Engine JAGUAR XFR 2010 1.G Workshop Manual
[x] Cancel search | Manufacturer: JAGUAR, Model Year: 2010, Model line: XFR, Model: JAGUAR XFR 2010 1.GPages: 3039, PDF Size: 58.49 MB
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NOTE: A = Non-deployed hinge; B = Deployed hinge
Item Description 1 Firing pin 2 Stabilizing link 3 Engine compartment lid leaf 4 Intermediate leaf 5 Body leaf The hinge system incorporates a number of leaves. This includes a leaf attached to the body, an intermediate leaf and a leaf
attached to the hood. During normal operation the hinge opens and closes using the hood and intermediate leaves. These are
attached together by a firing pin. When the actuators are fired the firing pins fail. This allows the hood and intermediate
leaves to separate and deploy the hood upwards. When the hood deploys the hood latches act as temporary hinges.
NOTE: The hinges deform during the deployment process and will need to be replaced.
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Item
Description 1
Deformation area - roof rail 2
Deformation area - roof 3
Deformation area - door rocker panel Body measurements
Measuring options
Comparison measurements can also be made on the outside of the body. Depending on the damage, comparison
measurements and diagonal measurements can be carried out using compass, telescopic rod, tape measure or ruler.
NOTE: The same reference points must be chosen on both sides when checking for changed dimensions (e.g.
bores, edges, beads/swage lines etc).
All of the important external body dimensions are listed in Tolerance Checks.
For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
Measurements with a measuring/straightening jig.
A measuring/straightening jig is required for accurate measurements of the body. The measuring systems are
categorised by their means of operation:
Mechanical measuring system.
Optical measuring system.
Quick and accurate measuring results can be obtained using computerised measuring systems.
A minimum of three intact measuring points on the body are required for measurements of length, width and height
dimensions.
In some cases this may mean making the measuring points accessible. All of these measuring systems can be used to make
body measurements, provided all the equipment is available.
Planning a repair
The following decisions have to be made before the repairs are started:
Does the vehicle need to be put on a straightening jig, or can it be straightened by other means?
Does the body need to be measured?
Do aggregates like engine or axles need to be removed? Impact energy is transferred via the side member to the A-pillar
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NOTE: It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell
intact.
Which body parts need to be renewed?
Which body parts can be repaired?
Obtaining spare parts
The availability of spare parts often determines how easily the body repairs can be carried out. The following procedure is
recommended:
Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine identification letters,
initial registration etc.
Establish all of the metal parts that need to be renewed.
Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.
Straightening repairs
WARNING: The use of heat when pulling to straighten body panels, (such as side members), is not recommended.
Longitudinal pulling, (hot or cold), is also not recommended. A small amount of side to side pull is permissible, (cold).
When any type of pulling or straightening operation is performed it is important to observe for any movement in adjacent
panels.
A panel must retain its strength and integrity, if there is any doubt the panel must be renewed.
Straightening repairs are often required to restore the body to its original shape after an accident. This can be done with:
Alignment jigs.
Universal straightening and measuring jigs.
Welding jig system.
The following points must be followed to Make sure that the repairs are carried out professionally and that all the dimensions
are correct after the repairs have been carried out.
Structure:
- The repair sequence depends on the individual repair plan (taking any necessary disassembly work into
account).
- Clean the attachment areas.
- Anchor the vehicle free of stress on the relevant system.
- Support the aggregates to take strain off the body.
- Decide on at least three measuring/mounting points that are undamaged and as far apart as possible (for basic
adjustment).
- Check the dimensions of the measuring/mounting points.
Straightening:
NOTE: Check dimensions and gaps continuously during straightening.
- A body is always straightened in the opposite direction to that of the impact. Always carry out straightening
repairs with the complete body shell assembled (do not cut out any parts beforehand). Carry out the
straightening work in several stages. This prevents the risk of over stretching or of welded joints tearing out.
