fuel type JAGUAR XFR 2010 1.G Workshop Manual

Viton

In common with many other manufacturers' vehicles, some components installed to the Jaguar range have 'O' rings, seals or
gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets
and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and
Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400º C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.

'O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.
DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal
or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may
be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement
of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a
limewater (calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final
cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding (and cutting).
Resistance Welding (Spot Welding)
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Arc Welding
This process emits a high level of ultraviolet radiation which may cause arc-eye and skin burns to the operator and to other
persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn,
and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is
believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens
is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied
coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly
in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined
spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases,
with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultraviolet emission is much less than that from arc welding,
and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may
be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.

General Information - Road/Roller Testing
Description and Operation Published: 11-May-2011

Road or roller testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine starting
and stopping, pre-driving checks, on-test checks to final checks on completion of the test is given in this section.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those
items particularly relevant to the system/s being checked can be extracted.

Pre - Test Checks


WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not
attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and
rectified.

It is suggested that pre-test checks, and functional tests of those systems/circuits which affect the safe and legal operations
of the vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test.

Engine oil level
Engine coolant level
Tires, for correct pressure, compatible types and tread patterns, and wear within limits
There is sufficient fuel in the tank to complete the test
All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any
apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of
the test
Starting the Engine


CAUTION: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond
half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or
with the accelerator pedal at full travel whilst the engine is cold.
With the ignition switched off, check:
The parking brake is applied
The transmission selector lever is in Park
All instrument gauges (except fuel gauge) read zero

With the ignition switched on, check:

Ignition controlled warning lamps come on
Engine coolant temperature gauge registers a reading compatible with the engine coolant temperature
Fuel gauge registers a reading appropriate to the fuel level in the tank
The operation of the parking brake and brake fluid level warning lamps

On Road or Roller Test Check:


CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If
the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found
and rectified.
Initial gear engagement is smooth
Parking brake control operates smoothly and the parking brake releases quickly and completely
Transmission takes up the drive smoothly, without judder
The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or
heavy, and engine speed returns to idle correctly
There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun
conditions
Steering operation, including power steering, is smooth, accurate, not excessively heavy or with excessive free play or
vibration. Does not pull to one side and self centres smoothly after cornering
Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer register the correct readings or
operate correctly
Switches and controls operate smoothly and positively, warning lamps operate correctly and the direction indicator
control self cancels when the steering is returned to the straight ahead position
Heating and ventilation systems work correctly and effectively
Brake operation and efficiency

Brake Testing


WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust
which is hazardous to health, see Health and Safety Precautions.

DTC Description Possible Causes Action P007D-00
Charge Air Cooler
Temperature Sensor Circuit
High (Bank 1) - No sub type
information
NOTE: - Circuit TMAP_TEMP_SENSOR
-

Charge air cooler temperature
sensor (Bank 1) circuit short circuit
to power, open circuit, high
resistance
Charge air cooler temperature
sensor (Bank 1) failure
Refer to the electrical circuit
diagrams and check charge air cooler
temperature sensor (Bank 1) circuit
for short circuit to power, open
circuit, high resistance
Check and install a new charge air
cooler temperature sensor (Bank 1)
as required. Refer to the warranty
policy and procedures manual, or
determine if any prior approval
programme is in operation, prior to
the installation of a new
module/component P0087-00
Fuel Rail/System Pressure -
Too Low - No sub type
information
NOTE: - Circuit
FUEL_HIGH_PRESS_SENSOR -

Fuel rail pressure sensor circuit
short circuit to ground, open
circuit, high resistance
Fuel rail pressure sensor failure
Fuel lines leaking or restricted
Fuel pump failure
Using the manufacturer approved
diagnostic system check datalogger
signal, Fuel Rail Pressure Sensor -
High Range Sensor Voltage (0x0377)
Refer to the electrical circuit
diagrams and check fuel rail pressure
sensor circuit for short circuit to
ground, open circuit, high resistance
Check for fuel pump related DTCs.
Check fuel lines for leakage or
restriction
Check and install new fuel rail
pressure sensor as required. Check
and install a new fuel pump as
required. Refer to the warranty policy
and procedures manual, or determine
if any prior approval programme is in
operation, prior to the installation of
a new module/component P0088-00
Fuel Rail/System Pressure -
Too High - No sub type
information
NOTE: - Circuit
FUEL_HIGH_PRESS_SENSOR -

