electrical JAGUAR XFR 2010 1.G Workshop Manual

7. CAUTION: Make sure no damage is occured to the
electrical connectors. Failure to follow this instruction may
result in damage to the vehicle.

Published: 11-May-2011
Supplemental Restraint System - Occupant Classification Sensor
Removal and Installation

Removal

WARNINGS:


To avoid accidental deployment, the restraints control module backup power supply must be depleted. Wait at least one
minute after disconnecting the battery ground cable(s) before commencing any repair or adjustment to the supplemental
restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these instructions may result in
personal injury.


Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag module. Failure to
follow this instruction may result in personal injury.


To minimize the possibility of premature deployment, do not use radio key code savers when working on the
supplemental restraint system. Failure to follow this instruction may result in personal injury.


To minimize the possibility of injury in the event of premature deployment, always carry a live air bag module with the
bag and trim cover pointed away from the body. Failure to follow this instruction may result in personal injury.


To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches which
have been ground bonded and with the trim cover facing up. Failure to follow these instructions may result in personal injury.


Never probe the electrical connectors of air bag modules or any other supplemental restraint system component. Failure
to follow this instruction may result in personal injury.


Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover and air
bags. Do not for any reason attempt to paint discoloured or damaged air bag module trim covers or instrument panel. Install a
new component. Failure to follow this instruction may result in personal injury.
CAUTIONS:


The front passenger seat occupant classification sensor is available only as a service kit. No attempt should be made to
replace individual components. Failure to follow this instruction may result in personal injury.


Check for correct operation of the front seat after completion of the procedure to make sure that the wiring harness has
not become trapped or stretched.
NOTES:


Note the routing of the seat harness.


Some variation in the illustrations may occur, but the essential information is always correct.

1. Make the air bag supplemental restraint system (SRS) safe.

Refer to: Standard Workshop Practices (100-00 General Information, Description and Operation).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

3. Refer to: Front Seat Backrest Cover (501-10 Seating, Removal and Installation).

4.
5. NOTES:


An audible click is heard when the clips are fully
latched.


Make sure the electrical connector is securely
connected.









6. www.JagDocs.com

17.
18.
19.













































WARNING: Do not probe supplemental restraint
system (SRS) electrical connectors. www.JagDocs.com

12.
















13.
14. CAUTION: Make sure that the wiring harness is routed
above the drive bar as shown, to avoid damage to the
wiring harness during movement of the front seat.














NOTES:


An audible click is heard when the clips are fully
latched.


Make sure the electrical connector is securely
connected.









Torque: 1.3 Nm

18.























19.
20. WARNING: Do not probe supplemental restraint
system (SRS) electrical connectors.




















21.
Refer to: Front Seat Backrest Cover (501-10 Seating, Removal and Installation).

22. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

19.

































20.
CAUTION: Note the fitted position of the component
prior to removal.


NOTE: Make sure that the component is installed to
the position noted on removal.




























CAUTIONS:


Make sure that the clips are correctly located.


Note the fitted position of the component prior to
removal.
NOTES:


Make sure that this component is installed to the
noted removal position.


Federal vehicles only.

Torque: 9 Nm

21. WARNING: The SRS electrical connectors are unique.
DO NOT force, or attempt to connect electrical connectors
to the wrong sockets.


CAUTION: Note the fitted position of the component
prior to removal.
NOTES:


Make sure that the component is installed to the
noted removal position. www.JagDocs.com

Pedestrian Protection System - Pedestrian Protection System
Diagnosis and Testing

Principles of Operation Published: 09-Dec-2013

For a detailed description of the Pedestrian Protection System, refer to the relevant Description and Operation section in the
workshop manual.
REFER to: Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation).
Inspection and Verification

WARNINGS:


TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED
BEFORE REPAIRING OR REPLACING ANY PEDESTRIAN PROTECTION SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER
SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT TWO MINUTES. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN PERSONAL INJURY.


Do not use a multimeter to probe the pedestrian protection system actuators. It is possible for the power from the
multimeter battery to trigger the activation of the actuator. Failure to follow this instruction may result in personal injury.


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 tested and/or the donor vehicle.
NOTES:


If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the installation of a new module/component.


When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.


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


It is advisable not to use a cellular phone or to have a cellular phone in close proximity when working on the pedestrian
protection system or components


Given the legal implications of a restraints system failure, harness repairs to pedestrian protection system circuits are
not acceptable. Where the text refers to "REPAIR the circuit", this will normally mean the replacement of a harness.


After 5 hood deployment events, a new Pedestrian Protection System Control Module (PPSCM) and wiring harness must be
installed.
1. Verify the customer concern

2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical Electrical
Hood
Hood hinge
Hood deployment controls
Fuses
Wiring harnesses and connectors
Pedestrian Protection System Control Module (PPSCM)
Impact sensors
Hood deployment controls
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

- 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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Item
Description 1
Rubber strip 2
Window frame 3
Adhesive 4
Window glass Removing and installing bonded windows

Safety measures

The following safety measures must always be followed to prevent personal injury:
- Wear protective gloves and arm protection.
- Wear protective goggles.

Preparations

Before cutting out a bonded window, undo and remove any attached parts in the cutting area that are at risk, e.g. trim
panels and decorative strips, as well as all electrical connections.
Mask any painted areas that are adjacent to the window.
Cut off any surplus adhesive, as this makes it easier to cut out the window.
Secure vertical windows against dropping out.
Cutting out the window

Cut into the adhesive bead at easily accessible points using the cutting tool.
Carefully guide the cutting tool around the window, cutting through the adhesive bead.
Avoid touching the window frame and the body flange.
Use cup suction tools to lift the cut-out window out of the window aperture.
General preparations for bonding

Follow the manufacturer's instructions.
Cut back the remaining adhesive bead on the metal flange to a residual height of about 1mm. Do not touch or clean the
cut surface afterwards.
Carefully rectify any paint damage (apply primer and top coat).
Renew the window stops as necessary.
Bonding the window glass
Apply an even bead of adhesive to the window or to the body flange.
Insert the window glass into the window aperture and centre it (2 technicians required).
Check the gaps.

NOTE: Open the windows and doors while the window is left to dry and do not move the vehicle (slamming doors
creates excess pressure which could cause the window to become loose).
Use adhesive tape to prevent the window from falling out or slipping.

Finishing operations

Reconnect all electrical connections and check that the components operate correctly.
Install the attached parts and check that the fit is accurate and secure.
- Carry out a visual inspection to Make sure that the gaps and joints are even.
Thoroughly clean the window glass.

Protective equipment and safety at work

Various safety measures and legal requirements must be met when carrying out repairs. All regulations relating to
health and safety at work must be followed. Adhesive bonding of bonded windows