During the individual straightening steps, relieve tension by striking with an aluminium hammer while the part is
subjected to a tensile load (in the area of pre-determined folding points, dents, welded joins etc.).
Special features:
- Ultra high strength steel cannot be straightened due to its brittleness and must always be replaced. www.JagDocs.com
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- 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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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)
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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
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NOTE: The illustration may indicate either hand of the service panel, the opposite hand will be similar.
Item Description 1 Front bumper cover 2 Front bumper 3 Front fender 4 Hood 5 Hood hinge 6 Hood latch panel 7 Hood latch panel mounting bracket 8 Front fender support bracket 9 Fender apron panel front extension 10 Fender mounting plate 11 Hood strut mounting bracket 12 Front wheelhouse section 13 Front bumper mounting 14 Front side member 15 Front side member section 16 Front side member closing panel 17 Front side member closing panel section 18 Front side member & suspension top mount assembly 19 Fender apron panel 20 Fender apron panel front section 21 Fender apron panel closing panel Time schedules, front end
The following information shows the total time taken to replace single panels and complete assemblies. This time includes
removal of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panels are not included).
The times shown were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide
only.
Single panel times
Panel Description Hours Hood 7.4 Front bumper cover 7.8 Front fender L/H 8.9 Front Fender R/H 9.1 Hood latch panel 6.6 Instrument panel console remove and install 5.3 Engine and suspension assembly remove and install 9.3 Combination panel replacement times
The following panel combination times show the total time to remove/install body panels, MET items and paint times based on
Metallic Clear Over Base Paint process, (blends to adjacent panels are not included).
Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender Hood latch panel Hood latch panel mounting bracket Front fender support bracket Total Time L/H 23.5
R/H 23.6 Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender L/H and R/H Hood latch panel Hood latch panel mounting bracket L/H and R/H Front fender support bracket L/H and R/H Total Time 26.8 www.JagDocs.com
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Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender Hood latch panel Front fender support bracket Fender apron panel Fender apron panel closing panel Front side member & suspension top mount assembly Fender mounting plate Front fender lower mounting Engine and suspension assembly remove and install Instrument panel console remove and install Total Time L/H 44.3
R/H 44.5 Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender L/H and R/H Hood latch panel Front fender support bracket L/H and R/H Fender apron panel L/H and R/H Fender apron panel closing panel L/H and R/H Front side member & suspension top mount assembly L/H and R/H Fender mounting plate L/H and R/H Front fender lower mounting L/H and R/H Engine and suspension assembly remove and install Instrument panel console remove and install Total Time 57.6 Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender Hood latch panel Front fender support bracket Front bumper mounting Front side member section Front side member closing panel section Total Time L/H 28.0
R/H 28.1 Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender Hood latch panel Front fender support bracket Front fender support bracket mounting Front fender lower mounting Front bumper mounting Front side member Front side member closing panel Front wheelhouse section Engine and suspension assembly remove and install Total Time L/H 37.6
R/H 37.4
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Front End Sheet Metal Repairs - Fender Apron Panel
Removal and Installation
Removal Published: 11-May-2011
1. NOTE: The fender apron panel is manufactured from mild
steel.
The fender apron panel is serviced as a separate weld-on
panel.
2. The fender apron panel is replaced in conjunction with:
Front bumper cover
Front fender
Fender apron panel closing panel
Hood
Hood hinge
Hood strut mounting bracket
Fender mounting plate
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.
For additional information, refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
5. Remove the hood hinge.
6. Remove the fender apron panel closing panel.
For additional information, refer to: Fender Apron Panel Closing Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
7. Disconnect the generator electrical connectors.
8. Remove the windshield wiper motor and linkage.
For additional information, refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
9. Remove the ECM (engine control module).
For additional information, refer to: Engine Control Module (ECM)
(303-14A, Removal and Installation) /
Engine Control Module (ECM) (303-14B Electronic Engine Controls - V6 3.0L Petrol, Removal and Installation) /
Engine Control Module (ECM) (303-14C, Removal and Installation). www.JagDocs.com
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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