Fuel rail pressure sensor circuit
short to each other, high
resistance, short circuit to power
Fuel rail pressure sensor failure
Using the manufacturer approved
diagnostic system check datalogger
signal, Fuel Rail Pressure Sensor -
High Range Sensor Voltage (0x0377)
Refer to the electrical circuit
diagrams and check fuel rail pressure
sensor circuit for short to each other,
high resistance, short circuit to
power
Check and install new fuel rail
pressure sensor as required. Refer to
the warranty policy and procedures
manual, or determine if any prior
approval programme is in operation,
prior to the installation of a new
module/component P008A-00
Low Pressure Fuel System
Pressure - Too Low - No sub
type information
NOTE: - Circuit
LOW_PRESS_FUEL_PRESS_SENSOR -

Low pressure fuel sensor circuit
failure, short circuit to ground,
short circuit to power, open circuit
Fuel pump driver module circuit
short circuit to ground, short circuit
to power, open circuit
Low pressure fuel
Fuel pump driver module failure
Using the manufacturer approved
diagnostic system check datalogger
signal, Fuel Rail Pressure - Low
Range Sensor Voltage (0x0376)
Check fuel system for leakage
Refer to the electrical circuit
diagrams and check low pressure
fuel sensor circuit for short circuit to
ground, short circuit to power, open
circuit
Refer to the electrical circuit
diagrams and check fuel pump driver
module circuit short circuit to
ground, short circuit to power, open
circuit
Check and install a new low pressure
fuel sensor as required. Check and
install a new fuel pump driver
module as required. Refer to the
warranty policy and procedures
manual, or determine if any prior
approval programme is in operation,
prior to the installation of a new
module/component

DTC Description Possible Causes Action B10A0-11
Wiper/ Washer Switch -
Circuit short to ground
Wash/wipe circuit - short to
ground
Refer to the electrical circuit diagrams and check
wash/wipe circuit for short to ground B10A0-15
Wiper/ Washer Switch -
Circuit short to battery
or open
Wash/wipe circuit - short to
power, open circuit
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check wash/wipe circuit for short to power,
open circuit B10A6-11
Main Light Switch -
Circuit short to ground
Master lighting switch circuit
- short to ground
Refer to the electrical circuit diagrams and check
master lighting switch circuit for short to ground B10A6-15
Main Light Switch -
Circuit short to battery
or open
Master lighting switch circuit
- short to power, open
circuit
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check master lighting switch circuit for short
to power, open circuit B112B-87
Steering Wheel Module -
Missing message
Steering wheel module
failure - slave node not
responding
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check the clockspring LIN circuit for short,
open circuit. Suspect the clockspring, check and
install a new clockspring as required, refer to the
new module/component installation note at the
top of the DTC Index B115C-7A Transfer Fuel Pump -
Fluid leak or seal failure
Fuel pump system fault
Check for fuel system jet pump or jet pump fuel
level sensor fault B1A85-15
Ambient Light Sensor -
Circuit short to battery
or open
Autolamp sensor circuit -
short to power, open circuit
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check autolamp sensor circuit for short to
power, open circuit B1B01-00
Key Transponder - No
sub type information
Operator only cycles one key
During transponder key
programming the instrument
cluster, smartcard docking
station or key loses
power/circuit failure
Faulty key during key
programming
Unable to program
transponder key due to
noise/EMC related error
Ensure all keys to be programmed are available.
Refer to electrical circuit diagrams and check
power and ground supply circuits to all relevant
modules. Replace faulty key and repeat key
programming. Check CAN network for
interference/EMC related issues B1B01-05
Key Transponder -
System programming
failures
Error following SCU
replacement
Smartcard docking station
power and ground supply
circuits - short, open circuit
LIN fault
Instrument cluster power
and ground supply circuits -
short, open circuit
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Perform the Immobilisation application
from the Set-up menu using the manufacturer
approved diagnostic system. Refer to the
electrical circuit diagrams and check smartcard
docking station power and ground supply circuits
for short, open circuit and instrument cluster
power and ground supply circuits for short, open
circuit. Check LIN communications between
smartcard docking station and instrument cluster B1B01-51
Key Transponder - Not
programmed
LIN fault
Instrument cluster power
and ground supply circuits -
short, open circuit
Key fault
Smartcard docking station
power and ground supply
circuits - short, open circuit
Attempted to program a non
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Check LIN communications between
smartcard docking station and instrument
cluster. Refer to the electrical circuit diagrams
and check smartcard docking station power and
ground supply circuits for short, open circuit and
instrument cluster power and ground supply
circuits for short, open circuit. Confirm www.JagDocs.com

