuel economy, etc).

Steels are divided into several groups according to their tensile and yield strength, that is to say the force necessary to bring
about plastic deformation of the material.
Yield Summary

Yield is the strength at which the metal changes from elastic to plastic in behaviour, the point of no return.
Tensile Summary

Tensile strength is the breaking strength of a material when subjected to a tensile (stretching) force, the point of no return.

Dual Phase (DP) steel falls into both the very high strength steel (VHSS) and extra high strength steel (EHSS) classifications,
dependant on grade of DP.

Steel Type Yield Strength Mild steel (MS) Maximum yield point up to 180 MPa High strength steel (HSS) Steel with a yield point up to 280 MPa VHSS Steel with a yield point up to 380 MPa EHSS Steel with a yield point up to 800 MPa Ultra high strength steel (UHSS) Steel with a yield point greater than 800 MPa Welding Ultra High Strength Steel

UHSS requires welding equipment which can achieve the following equipment settings.
Spot Welding
Information to follow.
MIG Brazing
When mig-brazing use the following type of welder meeting the specifications shown: Fronius Trans Plus Synergic 2700 4
R/Z/AL MIG Welder, with CuSi3 (DIN 1733) 1.0mm filler wire with setting parameters 4, which is 92 Amps, Wire feed 4.6
m/min. Shielding gas L1 = pure Argon (DIN 439). Vehicle Design

- 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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