Body Systems & Body Repair
A4.1.5 GENERAL REPAIR NOTES
The following advice should be noted before ANY repair work is carried out.
0 Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take
note of the reconnection procedures as detailed in Section 15.
0 Where structural parts are straightened or renewed, a body alignment / straightening jig must be used.
0 Where appropriate, structural sections should be straightened by cold processes. Heat, especially excessive
heat, will reduce the strength of steels.
0 Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts
and Jaguar approved materials are used.
0 Tools, procedures and facilities must be right for the job. Do not compromise the quality of the work by using
inappropriate methods.
0 All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal / replacement; this is especially important where hollow sections may contain harnesses, tubes or
foam, see section
A4.3.5.
0 The welding and gas processes detailed in the following sections are the only ones recommended by Jaguar
Cars Ltd.
0 Ensure that you have read and understood the safety related procedures in this and other relevant sections.
WARNING: DO NOT WORK
IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. READ WORKING PRAC- TICES AIR BAG, SECTION 15. ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED. PLEASE SEE SECTION
AGE LOCATIONS. 13 FOR IMPORTANT INFORMATION REGARDING 'TEAR LOOP' SEAT BELTS / BUCKLES AND ANCHOR-
CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high vottages produced by this process will cause irreparable damage to the electrical control and microprocessor systems.
A4.1.5.1 Welding and Gas Processes Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated,
metal.
The flanges of panels which are to be welded together must be clean, corrosion free and treated as appropriate,
with either weld-through primer or inter-weld sealer; use only materials and processes in accordance with the 'Body Seal-
ing and Preservation Manual' and relevant application areas in section A4.3.1.1.
See 'Zinc Coated Panels' section A4.2.
Generally, the resistance spot welding equipment used in the motor vehicle repair industry does not produce a weld
of equivalent strength to that of the manufacturer. Therefore, the expression 'single row of resistance spot welds'
means that the spots should be spaced on a pitch of
19mm to 25mm. This will usually result in more spot welds than
found in the original factory joint.
To remove resistance spot welds, a resistance spot weld cutter should be used.
If the new joint is to be MIG plug welded, the old resistance spot welds should be cut from the panel which is to be
retained and those holes used for plug welding.
Suitable holes may also be drilled or punched;
8,O mm dia for sections up to 1,6 mm, and 10,O mm dia for thicker sec- tions.
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X300 VSM Issue 1 August 1994 4