DTC Description Possible Causes Action B1261-13
Fuel Flap/Door Release
Switch - Circuit open
Fuel filler flap digital
input signal circuit -
open circuit
Refer to the electrical circuit diagrams and check
fuel filler flap digital input signal circuit for open
circuit B1A79-11
Rear Fog Lamp - Circuit
short to ground
Rear fog lamp control
circuit - short to ground
Carry out any pinpoint test associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check
rear fog lamp control circuit for short to ground B1A79-12
Rear Fog Lamp - Circuit
short to battery
Rear fog lamp control
circuit - short to power
Refer to the electrical circuit diagrams and check
rear fog lamp control circuit for short to power B1A79-13
Rear Fog Lamp - Circuit
open
Rear fog lamp control
circuit - open circuit
Refer to the electrical circuit diagrams and check
rear fog lamp control circuit for open circuit B1C55-12
Horn Relay - Circuit
short to battery
Horn control circuit -
short to power
Refer to the electrical circuit diagrams and check
horn control circuit for short to power B1C55-14
Horn Relay - Circuit
short to ground or open
Horn control circuit -
short to ground, open
circuit
Refer to the electrical circuit diagrams and check
horn control circuit for short to ground, open circuit B1C83-12
Rear Defog Relay -
Circuit short to battery
High Side output not
driven - diagnosis
feedback indicates
output is short to power
Refer to the electrical circuit diagrams and check
heated rear window power supply circuit for short to
power B1C83-14
Rear Defog Relay -
Circuit short to ground
or open
High Side output not
driven - diagnosis
feedback indicates
output is short to
ground, open circuit
Refer to the electrical circuit diagrams and check
heated rear window power supply circuit for short to
ground, open circuit B1C83-93
Rear Defog Relay - No
operation
High Side output not
driven - diagnosis
feedback indicates
output is at open load
or short to power
Carry out any pinpoint test associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check
heated rear window power supply circuit for open
load and short to power B1C91-12
Fuel Flap/Door Lock
Relay Coil Circuit -
Circuit short to battery
Fuel filler flap locking
motor control circuit -
short to power
Refer to the electrical circuit diagrams and check
fuel filler flap locking motor control circuit for short
to power B1C91-14
Fuel Flap/Door Lock
Relay Coil Circuit -
Circuit short to ground
or open
Fuel filler flap locking
motor control circuit -
short to ground, open
circuit
Refer to the electrical circuit diagrams and check
fuel filler flap locking motor control circuit for short
to ground, open circuit B1D35-12
Hazard Switch - Circuit
short to battery
Hazard warning lamp
switch digital input
circuit - short to power
Refer to the electrical circuit diagrams and check
hazard warning lamp switch digital input circuit for
short to power B1D35-23
Hazard Switch - Signal
stuck low
Hazard warning lamp
switch digital input
circuit - signal stuck low
Carry out any pinpoint test associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check
hazard warning lamp switch digital input circuit for
short to ground U0019-88
Low Speed CAN
Communication Bus -
Bus off
Bus off
Carry out any pinpoint test associated with this DTC
using the manufacturer approved diagnostic system U0140-00
Lost Communication
With Body Control
Module - No sub type
information
No sub type information
Carry out any pinpoint test associated with this DTC
using the manufacturer approved diagnostic system

Fuel Charging and Controls - V8 S/C 5.0L Petrol -
WARNINGS: Published: 11-May-2011

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components.
Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.


Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until
the work is complete.


CAUTION: Before disconnecting or removing components, make sure the area around the joint faces and connections are
clean. Plug open connections to prevent contamination.


