engine light JAGUAR XFR 2010 1.G Service Manual

Published: 21-Dec-2012
Battery and Charging System - General Information - Quiescent Drain
Description and Operation

VEHICLE QUIESCENT CURRENT TESTING

On vehicles fitted with a Battery Monitoring System (BMS), the diagnostic routine for quiescent drain testing in the approved
Jaguar or Land Rover diagnostic system should be utilized.

If a customer complains of a vehicle battery that discharges continuously or when left for a prolonged period of time, it is
recommended that a quiescent drain test is performed as described below.

The battery drain should be measured using the approved Jaguar or Land Rover diagnostic system or a Digital Multi-Meter
(DVOM). A procedure for quiescent drain measurement using the diagnostic system is available in the Diagnosis and Testing
section of the Workshop Manual. The vehicle should be in the locked/armed state (for example vehicle alarm fully armed), all
doors, engine and luggage compartment lids are open and latched (so as to appear closed from an electrical point of view).
The test should take place after the vehicle has entered shutdown mode. The time taken for this to occur after the ignition is
switched off varies according to model (Refer to the Topix On line resource for details).

When the vehicle is armed, the effect of the security system Light Emitting Diode (LED) flashing is to cause a pulsation in the
measured current drain. In this case, either the average current should be taken (using a Digital Multi- Meter (DVOM) with an
averaging system) or the current reading taken, ignoring the brief high current peaks.
EQUIPMENT
Approved Jaguar or Land Rover diagnostic system with current probeOR Digital Multi-Meter (DVOM) with current probe.

METHOD OF MEASUREMENT

Using an Approved Jaguar or Land Rover Diagnostic System.
1. Switch off all electrical loads and ensure that the ignition is off
2. Connect the current probe to the approved Jaguar or Land Rover diagnostic system
3. Calibrate the probe
4. Install a clamp around the battery lead/junction box lead
5. Go to the Quiescent Current Testing section in this procedure

Using a digital multimeter

Do not use an in-line DVOM to measure the quiescent drain on vehicles fitted with an electronic throttle (for example XK 2006
onwards). The current exceeds the maximum amount the fuse in the DVOM is capable of handling.
1. Switch off all electrical loads and ensure that the ignition is off
2. Connect the current probe to the digital multmeter
3. Calibrate the probe
4. Install a clamp around the battery lead/junction box lead
5. Go to the Quiescent Current Testing section in this procedure

QUIESCENT CURRENT TESTING

1. Switch ignition to ‘on’ or select ignition mode in keyless vehicles and switch to ‘off’ (do not crank)
2. Remove key from ignition switch (if equipped)
3. Open and latch all doors, hood and luggage compartment lid
4. Lock the vehicle using the remote function on the remote handset. (Single lock only to avoid volumetric alarm arming)
5. Remove any other potential electrical drains such as accessories plugged into accessory sockets
6. Record the amperage readings after the shutdown period referenced in the Topix on line resource for details. Note all
cars from 10MY onwards and XK from 07MY and XF from 08MY should be less than 30mA after 30 minutes
7. Record the final reading on the battery report form

The preferred method of testing following an excessive current consumption figure is to use a current probe around individual
junction box leads to the various suspected circuits to identify a potential cause. This is in preference to the old method of
removing fuses for the following reasons:

The drain may be caused by a module remaining active and preventing the quiescent drain from reducing to normal
levels
The drain may be caused by a relay winding that is activated. Pulling the fuse can allow this to ‘reset’ and the drain will
be lost and go un-diagnosed

QUIESCENT DRAIN - TYPICAL VALUES


NOTE: The quiescent drain after the initial shutdown period should not exceed the value shown in the table.

