2010 JAGUAR XFR maintenance

Published: 07-Aug-2014
Battery and Charging System - General Information - Battery Care
Requirements
Description and Operation
1. INTRODUCTION

This document defines the requirements for care and maintenance of batteries, and the standard of battery care at dealers and
retailers for new vehicles.

This applies to all types of 12 Volt Lead Acid Batteries used in Jaguar and Land Rover vehicles whether they are conventional
flooded technology or Absorbed Glass Mat (AGM – also known as Valve Regulated Lead Acid (VRLA)) technology and also
applies to both Primary, Secondary and Auxiliary Batteries. AGM batteries offer improved resistance to cycling as seen in stop
start applications.

In order to prevent damage to the battery and ensure a satisfactory service life, all processes detailed within this document
must be rigorously adhered to.
It is equally important therefore to note the following key points:

All new vehicles leave the factory with either a transit relay installed and/or have a transit mode programmed into the
vehicle control modules. The transit relay must be removed and the transit mode disabled (where applicable) using an
approved diagnostic system, NOT MORE THAN 72 HOURS before the customer takes delivery.
The battery can be discharged by the following mechanisms:
- Self Discharge: - A lead acid battery will very slowly discharge itself due to its own internal chemical processes
whether it is connected to a vehicle or not.
- Quiescent Discharge: - The vehicle electrical systems when connected to the battery will draw charge from the
battery.

12 Volt Lead Acid Batteries rely on internal chemical processes to create a voltage and deliver current. These processes and
the internal chemical structure of the battery can be damaged if the battery is allowed to discharge over a number of weeks /
months, or is left in a discharged state for a lengthy time period.

On vehicles with conventional ignition keys, these must not be left in the ignition lock barrel when the transit relay
has been removed, otherwise quiescent current will increase and the battery will discharge more rapidly.
For keyless vehicles, the Smart Key must be stored at least 5m (16 ft) away from the vehicle when the vehicle is
parked or stored.
AGM Batteries are fully sealed and cannot have the electrolyte level topped up.


NOTE: Dealers and retailers involved in the storage / handling of vehicles and replacement batteries have a responsibility
to ensure that only a fully charged battery may be processed through the distribution selling chain.
2. GENERAL RULES FOR BATTERY CARE
2.1 Dealer Demonstration Vehicles

Vehicles used as dealer demonstrator(s), in a showroom, must be connected to a JLR approved showroom conditioner capable
of delivering 50 Amps. This will prevent the battery from being damaged.
2.2 Software Reflash, SDD work or Ignition On related workshop activities

Due to the high electrical current demand and high depth of discharge that can occur during vehicle software re-flash activities,
SDD work or ignition on (power mode 6) related work in the workshop, vehicles that are undergoing such activities MUST have a
JLR approved power supply capable of delivering 50 Amps or more.
2.3 Extended Vehicle Rework

For any extended vehicle rework that results in consuming vehicle power, either the battery should be disconnected or a JLR
approved power supply connected.
2.4 Jump Starting New vehicles before they have been delivered to the customer

It is the dealer / retailers responsibility to make sure the battery is not allowed to discharge by following the
instructions and processes defined in this manual.
However, if circumstances dictate that a new vehicle must be jump started due to a discharged battery whilst the
vehicle is in the dealer / retailers care, the battery on this vehicle must be replaced with a new one prior to delivery
to the customer at the dealer / retailers liability.
The vehicle should also undergo investigation as to why the battery became discharged.
Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended
earth point. As defined in the owners handbook or service documentation for that vehicle. 2.5 AGM Batteries

AGM batteries must not be charged above 14.8 Volts. Doing so will damage them.
AGM Batteries must be tested with a capable battery tester as detailed in the Equipment section (Section 5) of this

Any actions must be carried out in accordance with the table shown in the Determining Battery Condition section (Section 6)
of this procedure. The details must be recorded on the New Vehicle Storage Form which is part of the new vehicle storage
document.
For additional information, refer to: New Vehicle Storage Form (100-11 Vehicle Transportation Aids and Vehicle Storage, Description and Operation).
4.3 PDI / DELIVERY TO CUSTOMER

Before the vehicle is handed over to the customer and as part of the PDI, the condition of the battery needs to be confirmed.
The battery condition must be checked in accordance with the battery test process utilizing a JLR approved tester as outlined
in the Equipment section (Section 5) of this procedure.


