2010 JAGUAR XFR light

1 Occupant classification system pressure pad (NAS only) 2 Safety belt tension sensor (NAS only) 3 Occupant detection system pad (all, except NAS) 4 Occupant classification system control module (NAS only) 5 RH side impact sensor (pressure sensor) 6 RH rear impact sensor 7 LH rear impact sensor 8 Passenger airbag deactivation LED (light emitting diode) 9 Driver's seat position sensor 10 LH side impact sensor (pressure sensor) 11 Instrument cluster 12 LH front impact sensor 13 RH front impact sensor

6 Occupant classification system pressure pad (NAS only) 7 Passenger airbag deactivation LED (light emitting diode) 8 Instrument cluster 9 Occupant detection system pad (all, except NAS) 10 Driver's seat position sensor 11 Front passenger seat safety belt pretensioner 12 Driver's seat safety belt pretensioner 13 LH (left-hand) front impact sensor 14 RH (right-hand) front impact sensor 15 RH rear impact sensor 16 RH side impact sensor 17 LH rear impact sensor 18 LH side impact sensor 19 RCM (restraints control module)

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:

Part N-umber
Body Repairs - General Information - Body Repairs
Description and Operation

General Information

Introduction Published: 11-May-2011

The body plays a significant role in the increasing trend of ever more rapidly changing model variants. The different customer
groups are strongly influenced by the design and shape of the body. At the same time the stability of the body plays the most
important part in ensuring passenger and driver safety. Lightweight construction, alternative materials, composite materials,
plastics and appropriate joining processes are all design features that characterise modern Jaguar vehicle bodies.

In terms of manufacturing technology, modern safety cell bodies can be produced almost without any problems. Jaguar
guarantee high quality standards by ensuring that mechanical strength properties are tried and tested in numerous computer
simulations, crash tests, by testing materials and by employing sophisticated manufacturing technologies. In the event of
repairs it is vital that the production quality standards are upheld. This requires a well-equipped workshop, and places
particular emphasis on the qualifications of the workshop technicians. Up-to-date knowledge of current manufacturing
technologies and continuous training on new repair methods and techniques are vital for high-quality body repairs. The model-
specific repair manuals and the general repair techniques provide valuable support when undertaking body repairs.

Always follow the repair instructions published in this manual. Failure to observe this instruction can result in serious
impairment of vehicle safety. All specified safety requirements must be met after the work has been carried out.

Vehicle design

The body

The XF adopts the latest generation steels, especially in the upper body – including high carbon steels, dual-phase,
hot-formed boron steels, and bake-hardened steels to form a vertical safety ‘ring’ around the occupant cell. As well as
combining strength with lightness, these steels improve corrosion resistance, by making best use of zinc and improving e-coat
paint flow – and new thinking means that in spite of their strength, the XF’s A and B-pillars are impressively slim, to the
benefit of both visibility and accessibility. Similarly, the lower sills are the first component on any Jaguar to use incredibly
strong, dual-phase DP600 steel.
The safety of the driver and the passengers is paramount for every body design. There are two key safety aspects in the body:
Safety passenger cell
Crumple zones

Safety passenger cell

Stable pillars, rocker panel and door profiles.
Side impact protection in the doors.
Doors are designed to open even in the event of extreme deformation.
Crumple zone

Dynamic absorption of deforming forces.
Protection of the passenger cell. www.JagDocs.com

- Sealing welded seams.
- Applying underbody protection.
- Sticking damping matting in place.
- Filling cavities with cavity wax.
- Cavity wax (after painting).

Panel Beating

Fundamentals of panel beating

Before carrying out any sectional replacements or complete replacements of body panels, always check carefully
whether the damaged panel(s) can be rectified by panel beating.
Panel beating is usually the easiest and most economical method of repairing a damaged panel.
Examples of applications of different panel beating techniques:
Aluminium hammer and mallet.
- Advantage: Low risk of over-stretching the panel.
- Used for repairs of small dents on panels that are accessible from both sides.
- These two panel beating tools are usually used for "finishing repairs".
Fine straightening with an aluminium hammer and a universal dolly



Sliding hammer
- If the damaged panel is only accessible from the outside, use a sliding hammer to pull it back into shape. The
discs or studs needed to mount the sliding hammer are welded onto the bare surface. Dents in the panel can be
flattened out using controlled application of the sliding hammer.

Heat-treatment of panels

It is usually inevitable that some parts of the body panels show excess material as a result of mechanical strain. If
there are any areas of excess material this will cause localised instabilities due to differences in tension. These
localised instabilities can be stabilised by applying heat-treatment techniques.

NOTE: This does not apply to high-strength low alloy steel, ultra high strength steel and aluminium.

Rule: Flattening panels by heat-treatment reduces the amount of excess material by more than they were originally
stretched.
Different heat-treatment techniques.