NOTE: Tighten the fuel rail high pressure fuel pump fuel line unions and fuel rail crossover pipe unions as it is instructed
in service manual.

Description Nm lb-ft lb-in Ignition coil-on-plugs retaining bolts 7 - 62 Spark plugs 20 15 - Fuel rail retaining bolt Stage 1 - 20 Stage 2 - 30 Stage 1 - 15 Stage 2 - 22 - Fuel rail crossover pipe unions 21 15 - Fuel rail crossover pipe retaining bolts 12 9 - Fuel pressure regulator 33 24 - Fuel rail high pressure fuel pump fuel line unions 21 15 - Fuel rail high pressure fuel pump fuel line M8 bolt 25 18 - Fuel rail high pressure fuel pump fuel line M6 bolt 11 8 - Fuel rail high pressure fuel pump fuel line M5 nut 6 - 53 Fuel rail high pressure fuel pump fuel line shield M10 bolt 29 21 - Fuel rail high-pressure fuel pump fuel line shield M6 bolt 11 8 - Fuel rail high pressure fuel pump torx bolts 12 9 - Throttle body retaining bolts 10 7 - Accessory drive belt idler pulley retaining bolts 25 18 - Steering gear retaining bolts 100 74 - Steering column lower universal joint assembly bolts 35 26 - Coolant expansion tank retaining bolt 10 7 - Engine compartment brace retaining bolts 45 33 - www.JagDocs.com

Published: 11-May-2011
Fuel Charging and Controls - V8 S/C 5.0L Petrol - Fuel Injection Component Cleaning
General Procedures

General Equipment




WARNINGS: Cleaning

Do not carry out any repairs to the fuel system with the engine running. Failure to follow this instruction may result in
personal injury.


Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components.
Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.


If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.


Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle.


Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek
medical attention.


Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors
are always present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTIONS:


Before using the cleaning fluid, protect all electrical components and connectors with lint-free non-flocking material.
Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking material.
Make sure that any protective clothing worn is clean and made from lint-free non-flocking material.


Make sure that clean non-plated tools are used. Clean tools using a new brush that will not lose its bristles, prior to
starting work on the vehicle.


Use a steel topped workbench and cover it with clean, lint-free non-flocking material.


Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign
matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result
in later malfunction.

1. Using a new brush that will not lose its bristles, brush the components
being removed and the surrounding area.

2. Using a pneumatic vacuum gun, remove all traces of foreign material.

General Equipment: Pneumatic vacuum gun Pneumatic vacuum gun

14.


















15.


















WARNINGS:


Do not
smoke or
carry lighted
tobacco or
open flame
of any type
when
working on
or near any
fuel related
components.
Highly
flammable
vapors are
always
present and
may ignite.
Failure to
follow these
instructions
may result
in personal
injury.


Do not
smoke or
carry lighted
tobacco or
open flame
of any type
when
working on
or near any
fuel related
components.
Highly
flammable
vapors are
always
present and
may ignite.
Failure to
follow these
instructions
may result
in personal
injury.

CAUTIONS:


Make
sure that
the fuel line
union does
not rotate.


Be
prepared to
collect
escaping
fluids.

Installation

1. To install, reverse the removal procedure.


2.
WARNING:
Do not
smoke or
carry lighted
tobacco or
open flame
of any type
when
working on
or near any
fuel related
components.
Highly
flammable
vapors are
always
present and
may ignite.
Failure to
follow these
instructions
may result
in personal
injury.

NOTES:


Lubricate
only the
union
threads with
clean engine
oil.


Do not
tighten at

this stage.


Remove and
discard the
blanking
caps.


3.
WARNING:
Do not
smoke or
carry lighted
tobacco or
open flame
of any type
when working
on or near
any fuel
related
components.
Highly
flammable
vapors are
always
present and
may ignite.
Failure to
follow these
instructions
may result in
personal
injury.

Torque:
Union 21 Nm M6 12 Nm
4. WARNINGS:


Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable vapors
are always present and may ignite. Failure to follow these instructions may
result in personal injury.


After carrying out repairs, the fuel system must be checked visually for
leaks. Failure to follow these instructions may result in personal injury.

Torque: 21 Nm