Jaguar Quiescent Drain Values
MODEL SHUT DOWN PERIOD (minutes) TYPICAL VALUES BATTERY DRAIN (mA) XJS 3.2 60 <30 Sovereign 3.2 60 <37.3

1. Turn on the ignition but do not start the vehicle
2. Switch on the headlamps on high beam for a minimum 3 minutes
3. Switch off the headlamps
4. Wait a minimum of 5 minutes before recording test results for any battery measurements

PINPOINT TEST A : VOLTAGE DROP TEST CONDITIONS DETAILS/RESULTS/ACTIONS A1: GROUND CIRCUIT
NOTE: This test checks for high resistance between the battery terminal and the battery clamp 1 Start the engine, turn on the following: (1) ) Air conditioning

(2) ) Blower fan on full speed
(3) Headlights on main beam

(4) Heated screen - rear

(5) Heated screen - front (if installed)
(6) Heated seats (if installed) 2 Connect the multimeter between the battery negative terminal and the battery clamp as shown in picture below (do not
disconnect the battery at this stage) 3 Set the multimeter to read DC voltage and record the reading Is reading equal to or below 0.1 volts? Yes
GO to A2. No
Switch all electrical loads and engine off, return the vehicle to
an ignition off condition. Disconnect the battery negative
clamp, clean clamp and terminal then reconnect and repeat test
GO to A1. A2: POWER CIRCUIT
NOTE: This test checks for high resistance between the battery terminal and the battery clamp 1 Start the engine, turn on the following: (1) ) Air conditioning
(2) ) Blower fan on full speed

(3) Headlights on main beam

(4) Heated screen - rear
(5) Heated screen - front (if installed)

(6) Heated seats (if installed) 2 Connect the multimeter between the battery positive terminal and the battery clamp as shown in picture below (do not
disconnect the battery at this stage) 3 Set the multimeter to read DC voltage and record the reading Is reading equal to or below 0.1 volts? Yes
Carry out midtronics battery test procedure
No
Switch all electrical loads and engine off, return the vehicle to
an ignition off condition. Disconnect the battery power clamp,

Published: 11-May-2011
Daytime Running Lamps (DRL) - Daytime Running Lamps (DRL) - System
Operation and Component Description
Description and Operation



CENTRAL JUNCTION BOX (CJB) System Operation

The CJB (central junction box) controls the operation of the DRL (daytime running lamps). The DRL are activated once the CJB detects an ignition on power mode 6 signal.
The CJB also monitors the lighting control switch and the auto lamps feature and overrides the DRL if required.


DAYTIME RUNNING LAMPS - CANADA Component Description

The DRL for this market use full intensity low beam headlamps. The side marker lamps, tail lamps and license plate lamps will be on, but instrument cluster illumination will be off. DRL are active when the following parameters are met:
PARK is not selected on the electronic transmission selector
Electronic Parking Brake (EPB) is off
Power mode 6 (ignition on) detected by the CJB The CJB receives an engine running signal The lighting control switch is in the off or side lamps position.
NOTES:


If the lighting control switch is moved to the headlamp position, DRL are deactivated and normal side lamp and headlamp functionality is operational.


When DRL are active, the headlamp flash function using the left hand steering column multifunction switch will operate normally.

The high beam headlamp function using the left hand steering column stalk switch will be deactivated. When the transmission
is in PARK, DRL are turned off. This is to reduce battery discharge during long periods of engine idling in cold climate conditions. When the electronic transmission selector is moved from the PARK position, normal DRL functionality is restored.
DAYTIME RUNNING LAMPS - DENMARK, HOLLAND, NORWAY, SWEDEN, FINLAND AND POLAND


NOTE: DRL for Poland is on vehicles from 2008MY.

DRL for these markets use full intensity low beam headlamps. Side lamps and license plate lamps will be on, but instrument cluster illumination will be off. DRL are active when the following parameters are met:
Power mode 6 (ignition on) detected by the CJB The CJB receives an engine running signal The lighting control switch is in the off position.


NOTE: When DRL are active, the headlamp flash function using the left hand steering column multifunction switch will operate normally. The high beam headlamp function using the left hand steering column stalk switch will be deactivated.

If the lighting control switch is moved to the side lamp or headlamp positions, DRL are deactivated and normal side lamp and headlamp functionality is operational.

