JAGUAR XFR 2010 1.G Workshop Manual

Seam Sealer

A heat cured, PVC based sealant is applied to specific joint seams during factory assembly. This material is not suitable for
service use and during repair and should be substituted by an approved seam sealer.


NOTE: Where seams are inaccessible following the reassembly or fitting of components, ensure that a paste-type seam
sealer is applied to such seams. Certain seams also become inaccessible after the completion of panel repairs. In such
instances apply seam sealer and paint before final assembly.

Apply seam sealers after the application of primer and before the application of top coat. The sealer must form a continuous
bead, with the profile of the bead dependent on the type of seam. If the seam sealer is applied with a brush take particular
care to maintain the required coverage of the seam.

Ensure that all accessible repair seams are sealed following a repair. Damage to a vehicle often flexes areas of the body
remote from the impact. As a result the seam sealer in these areas may be disturbed by subsequent straightening and repair
operations. Check all seams in the vicinity of the area undergoing repair for evidence of cracked seam sealer, then clean out as
required and apply fresh seam sealer using the following procedure:

Clean the affected seam and re-treat any exposed metal areas with a suitable etch phosphate primer.
Treat affected area with an etch-acid primer.
Apply appropriate seam sealer as necessary.
apply appropriate colour coat (and under body sealer as applicable).

Provided access is adequate, apply seam sealer to both sides of a repair joint. Where access is limited to one side only, (e.g.
box section), treat the affected box member with cavity wax.

Cavity Wax

After repairs, always re-treat these areas with an approved cavity wax. In addition, treat all interior surfaces which have been
disturbed during repairs whether they have been treated in production or not. This includes all box members, cavities and door
interiors.

Before wax injection, ensure that the cavity to be treated is free from any contamination or foreign matter. Where necessary,
clear out any debris.
Ensure that cavity wax is applied after the final paint process and before refitting any trim components.

During application ensure that the wax covers all flanges and seam areas and that it is adequately applied to all repaired
areas of both new and existing panels.

It should be noted that new panel assemblies and complete body shells are supplied without wax injection treatment. Ensure
that such treatment is carried out after repairs.
Effective cavity wax protection is vital. Always observe the following points:
Complete all paint refinish operations before wax application.
Check the spray pattern of injection equipment.
Mask all areas not to be waxed.
Remove body fixings, such as seat belt retractors, if contamination is at all likely.
Move door glasses to fully closed position before treating door interiors.
Treat body areas normally covered by trim before refitting items.
Check that body and door drain holes are clear after the protective wax has dried.
Keep all equipment clean, especially wax injection nozzles.

Part N-umber
Body Repairs - Water Leaks - Water Leaks
Description and Operation

General Published: 11-May-2011

If water leaks occur after bodywork repairs, the cause can be established using the checks described below. A
systematic and logical procedure is required to locate water leaks. Before beginning extensive checks, a thorough visual
inspection must be carried out.
Visual Inspection
- The following characteristics may indicate existing leaks:
- Check the clearance and accurate fit of ancillary components such as the hood, tailgate, liftgate, doors, and so
on.
- Check for correct fit and possible damage to sealing elements such as blanking plugs, rubber door seals, and so
on.
- Check water drain holes for unhindered flow.
Various tests can be used to provide further information on possible leaks:
- Water test
- Washer test
- Road test
- Chalk (powder) test

Practical execution of tests and checks

Water test


NOTE: Never aim a jet of water directly at a rubber seal.

Carry out the water test with a second person present (in the passenger compartment).
Use variable washer nozzles (concentrated water jet to fine spray mist).
Start in the lower section and spray the whole area, working upwards in stages.

Washer test

Further tests can be carried out in the washer system.
Some leaks originate here, or only occur here.
The relevant passenger compartment should be checked using a torch during the wash procedure.
Road test

If no leaks are located during the tests above, road tests should be carried out on wet roads.
Road tests under various conditions:
- At various speeds.
- On various road surfaces (asphalt to cobbles).
- With loaded or unloaded vehicle.
- Driving through puddles (splash water).

Chalk test (powder test)

In this test, the clamping load and the bearing surface of the seal are checked.
Performing the test:
- Dust the door seal with powder or coat with chalk.
- Coat the bearing surface of the seal with a thin film of Vaseline.
- Slowly close the door and open it again.
- Check the width and continuity of the imprint on the door seal.

Other test equipment

Other equipment such as stethoscopes, UV lamps, special mirrors or ultrasound measuring instruments can be used to
locate leaks.

