JAGUAR XFR 2010 1.G Workshop Manual

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.

8. NOTE: If the front fender lower mounting is
undamaged it should be retained for reuse.
Remove the front fender lower mounting retaining bolt.












9. drill.
NOTE: Use a belt sander where there is no access to

Drill out the spot welds.










10. Separate the joints and remove the old panel.

Installation

1. Prepare the old and new panel joint surfaces.

2. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.


3. NOTE: Spot welds must be installed 5mm away from the
originals and in the same quantities, whenever this is
possible. Where this is not possible spot welds should be
installed adjacent to the original.
Spot weld.

4. Offer up the front fender lower mounting and loosely install
its fixing bolt. Check alignment, if correct, proceed to next
step, if not rectify and recheck before proceeding.












5. Tighten the front fender lower mounting fixing bolt.
Tighten to 10 Nm.

6. Dress all welded joints.

7. The installation of associated panels and components is the reversal of
removal procedure.

Front End Sheet Metal Repairs - Front Side Member
Removal and Installation

Removal Published: 11-May-2011


1. NOTE: The front side member is manufactured from High
Strength Low Alloy Steel, 350MPa, (HSLA350).

The front side member is serviced as a separate weld-on
panel, which includes the hood latch panel mounting
bracket. This method is to install a "long" section of the
service panel.








2. In this procedure, make sure that the vehicle is correctly aligned, it must
be placed on an approved alignment jig.

3. The front side member is replaced in conjunction with:
Front bumper cover
Front bumper
Front bumper mounting
Hood
Hood latch panel
Front fender support bracket
Front fender support bracket mounting
Front wheelhouse section
Front side member closing panel
Engine, transmission / transaxle, front subframe and front
suspension, as an assembly

4. 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).

5. Remove the hood.
For additional information, refer to: Hood (501-02 Front End Body Panels, Removal and Installation).

6. Remove the front wheelhouse section.
For additional information, refer to: Front Wheelhouse Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).

7. Remove the engine, transmission / transaxle, front subframe and front
suspension, as an assembly.
For additional information, refer to: Engine (303-01A, Removal) /
Engine (303-01B Engine - V6 3.0L Petrol, Removal) / Engine (303-01D, Removal) /
Engine (303-01E, Removal) /
Transmission - 2.7L Diesel (307-01, Removal) /
Transmission - TDV6 3.0L Diesel (307-01B Automatic Transmission/Transaxle - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L
Petrol, Removal) / www.JagDocs.com

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.

14.
15. Remove the bulk of the damaged panels by cutting through
the front side member and the front side member closing
panel as indicated.

















CAUTION: Care should be taken not to cut through
into the front side member or its inner lower reinforcement.
Cut the front side member closing panel as indicated.











16.
Drill out the spot welds from the front side member closing panel as
indicated.

17. NOTE: Retain the front side member closing panel remnant as it
will be used as a template.

Separate the joints and remove the front side member closing panel
remnant.


18. NOTE: Care should be taken not to cut through into
the front side member inner lower reinforcement.

Mark out the position where the front side member MAG
butt joint is to be made and cut through the panel at this
point as indicated.










19. NOTE: Where possible spot welds must be drilled out as indicated,
to allow the new panel to be spot welded on installation.
Drill out the spot welds as indicated.

20. NOTE: Retain the bolts for refitment on installation.

Remove the retaining bolts as indicated.












21. NOTE: Retain the front side member remnant as it will be used as
a template.
Separate the joints and remove the front side member remnant.

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