AUTOMATIC HEADLAMPS

On vehicles fitted with the automatic headlamps feature, DRL are overridden if the lighting control switch is in the 'Auto' position and the CJB receives a signal from the rain/light sensor to activate the exterior lights.
When the CJB receives a signal to de-activate the automatic headlamps feature the DRL function is restored providing the parameters for DRL activation are met.

The battery backed sounder is disconnected (partial trigger only).
The vehicle battery is disconnected on a vehicle fitted with a battery backed sounder (partial trigger only).
The inclination sensor detects a change in vehicle attitude.
The intrusion detection module detects movement within the cabin.



Door Modules Component Description

The door modules provide the interface between the door latch-motors, the door latch-switches and the CJB. The door modules
provide door switch status information and enable the door latch-motors on request from the CJB or the keyless vehicle
module.

Keyless Vehicle Module

The keyless vehicle module interfaces with the Central locking, Radio Frequency (RF) receiver and collects RF signal information
which is transmitted from the Smart Key. This information is translated into commands which are passed on the medium speed
CAN bus to the:

CJB,
RJB,
door modules, and
instrument cluster.
The keyless vehicle module also monitors:
2 interior antennae,
1 luggage compartment antenna,
a rear bumper antenna, and
4 door handle antennae if the passive entry system is fitted.

On vehicles with passive entry, the additional fast latch motors are controlled via the keyless vehicle module and the locking
status is passed to the CJB on the medium speed CAN bus.

Instrument Cluster

The instrument cluster controls the alarm indicator, and in conjunction with the ECM (engine control module), the engine
immobilization. The ECM controls the engine crank and fuel functions and the instrument cluster processes the valid
transponder information.

Alarm Indicator

The alarm indicator is a LED (light emitting diode) located in the body of the sunload/light sensor. When the ignition is off the
indicator gives a visual indication of the active anti-theft system to show if the alarm system is active or not active. Operation
of the alarm indicator is controlled by the instrument cluster which varies the flash rate of the LED to indicate the system
status of the alarm and the immobilization systems.

When the ignition is on, the indicator provides a visual indication of the status of the passive anti-theft (engine
immobilization) system. If the immobilization system is operating correctly, the LED will be illuminated for 3 seconds at
ignition on and then extinguish. If a fault exists in the immobilization system, the LED will be either permanently illuminated
or flashing for 60 seconds. This indicates that a fault exists and fault code has been recorded. After the 60 second period the
LED will flash at different frequencies which indicate the nature of the fault.
Refer to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation).
Passive Anti-Theft Horn

The passive anti-theft horn is hardwired to the CJB which activates the horn when the alarm is triggered.

Battery Backed Sounder

Operation of the battery backed sounder is controlled by the CJB on the LIN bus. The sounder is also connected with a
permanent battery supply via the CJB. An integral, rechargeable battery powers the sounder if the battery power supply from
the CJB is interrupted.

Dependant on vehicle, a incitation sensor is incorporated into the battery backed sounder, to monitor vehicle attitude, see
Inclination Sensor.

Inclination Sensor

The CJB monitors the inclination sensor and will activate the alarm system if the vehicle is being raised.

Intrusion Detection Module

The intrusion detection module comprises an ultrasonic sound wave sensor which monitors the vehicle's interior.

The intrusion detection module is activated with volumetric mode which in turn is enabled when the vehicle is double locked.
The vehicle can be locked and alarmed with the module de-activated if a pet is to be left in the vehicle for example by single-

Module Network System Function Vehicle Location
Steering wheel
clockspring LIN Passes digital messages from the steering wheel
audio switches to the instrument cluster. Behind the steering wheel,
on the upper steering
column.
Instrument cluster LIN Receives digital signals from other vehicle systems. On the driver's side of the
instrument panel.
Battery backed sounder LIN Activated by CJB when alarm trigger is received. In the LH side of the engine compartment, near the
bulkhead.
CJB LIN Controls body functions and power distribution. On the RH 'A' pillar.
RJB LIN Controls body functions and power distribution. On the RH of the luggage compartment.
Battery monitoring
system module

Intrusion detection
module LIN Monitors the condition and charge of the vehicle
battery.