Rectifying the leak using recommended tools, auxiliary equipment and materials

Tools and auxiliary equipment:
- Dry, absorbent cloths
- Variable washer nozzle
- Torch, fluorescent tube
- Mirror
- Compressed air
- Seal lip installer
- Wet/dry vacuum cleaner
- Sealing compound compressor
- Remover for interior trim
- Cutter blade or pocket knife
- Wedge (wood or plastic)
- Hot air blower
- Special mirror for concealed leaks

- Air flow checker
- Sealing compound (tape and plastic compound)
- Multi-purpose sticker
- Clinched flange sealer
- Window sealing compound
- Water shield (PVC)
- Double-sided adhesive tape for water shield
- Methylated spirit (available from trade outlets)
- PU adhesive
- Silicone remover
- Tar remover

Water leaks according to mileage or running time
Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing factors are:
Servicing and maintenance of seals:
- No maintenance, lack of maintenance or incorrect maintenance
- Using an incorrect agent
Damaged seals:
- As a result of aging, wear or incorrect handling/assembly.
Heavy soiling of the vehicle:
- Heavy soiling of a vehicle can seriously impair the function of water drainage channels in particular, and also of
rubber seals.
Age-related factors:
- Environmental factors
- UV radiation
- Extreme climatic conditions
Corrosion can have a serious impact on bodywork, in particular as a result of:
- Lightly or heavily rusted seal carriers
- Rusted body seal welds
- Perforation corrosion

Water leaks after body repairs
If a vehicle develops a leak after body repairs, the following points must be taken into consideration in particular:
The correct seating of ancillary components and their seals must be checked.
The correct alignment of doors/tailgate and liftgate must be checked. The associated seals must not be damaged and
must be installed correctly.
Check that panel seams are correctly sealed.
The correct seating of rubber grommets must be checked.
Directly-glazed windows must have correct and complete bonding.

Water drainage system

If a vehicle develops water leaks, then areas into which water is routed or drained should be checked first.

1
Water drainage, front 2
Water drainage, side and rear 3
Roof drainage 4
Engine compartment drainage Water leaks, diagnosis and corrective action: Front passenger compartment

Windscreen

Diagnosis:
- Ingress of water into A-pillar area or instrument cluster area and rocker panel area.
Cause:
- Breaks in adhesive beads
Corrective action:
- The breaks in adhesive beads can be located from inside by using compressed air. The leak can be identified
from outside by the escaping air.
- The second test method is by means of a water test. The outer trims must be raised carefully using a plastic
wedge. The leak should be located from inside by a second assistant. Water drainage system (illustration for reference only)
www.JagDocs.com

Side windows

In the case of side windows, the same problems can arise as for a windscreen. The same corrective actions must therefore be
used.
Door seal

Diagnosis:
- Water ingress in the lower part of the interior door trim or in the rocker panel area.
Cause:
- The water shield fitted behind the interior door trim exists to drain off water that has entered the door via the
drainage holes, either downwards or outwards. If the water shield seal is damaged or has been fitted incorrectly,
then water can get into the passenger compartment.
- In addition to this, the drainage holes can become clogged with leaves, dirt or excess cavity protection agents.
Water gathers in the door and ingresses into the passenger compartment.
- Check water shield for damage or correct fitting.
- If the water shield needs to be re-bonded, then approved seam sealer should be used.
- Before the water shield is installed, the drainage holes must be checked for unhindered flow.
Door seals

Diagnosis:
- Ingress of water into the rocker panel area
Cause:
- Insufficient clamping load between seal and door.
Corrective action:

NOTE: When adjusting the clamping load, the profile alignment of the relevant components must always be taken
into consideration.


NOTE: Do not realign the flange too far in the direction of the door, as this can reduce the bearing surface of the
seal to the door.
- Check clamping load:
- The easiest way to check the clamping load of a seal to the respective bearing surface is by means of a paper
strip test. This consists of trapping strips of paper at various points between the door and the seal, and fully
closing the door. If it is possible to pull out the paper with no great resistance, then the clamping load is too
low.
- Adjust the clamping load:
- The clamping load is normally adjusted using the striker. When doing so, the edge alignment from the door to
the side panel, or from the front door to the rear door must be taken into account.
- Another setting method is to realign the panel flange for the seal mounting. The clamping load is increased by
moving the flange towards the door.
- Check the bearing surface:
- Apply chalk evenly to the surface of the seal. Evenly coat the bearing surface of the door with Vaseline.
- Close the door fully, the lock must engage. Open the door. The imprint of the chalk (bearing surface) can be
identified in the film of Vaseline.
- The bearing surface should be at least 5mm across at all points.

