PID JAGUAR XFR 2010 1.G Owner's Manual

occupant position and the crash severity. To reduce the risk of an airbag module induced injury to a driver that is positioned
close to the steering wheel, the airbag module deploys radially. It has a non-azide propellant that reduces particulates and
effluents. It consists of a two stage inflator with separate chambers for the two inflation stages, each being independently
activated by the RCM. It has two electrical connectors that are color coded and mechanically keyed to the respective connector on the inflator.

Passenger Airbag Module



The passenger airbag module is controlled by the RCM which chooses between single or dual stage deployment, depending on the occupant status and the crash severity. It consists of a two stage inflator with two airbag electrical connectors to
accommodate the two stage inflation.

The heated gas inflator consists of a high-pressure mix of clean air and hydrogen gas, triggered by two separate ignition
squibs. It produces a controlled generation of clean gas to rapidly fill the airbag. It is classified as a stored flammable gas
(not as an explosive) and as such, has less restrictive storage and transportation requirements. It produces a very clean burn
and almost no particulates and is almost free of any toxins, making disposal or recycling much easier. Drivers Airbag Module

position sensor consists of a Hall effect sensor attached to the driver seat frame. While the ignition is on, the RCM supplies the sensor with power, and monitors the return current. When the seat frame moves forwards, the sensor moves over the edge
of the seat track, which changes the reluctance of the sensor. The change of current is detected by the RCM and used as a switching point. The switching point is when the center of the sensor is 3 ± 4 mm from the leading edge of the seat track.

When the driver seat is forward of the switching point, the RCM increases the time delay between firing the two stages of the inflator in the driver airbag. When the driver seat is rearward of the switching point, the RCM uses the normal time delay between firing the two stages.

Safety Belt Sensor

A safety belt switch is installed in the buckle of each front safety belt to provide the RCM with a status signal of the related safety belt(s). When the safety belt is unfastened the switch outputs a low current to the RCM. When the safety belt is fastened the switch outputs a high current to the RCM.
Pretensioners



Item Description 1 Front seat safety belt switch 2 Front seat safety belt pretensioner 3 Electrical connector The pretensioners are used to tighten the front safety belts during a collision to ensure the occupants are securely held in
their seats. A pretensioner is integrated into each front safety belt buckle and attached to a bracket on the inboard side of the
seat.

Each pretensioner has a tube containing propellant and a piston. The piston is attached to a steel cable, the opposite end of
which is attached to the safety belt buckle. A squib in the base of the tube provides an ignition source when triggered by a fire
signal from the RCM.
On receipt of a fire signal from the RCM, the squib ignites the propellant. The propellant produces nitrogen gas that rapidly expands to drive the piston along the tube, pulling the cable and drawing the buckle downwards.

Part N-umber
Body Repairs - General Information - Body Repairs
Description and Operation

General Information

Introduction Published: 11-May-2011

The body plays a significant role in the increasing trend of ever more rapidly changing model variants. The different customer
groups are strongly influenced by the design and shape of the body. At the same time the stability of the body plays the most
important part in ensuring passenger and driver safety. Lightweight construction, alternative materials, composite materials,
plastics and appropriate joining processes are all design features that characterise modern Jaguar vehicle bodies.

In terms of manufacturing technology, modern safety cell bodies can be produced almost without any problems. Jaguar
guarantee high quality standards by ensuring that mechanical strength properties are tried and tested in numerous computer
simulations, crash tests, by testing materials and by employing sophisticated manufacturing technologies. In the event of
repairs it is vital that the production quality standards are upheld. This requires a well-equipped workshop, and places
particular emphasis on the qualifications of the workshop technicians. Up-to-date knowledge of current manufacturing
technologies and continuous training on new repair methods and techniques are vital for high-quality body repairs. The model-
specific repair manuals and the general repair techniques provide valuable support when undertaking body repairs.

Always follow the repair instructions published in this manual. Failure to observe this instruction can result in serious
impairment of vehicle safety. All specified safety requirements must be met after the work has been carried out.

Vehicle design

The body

The XF adopts the latest generation steels, especially in the upper body – including high carbon steels, dual-phase,
hot-formed boron steels, and bake-hardened steels to form a vertical safety ‘ring’ around the occupant cell. As well as
combining strength with lightness, these steels improve corrosion resistance, by making best use of zinc and improving e-coat
paint flow – and new thinking means that in spite of their strength, the XF’s A and B-pillars are impressively slim, to the
benefit of both visibility and accessibility. Similarly, the lower sills are the first component on any Jaguar to use incredibly
strong, dual-phase DP600 steel.
The safety of the driver and the passengers is paramount for every body design. There are two key safety aspects in the body:
Safety passenger cell
Crumple zones

Safety passenger cell

Stable pillars, rocker panel and door profiles.
Side impact protection in the doors.
Doors are designed to open even in the event of extreme deformation.
Crumple zone

Dynamic absorption of deforming forces.
Protection of the passenger cell. www.JagDocs.com

- 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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