LIN Detects movement in the vehicle interior and
activates the anti-theft system. On the vehicle battery
positive terminal in the
luggage compartment.
In the front overhead
console.
Rain/light sensor LIN Detects ambient light levels and moisture on the
windscreen for operation of the automatic
headlamps and wiper systems.
Start control module LIN Used to identify the Smart Key - component of the
keyless start system.
Rear view camera LIN Passes digital images data from the rear view
camera to the RJB On the inside of the
windshield behind the interior
rear view mirror.
In the lower instrument panel
on the driver's side.
In the luggage compartment
lid trim finisher.
Driver's window switch LIN Controls operation of the driver's window. In the driver's door trim
panel.
Electronic transmission
selector LIN Sends selector position to the TCM. In the floor console. TCM LIN Receives selector position information to control the Inside the transmission and


Information control
module

Media Oriented
System Transport
(MOST) transmission.

Contains controls for the entertainment system and
gateway between audio system and other vehicle
systems. accessible by removal of the
fluid pan.
In the instrument panel
below the integrated control
panel.
Integrated control
panel MOST Contains controls for the entertainment system. In the instrument panel.
Digital Audio Broadcast MOST Receives digital radio broadcasts. In the LH side of the luggage (DAB) receiver (SDARS
NAS only)
Bluetooth® phone
module compartment, above the
keyless vehicle module.
MOST Controls operation of the Bluetooth® phone system. Below the LH front seat, adjacent to the portable
audio module.
Amplifier/tuner MOST Provides amplification for the entertainment systems In the LH side of the luggage and reception of radio RF broadcasts.
Navigation computer MOST Reads map data from a DVD (digital versatile disc)
to calculate and display visual route guidance
information via the TSD and audible guidance via the
amplifier to the driver. compartment.
In the LH side of the luggage compartment.
Touch Screen Display
(TSD) MOST Provides the driver interface to the entertainment,
navigation and driver personalization functions. In the center of the
instrument panel.
TV tuner MOST Controls the reception of television signals and
audio/visual inputs.
Portable Audio Module MOST Controls the auxiliary inputs for additional audio
inputs via the portable audio interface. In the LH side of the luggage compartment.
Below the LH front seat, adjacent to the Bluetooth®
phone module.
MOST diagnostic
connector MOST Allows for diagnostic fault detection of the MOST
ring. Below the air ducting in the
floor console.
Refer to Communications Network section for further details.
Refer to: Communications Network (418-00 Module Communications Network, Description and Operation).

8 LH door module 9 Exterior mirror control switches
System Operation
The rear view mirrors comprise an interior mirror mounted to the windshield, and an exterior mirror mounted on each front door
cheater. The types of mirrors and associated operating functions installed depend on the specification and trim level of the
vehicle.

Interior Mirrors

The interior rear view mirror is provided as a manual dimming or an electrically operated automatic dimming type.

The manual dimming mirror comprises a prismatic glass housed within a surrounding case that is attached with a ball joint
connector to the mirror stem. Manual dimming of the mirror is achieved using the lever mounted on the underside of the mirror
body. Operating the lever will tilt the mirror head from the 'day' position to the 'night' position.

The automatic dimming mirror comprises an electro-chromatic glass housed within a surrounding case that is attached with a
ball joint connector to the mirror stem. The mirror stem incorporates an 8-pin electrical connector that is connected to the roof
panel wiring harness. The wiring harness provides hardwired and a LIN connection to the CJB.
Light sensors are mounted on the front and rear of the mirror surround case. The sensors control the automatic dimming
feature to reduce glare from the headlights of following vehicles.

The automatic dimming function is permanently active when the ignition is in power mode 4 (Accessory) and power mode 6
(Ignition). The forward facing light sensor monitors the ambient light level at the front of the vehicle; the rearward facing light
sensor monitors the light level coming from the rear of the vehicle. When light from the rear of the vehicle exceeds the
ambient light level from the front of the vehicle, the automatic dimming circuit darkens the interior mirror surface.