Other causes:
- The door seal must completely seal the door where it meets the bodywork.
- Water can ingress directly or indirectly into the interior of the vehicle if the seal is damaged at any point.
Corrective action:
- A damaged or worn door seal must always be renewed in full.
- When renewing the seal, the following must be taken into account:
- Always fit the seal first in the area of the narrow radii (corner points).
- Next, secure the seal to the flange evenly by tapping lightly with a rubber hammer. The installed seal must not
be kinked at any point.

NOTE: The prescribed length of a seal must not be shortened.
Other cause:
- The door seal is attached to the welded flange all the way round. If this welded flange is uneven or damaged at
any point (usually in areas with small radii) then this point could be subject to leaks.
- A stretched seal carrier can also cause a leak.
- In both cases, water gets into the vehicle interior under the seal carrier.
Corrective action:
- Align the deformed welded flange using a hammer and anvil block, prevent and, if necessary, repair any paint
damage.
Sliding roof/tilting roof

Diagnosis:
- Ingress of water at sliding roof aperture
Cause:
- The sliding roof/tilting roof is installed in a water trap. The water drains off via the water trap, water drain holes
and drain hoses. The drain hoses lead downwards on both sides via the A-pillar and B-pillar.
- The drain holes or drain hoses can become clogged with leaves, dirt, underbody protection and so on.
Corrective action:

NOTE: In the case of a sliding or tilting roof, the external rubber seal and the lock actuator or latch mechanism
must be checked first of all.
- Check the water trap for leaks.
- Check the drain hoses for leaks and for correct connection to the water trap.
- Check the drainage system for unhindered flow, and blow out with compressed air if necessary.
- Check the external seal and the correct adjustment of the sliding roof.

Liftgate

Diagnosis:
- Ingress of water into rear headlining area and luggage area.
Cause:
- The leak problems of the tailgate and liftgate correspond to those of the doors.
- In addition to this, the area to be sealed is much bigger. The routing holes for cables and hoses must also be
sealed.
- The rubber grommets for the routing holes must be checked for damage and correct seating (fully unhooked).
- The mounting points of the liftgate hinges may leak.
Corrective action:
- Check the rubber grommets and renew if necessary.
- Check the hinge mounting points, and re-seal with sealing compound if necessary.
Forced air extraction

Diagnosis:
- Ingress of water into side luggage compartment area
Cause:
- The forced air extraction for the vehicle interior is located in the quarter panel lower extension.
- The rubber flap of the forced air extraction must be able to move freely.
Corrective action:
- Remove the forced air extraction.
- Check the seal area between the bodywork and housing, as well as the rubber flap.
- Renew seal if necessary.

Rear window
Diagnosis:
- Ingress of water into the luggage compartment area
Cause:
- Rear window leaking.
- Check for leak in the same way as for leaking windscreen.

Published: 11-May-2011
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body and
Frame
Description and Operation

Front End Body Dimensions

NOTES:


All dimensions shown are in millimetres (mm).


Dimensions shown to holes, are always taken from/to the hole centre. They are also always to the body panel surface,
not to the top of bolts or components.

Item From To Dimension A Headlamp RH inboard fixing hole Front fender LH forward fixing hole 510.5 B Transmission LH mounting, forward stud Engine RH mounting, forward fixing hole 987.2 C Transmission LH mounting, rear stud Engine RH mounting, forward fixing hole 1091












































Item From To Dimension A Front fender RH, rear fixing hole Front fender LH, rear fixing hole 1549.6 B Front fender RH, centre fixing hole Front fender LH, centre fixing hole 1518.1 C RH Headlamp top inboard fixing hole LH Headlamp top inboard fixing hole 771

Item From To Dimension A Front bumper RH top inboard fixing hole Front bumper LH top inboard fixing hole 770.9 www.JagDocs.com

A Instrument panel carrier RH top fixing hole Instrument panel carrier LH top fixing hole 1416 B Instrument panel carrier RH bottom fixing hole Instrument panel carrier LH bottom fixing hole 1416 Side Panel Dimensions



Item From To Dimension A Front door top hinge, top fixing hole Rear door top hinge, top fixing hole 1129.4 B Front door top hinge, top fixing hole Rear door bottom hinge, top fixing hole 1133.8 C Front door bottom hinge, top fixing hole Rear door top hinge, top fixing hole 1206.7 D Front door bottom hinge, top fixing hole Rear door bottom hinge, top fixing hole 1122.4