NOTE: The Midtronics code from the tester must be recorded on the form.

Any actions must be carried out in accordance with the table shown in the Determining Battery Condition section (Section 6)
of this procedure. The details must be recorded on the New Vehicle Storage Form which is part of the new vehicle storage
document.
For additional information, refer to: New Vehicle Storage Form (100-11 Vehicle Transportation Aids and Vehicle Storage, Description and Operation).
4.4 REPLACEMENT BATTERIES FOR SERVICE

All service replacement batteries must have the battery condition checked within 24 hours of receipt and controlled on a ‘First
In First Out’ basis to ensure batteries are not allowed to age unnecessarily.

For batteries in storage and not yet fitted to a vehicle, they must be stored in a dry environment, not in direct sunlight or
under any direct heat source. Any batteries exhibiting any forms of damage or corrosion must not be fitted to any vehicle. Any
batteries which are dropped must be scrapped, this applies even if no external damage is apparent.

The battery condition must be checked every 30 days in accordance with the battery test process utilizing a JLR approved
tester as outlined in the Equipment section (Section 5) of this procedure.

Any actions must be carried out in accordance with the table shown in the Determining Battery Condition section (Section 6)
of this procedure.The details must be recorded on the New Vehicle Storage Form which is part of the new vehicle storage
document.
For additional information, refer to: New Vehicle Storage Form (100-11 Vehicle Transportation Aids and Vehicle Storage, Description and Operation).
4.5 BATTERY MAINTENANCE

Any battery whether it is in a vehicle or a replacement part must be tested and/or re-charged every 30 days and MUST be
re-charged after every 90 day period.
4.6 BATTERY TEST PROCESS

It is recommended that this test is conducted at least 24 hours after the vehicle engine has been run or the battery charged to
avoid the need of surface charge removal. If time constraints make this unacceptable then the surface charge must be
removed.
Surface Charge Removal

A vehicle which has had its battery charged or been driven in a 24 hour period before the test, must have its surface charge
removed.

Turn on the ignition (power mode 6) but do not start the vehicle
Switch on the headlamps on high beam for a minimum 3 minutes
Switch off the headlamps
Wait a minimum of 5 minutes before recording test results for any battery measurements
Battery Test

The battery may be tested either on a bench or on the vehicle.

The battery condition must be checked in accordance with the battery test process utilizing a JLR approved tester as outlined
in the Equipment section (Section 5) of this procedure.


NOTE: The Midtronics code from the tester must be recorded on the form.

Any actions must be carried out in accordance with the table shown in the Determining Battery Condition section (Section 6)
of this procedure. The details must be recorded on the New Vehicle Storage Form which is part of the new vehicle storage
document.
For additional information, refer to: New Vehicle Storage Form (100-11 Vehicle Transportation Aids and Vehicle Storage, Description and Operation).


CAUTION: DO NOT connect the tester to any other circuit or chassis point other than the battery negative terminal.

system.
9 CONFIRMING ELECTROLYTE LEVEL

WARNINGS:


BEFORE CHECKING AND TOPPING-UP THE BATTERY ELECTROLYTE, REFER TO THE HEALTH AND SAFETY PRECAUTIONS
SECTION.


AGM TECHNOLOGY BATTERIES ARE FULLY SEALED FOR LIFE AND NO ATTEMPT SHOULD BE MADE TO CHECK OR TOP UP
THE ELECTROLYTE LEVEL.
On certain types of battery the electrolyte level may need to be checked.

Make sure the battery is of a type suitable for topping up. These types of batteries will have cell plugs visible on the
top face of the battery or a removable access panel to allow access to the cells.
On batteries with a clear or opaque case and level marks, check the electrolyte level by visual inspection of the
maximum level indicator mark on the battery casing indicating adequate level above the battery separators.
On batteries with black cases, remove the cell plugs or access panel and ensure the electrolyte level is level with the
indicator in the cell hole. A flashlight may be required to see the electrolyte level on this type of battery.
If the electrolyte level is low, top-up using distilled water.


NOTE: Maintenance free and Valve Regulated (AGM) batteries are sealed and therefore cannot be topped up.
CAUTION: DO NOT overfill.

metal surfaces are bolted together always interpose a suitable interface material such as weldable zinc rich primer, extruded
strip, or zinc tape.