Automatic dimming is inhibited when reverse gear is selected to provide the driver with maximum vision. On vehicles with
automatic transmission, the reverse gear signal is provided by the TCM (transmission control module) via the high speed CAN bus to the CJB. The CJB then provides a power feed to the mirror. On vehicles with manual transmission, the reverse gear signal is provided by a transmission switch that is hardwired to the CJB.
Exterior Mirrors

Electrically operated and heated exterior mirrors are installed as standard. Depending on the specification and trim level of the
vehicle, the following options are available:

Power fold (switch pack operated feature) and auto fold (remote handset operated feature)
Memory recall
Reverse gear mirror dip
Mirror heating
Exterior mirror lamps.

The power fold/auto fold feature is available only when power fold mirrors are installed to the vehicle.

The mirrors can be configured to automatically fold when the vehicle is locked and unfold when unlocked. This feature can be
enabled or disabled via the Vehicle settings area of the touch screen:

Select 'Settings' from the touch screen Home menu.
Select ' Security/Vehicle'
Select 'Windows/Mirrors'
Select Power Fold 'On' or 'Off' as appropriate.

The pasenger side mirror can be configured to automatically dip when reverse gear is selected. This feature can be enabled or
disabled via the Vehicle settings area of the touch screen:

Select 'Settings' from the touch screen Home menu.
Select ' Security/Vehicle'
Select 'Windows/Mirrors'
Select Reverse dip 'On' or 'Off' as appropriate.

The LH door mirror incorporates an ambient air temperature sensor that is hardwired to the ECM (engine control module). The ECM is connected to the CJB and other control modules via the high speed CAN bus. The sensor provides information to the ECM that is then transmitted on the medium speed CAN bus for use by other control modules. On vehicles installed with a high-line instrument cluster, the CJB transmits the temperature signal to the instrument cluster that provides a display of the ambient temperature to the driver.
The exterior mirror lamps are controlled by the interior lighting function.

The door mirrors are controlled using a switch pack located on the driver's door. The switch pack contains 2 non-latching mirror
select switches labeled 'L' and 'R' and a 4-way directional joystick. The switch pack is connected to the driver door control
module via the LIN bus. The driver and front passenger door control modules are connected via the medium speed CAN bus. A hardwired connection between each door control module and the corresponding door mirror, provides the supply and ground
paths for the mirror motors.
Each exterior door mirror incorporates 2 motors to control horizontal (left/right) and vertical (up/down) adjustments. www.JagDocs.com

memory positions to be stored and 'set' button with integral LED (light emitting diode). The seat, door mirror and steering
column motors have position sensors which provide feedback to driver's seat module.

Once the driver's seat, steering column and exterior mirrors have been adjusted, the vehicle is able to memorize these
settings for future use by using the following procedure:
Push the memory 'SET' button, the LED in the switch will illuminate Press the memory button 1 or 2 to memorize the current settings. The LED will extinguish, and a chime will sound to confirm that the settings have been memorized. If the ignition is on, power mode 6, the message center will display a
confirmation message.
The positions can be recalled by pressing the applicable button 1 or 2.
Stall Detection

Seat, steering column and mirror motors are deemed to have stalled if there is no change in the inputs that are received from
the corresponding feedback sensors for 200 ms (seat).

If a stall condition is detected then the drive to that motor is cancelled for the remainder of that memory operation (memory
recall) or until the switch is re-selected (manual movement).

If the motor movement has stopped due to loss of sensor feedback, either stall or sensor failure, then that motor may be
activated again, to move past the stall position, by re-selecting the appropriate switch and pressing for longer than 2 seconds.
This allows control of the motor to be maintained if sensor feedback is lost.

Upon re-selection of movement, if sensor pulses are detected then the motor will continue to be driven until the switch is
released or another stall condition is detected. If sensor feedback is not detected then the motor is only driven for 0.5 second
and then stops until the switch is released and then pressed again, when a further 0.5 second of activation is permitted, and
so on, this is known as inch mode.

