JAGUAR XFR 2010 1.G Workshop Manual

DP600 Dual phase steel - 600 MPa HSLA380 High strength low alloy steel - 380 MPa Boron Boron BH220 Bake hardened steel - 220 MPa Steels used in body structure - Rear end panels

MS1-4 Mild steel HSLA380 High strength low alloy steel - 380 MPa HSLA300 High strength low alloy steel - 300 MPa HI ST BAR High strength steel bar HSLA340 High strength low alloy steel - 340 MPa Other Other HSLA350 High strength low alloy steel - 350 MPa

Steels used in body structure - Floor panels





















































Item Type of Steel MS1-4 Mild steel HSLA380 High strength low alloy steel - 380 MPa HSLA340 High strength low alloy steel - 340 MPa BH260 Bake hardened steel - 260 MPa HSLA350 High strength low alloy steel - 350 MPa

Item Type of Steel Other Other NOTES:


When installing the A-pillar outer panel, the rocker panel and B-pillar outer panel, or the roof panel, they must be slot
brazed where they adjoin the A-pillar reinforcement upper.


The size of the slots are to be 20mm x 8mm and 30mm apart. Slots should be installed in accordance with this spacing.
Where this is not possible, due to the indents in the panel, the slot should be made in the location of the original spot weld.
Rocker panel and b-pillar outer panel



Item Description 1 Drill 2 x 8mm holes to form basis of slot 2 Mill out to form 20mm x 8mm slot 3 Slots spaced at 30mm intervals www.JagDocs.com

1 Drill 2 x 8mm holes to form basis of slot 2 Mill out to form 20mm x 8mm slot 3 Slots spaced at 30mm intervals

Item Description 1 Drill 2 x 8mm holes to form basis of slot 2 Mill out to form 20mm x 8mm slot 3 Slots spaced at 30mm intervals
NOTE: Mig brazing is carried out at a temperature of 650°C to 950°C. To avoid degradation of the ultra high strength
steel material properties, the temperature must be below 950°C.

Mig braze the slot(s) using a 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).
Dress the surface of the weld cap (brazed slot) with 60/80 grit belt sanders.

Accident damage and diagnosis

General notes

Exact diagnosis of the extent of the damage enables proper repair planning.
All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual.
The stability and strength properties of the body must be taken into account during body repairs. The body has exact
defined deformation patterns that must not be affected by any repair work. Roof panel

For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques or
methods are used in these areas then this can pose a fundamental threat to vehicle safety.
Hidden damage

As well as looking at external indicators like flaked off paint, it is vital to check for hidden body damage or deformation
that is not visible from the outside. Large attached parts like bumpers and inner fenders often need to be removed to
allow accurate assessment of damage to underlying body parts.
Gap dimensions

Gap dimensions offer another alternative for diagnosis by visual inspection. If any changes or misaligned edges are apparent,
then this usually indicates that the dimensions of the affected part are incorrect.
Changes in gap dimension



Item
Description 1
Gap too wide 2
Gap too small Impact effects on the body


NOTE: Vehicle components like drive shafts and trailer attachments transfer forces. If a vehicle is subjected to a rear
impact then all connected body parts and mechanical components (e.g. transmission mountings) should be thoroughly checked.
Electronic components should be checked to make sure that they still operate correctly.

Furthermore it is possible to deduce the overall extent of damage from the direction and magnitude of the impact forces. This
does however require extensive body-specific knowledge.

If, for instance, an impact occurs at the front left-hand side member, then the right-hand side member is usually also affected
as a result of the rigid body-shell design (crossmember). Often the length of this side member will not have changed, but
because of the rigid body-shell design it may have moved from its original position (often only by a very small amount). If any
deviations are present this can usually be detected by checking the gap dimensions between door and fender or by checking for
changes in dimension.

In the case of more severe impacts, the front part of the body cannot absorb all of the impact energy, and the passenger cell
is also deformed. Here the impact energy is transferred via the side member to the A-pillar (see diagram). This results in
deformations in the area of the roof and the door rocker panel.

The body reacts quite differently to side impacts where there is hardly any crumple zone. As the passenger cell is extremely
stable, there are comparatively few local deformations at the site of the impact. However, the impact forces are transferred to
the entire vehicle floor, which often results in so-called "banana damage", where the vehicle is bent into a banana shape.

Item
Description 1
Deformation area - roof rail 2
Deformation area - roof 3
Deformation area - door rocker panel Body measurements

Measuring options

Comparison measurements can also be made on the outside of the body. Depending on the damage, comparison
measurements and diagonal measurements can be carried out using compass, telescopic rod, tape measure or ruler.

NOTE: The same reference points must be chosen on both sides when checking for changed dimensions (e.g.
bores, edges, beads/swage lines etc).
All of the important external body dimensions are listed in Tolerance Checks.
For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
Measurements with a measuring/straightening jig.
A measuring/straightening jig is required for accurate measurements of the body. The measuring systems are
categorised by their means of operation:
Mechanical measuring system.
Optical measuring system.
Quick and accurate measuring results can be obtained using computerised measuring systems.

A minimum of three intact measuring points on the body are required for measurements of length, width and height
dimensions.

In some cases this may mean making the measuring points accessible. All of these measuring systems can be used to make
body measurements, provided all the equipment is available.

Planning a repair

The following decisions have to be made before the repairs are started:

Does the vehicle need to be put on a straightening jig, or can it be straightened by other means?
Does the body need to be measured?
Do aggregates like engine or axles need to be removed? Impact energy is transferred via the side member to the A-pillar

NOTE: It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell
intact.

Which body parts need to be renewed?
Which body parts can be repaired?
Obtaining spare parts

The availability of spare parts often determines how easily the body repairs can be carried out. The following procedure is
recommended:

Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine identification letters,
initial registration etc.
Establish all of the metal parts that need to be renewed.
Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.
Straightening repairs


WARNING: The use of heat when pulling to straighten body panels, (such as side members), is not recommended.
Longitudinal pulling, (hot or cold), is also not recommended. A small amount of side to side pull is permissible, (cold).

When any type of pulling or straightening operation is performed it is important to observe for any movement in adjacent
panels.
A panel must retain its strength and integrity, if there is any doubt the panel must be renewed.
Straightening repairs are often required to restore the body to its original shape after an accident. This can be done with:
Alignment jigs.
Universal straightening and measuring jigs.
Welding jig system.

The following points must be followed to Make sure that the repairs are carried out professionally and that all the dimensions
are correct after the repairs have been carried out.
Structure:
- The repair sequence depends on the individual repair plan (taking any necessary disassembly work into
account).
- Clean the attachment areas.
- Anchor the vehicle free of stress on the relevant system.
- Support the aggregates to take strain off the body.
- Decide on at least three measuring/mounting points that are undamaged and as far apart as possible (for basic
adjustment).
- Check the dimensions of the measuring/mounting points.
Straightening:

NOTE: Check dimensions and gaps continuously during straightening.

- A body is always straightened in the opposite direction to that of the impact. Always carry out straightening
repairs with the complete body shell assembled (do not cut out any parts beforehand). Carry out the
straightening work in several stages. This prevents the risk of over stretching or of welded joints tearing out.
During the individual straightening steps, relieve tension by striking with an aluminium hammer while the part is
subjected to a tensile load (in the area of pre-determined folding points, dents, welded joins etc.).
Special features:
- Ultra high strength steel cannot be straightened due to its brittleness and must always be replaced. www.JagDocs.com

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