Steam Cleaning

Due to the high pressure/temperature generated by steam cleaning equipment, there is a risk that certain adhesives and
corrosion prevention material may become softened or liquified.
Take care not to allow the steam jet to dwell on one area, and keep the nozzle at least 300mm from the panel surface.


CAUTION: Do not remove wax or lacquer from underbody areas during repairs.

Inspection During Maintenance Servicing

It is a requirement of the corrosion warranty that the vehicle is inspected for corrosion by a Jaguar Authorised Repairer during a
routine service, to ensure that the factory-applied protection remains effective.

Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to minimise the
extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion prevention treatment.

Underbody Protection Repairs

Whenever body repairs have been carried out, ensure that full sealing and corrosion protection treatments are reinstated. This
applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result either of
accident damage or repair operations.

Remove corrosion protection from the damaged areas before straightening or panel beating. This applies in particular to panels
coated with wax, PVC underbody sealer, sound deadening pads etc.


CAUTION: Do not use oxy-acetylene to remove corrosion prevention material. Large volumes of fumes and gases are
liberated by these materials when they burn.

The most common method of removal is by means of a hot air blower with an integral scraper. High temperatures can be
generated with this equipment which may cause fumes. Take care during its use.

Structural Adhesive


CAUTION: When separating a joint with metal to metal adhesive, it is important to avoid distortion. Heat gradually until
the bond weakens sufficiently to permit panel separation - do not apply excessive heat.


NOTE: When spot welding through metal to metal adhesive, take particular care to adjust the equipment setting to
ensure a suitable weld.

Metal to metal adhesive is applied to critical joint areas during factory assembly. The material used is a high temperature,
heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against ingress of dust,
moisture and fumes. This material is not suitable for service use and, during repair, should be substituted by an approved
structural adhesive. For panel specific information and to identify the areas of structural adhesive application in repair, refer to
the relevant sheet metal removal and installation procedure.

Expanding Foam Acoustic Seals

Expanding foam acoustic seals are used in various closed-sections of the body to improve vehicle refinement. The seals are
installed during the vehicle body manufacture and expand during the paint process up to ten times original size, thus locking
them into position. They are located such that they prevent noise accentuation along a section and reflect air borne noise
away from the cabin.

The seals have spilt functionality depending on location. The seals located at the base of the body pillars have a primary
function of preventing water ingress when wading. Their secondary function is to prevent noise and dust ingress.

The seal around the fuel filler has a primary function of preventing both fuel and water ingress. With a secondary function of
preventing noise and dust ingress.

The remaining seals primary function is to prevent noise accentuation along a section and reflect air borne noise away from the
cabin.

Another advantage of the seals is that they marginally increase the overall stiffness of the body and its structural performance
in case of a crash.
The seals are manufactured from an expandible polymer.

Replacing Expanding Foam Acoustic Seals

As paint oven temperatures used in a repair workshop are significantly lower than those that are used during manufacture of
the vehicle, (the temperatures are not sufficient to expand the foam), a different process is required to replicate the foam in
repair.

- Air flow checker
- Sealing compound (tape and plastic compound)
- Multi-purpose sticker
- Clinched flange sealer
- Window sealing compound
- Water shield (PVC)
- Double-sided adhesive tape for water shield
- Methylated spirit (available from trade outlets)
- PU adhesive
- Silicone remover
- Tar remover

Water leaks according to mileage or running time
Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing factors are:
Servicing and maintenance of seals:
- No maintenance, lack of maintenance or incorrect maintenance
- Using an incorrect agent
Damaged seals:
- As a result of aging, wear or incorrect handling/assembly.
Heavy soiling of the vehicle:
- Heavy soiling of a vehicle can seriously impair the function of water drainage channels in particular, and also of
rubber seals.
Age-related factors:
- Environmental factors
- UV radiation
- Extreme climatic conditions
Corrosion can have a serious impact on bodywork, in particular as a result of:
- Lightly or heavily rusted seal carriers
- Rusted body seal welds
- Perforation corrosion

Water leaks after body repairs
If a vehicle develops a leak after body repairs, the following points must be taken into consideration in particular:
The correct seating of ancillary components and their seals must be checked.
The correct alignment of doors/tailgate and liftgate must be checked. The associated seals must not be damaged and
must be installed correctly.
Check that panel seams are correctly sealed.
The correct seating of rubber grommets must be checked.
Directly-glazed windows must have correct and complete bonding.

Water drainage system

If a vehicle develops water leaks, then areas into which water is routed or drained should be checked first.