For all seat motor manual movements, whenever a motor is driven and a stall occurs, the memory control module records the
position at which the stall occurred. If movement occurs beyond a stall position, then that position is erased from the control
modules memory. This will always allow movement past a previously recorded stall position once movement has been
registered beyond that position. This is the case for both manual and memory movement.
Initialization

When a replacement driver's seat module is fitted, it should be calibrated a Jaguar approved diagnostic system so that the
module can learn the seats absolute position.
Battery Monitor

If the battery voltage drops below 10.5 Volts, then the driver's seat module ignores all requests for a memory recall until the
battery voltage has reached 11.5 Volts. This will conserve as much power in the vehicle battery as possible to enable engine
cranking.

REAR SEATS - DESCRIPTION

The rear seat features a single piece cushion and a 60/40 split squab. Two latches are secured to the rear bulkhead by a pair
of M8 bolts to retain the seat squabs in the upright position. The latches can be released to fold down the individual cushions
by pulling a cable release located below the rear window parcel shelf in the luggage compartment.
ISOFIX fastening points are attached to the vehicle floor to provide secure fastening for compatible child seats.

A centrally mounted center arm rest can be folded down from the 60% squab. The arm rest contains two drinks holders.

Published: 11-May-2011
Wipers and Washers - Wipers and Washers - System Operation and
Component Description
Description and Operation

Control Diagram

NOTE: A = Hardwired; N = Medium speed CAN (controller area network) bus; O = LIN (local interconnect network) bus



Item Description 1 Battery 2 EJB (engine junction box) 3 Wiper motor 4 Headlamp washer pump 5 Rain/Light sensor 6 Washer reservoir fluid level switch

Driver Passenger Applicable Pretensioner Driver airbag Passenger airbag Fastened - -
Fired at pretensioner
threshold Fired at belt fastened
threshold - Unfastened - - Not fired
Fired at belt unfastened
threshold - - Fastened Occupied allow
Fired at pretensioner
threshold -
Fired at belt fastened
threshold - Fastened
Unoccupied inhibit/empty Fired at pretensioner
threshold - Not fired - Unfastened Occupied allow Not fired -
Fired at belt unfastened
threshold Unfastened
Unoccupied inhibit/empty Not fired - Not fired The battery disconnect unit is fired:

At driver and passenger airbag belt fastened threshold in a frontal impact
At the driver and passenger side impact threshold in a side impact
At the rear impact threshold in a rear impact.

Crash Signal

When the RCM outputs any of the fire signals it also outputs a crash signal to the RJB and the ECM (engine control module) on the high speed CAN. The crash signal is also hardwired to the ECM and the RJB. The instrument cluster picks up the crash signal from the high speed CAN and gateways it to the LCM (lighting control module). On receipt of the crash signal, the RJB goes into a crash mode and the ECM cuts the power supply to the fuel pump relay. In the crash mode, the RJB: Activates all of the unlock signals of the vehicle locking system, even if the vehicle is already unlocked.
Ignores all locking/superlocking inputs until it receives an unlock input, when it returns the locking system to normal
operation.
Activates the interior lamps. The interior lamps remain on permanently until they are manually switched off at the lamp
unit, or the RJB crash mode is switched off and they return to normal operation. Disables the rear window child lock input until the crash mode is switched off.
Sends a crash message to the LCM, to activate the hazard flashers. The hazard flashers remain on until cancelled by the hazard warning switch or the crash mode is switched off.
The RJB crash mode is switched off by a valid locking and unlocking cycle of the locking system.


Restraints Control Module Component Description



The RCM is installed on the top of the transmission tunnel, in line with the B pillars, and controls operation of the SRS (supplemental restraint system). The main functions of the RCM include:
Crash detection and recording
airbag and pre-tensioner firing
Self-test and system monitoring, with status indication via the airbag warning lamp and non-volatile storage of fault
information.
The RCM determines which elements of the SRS are to be deployed by using two internal areas:

- 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.
www.JagDocs.com