NOTE: Different heat-treatment techniques are used depending on the amount of excess material.
Flattening using a flame.
- A welding torch is used if the material excess extends over a larger area (torch size 0.5 - 1.0 mm). Use a soft
flame.
- The surface of the metal is briefly spot-heated and then immediately cooled with a wet sponge.
- Requirement: Ability to handle a welding torch safely and knowledge of annealing colours of steel.
- Advantage: No damage to the surface of the metal.
Flattening using a flame, supported by hammer and counterhold.

NOTE: The flattening effect is increased by speeding up the heating and cooling stages.

- If the material excess is concentrated, then the flattening effect can be increased after heating by carefully
using an aluminium or wooden hammer.
- Requirement: Ability to recognise material tension by feeling the surface that is to be flattened.
Flattening using a carbon electrode.
- If panel areas are only accessible from one side, or the panel is only slightly destabilised, then the preferred
method is flattening using a carbon electrode.
- Requirement: Bare metal surface.

- 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

Part N-umber
Body Repairs - Corrosion Protection - Corrosion Protection
Description and Operation

General Published: 11-May-2011

The corrosion protection provided in production must be carefully maintained and/or reproduced during and after body repair
work. It is only then that the long-term warranty against penetrative corrosion damage can be assured.

Only Jaguar original bodywork components and Jaguar approved repair materials, (sealer, paint etc.), are to be used for
bodywork repairs.
Jaguar Original Parts



All Jaguar bodywork components have a cathodic base coating. Individual bodywork components are zinc plated on one or both
sides, (in different areas depending on vehicle model).

Together with elastic paint coating, this guarantees an optimum, highly resistant protection against corrosion caused by the
impact of small objects such as gravel.


NOTE: If possible, the individual protective layers, (zinc, cathodic base coat), on Jaguar bodywork components must not
be damaged or destroyed by sanding or other mechanical operations.

If hairline cracks at "bodywork connection areas" appear after reshaping work, (e.g. at door hinges), it must be ensured that
the corrosion protection provided in production is recreated. The complete paint covering must be re-created if necessary. The
same applies to reshaping work on heavily profiled bodywork components, (e.g. floor pan). Renew or touch-up the paint
coating, sealing beads and underbody protection as necessary.

After repair, any interior surfaces which are no longer visible or accessible must be primed before cavity wax is applied. To be
certain of an even coating on inner surfaces, careful application of spray, (twice, with drying time in-between), must be carried
out throughout the whole cavity.

If bodywork panels are strongly heated during repair work, this will invariably result in damage to or even destruction of the
applied corrosion protection material. The effectiveness of the cavity protection material is reduced if heating occurs.
Reworking of the affected areas is therefore vital.
Welded areas should be made good before corrosion protection is applied.

The corrosion protection measures to be taken when bodywork components are renewed are described on the following pages.

Corrosion Protection of New Components

All new components must be inspected for transport or storage damage such as scratches or dents. The following operations
may be necessary, depending on the extent of damage:
Undamaged New Component

Do not grind the cathodic primer.
Thoroughly clean with silicone remover and rub dry.
Slightly Damaged New Component
Sand out scratches.
Finely sand the surrounding surface.
Thoroughly clean with silicone remover and rub dry.
Apply corrosion protection primer to bare areas.
Damaged New Components (bumps and dents)
Beat out the dented area and sand down to bare metal.

Apply polyester filler (only onto bare metal).
Apply filler.
Lightly sand the whole component.
Thoroughly clean with silicone remover and rub dry.
Apply corrosion protection primer to bare areas.

The clinched flanges on the hood, doors, tailgate and liftgate must be sealed with clinched flange sealer, if this is not already
applied.

Weld Components

Use a stripping disc to remove the cathodic primer on the inside and outside of the area to be welded. The stripped area
should be kept as small as possible, retaining as much of the cathodic primer as possible, taking care not to damage the zinc
coating.
Apply Welding Primer




NOTE: The welding primer must be stirred well or shaken before application.

Clean the repair area thoroughly, (silicone remover).

Apply welding primer evenly to all weld flanges, (old and new components).


NOTE: The welding primer must be allowed to dry before welding is carried out.
All weld beads must be ground down after all welding is completed, taking care not to weaken the material.
Any unevenness at the joint must be made good.
If necessary, spot weld missing weld studs into position.
The vehicle must be completely cleaned of sanding dust and metal swarf because of the danger of corrosion.
Clean and prime all internal areas and those to be sealed.

NOTE: The primer must be dry before sealing mastic or underbody protection is applied. Do not use thinners when
applying sealing mastic, (the mastic will not dry).

Partial Renewal

The procedure to follow when partially renewing components is the same as described in the section "Welded Components".

The main difference when components are partially, rather than completely renewed, concerns the preparation of butt or lap
joints.

When bodywork components are cut through, attention must be paid to the adequate removal of the paint and zinc
coatings on inner areas. This specially applies to areas which are difficult to access internally.
It is important for the weld quality that the inner area is bare metal. Zinc and paint residues in the weld area burn and
cause serious hole formation during welding.
If the zinc layer and the paint coating are not removed, the zinc and paint will burn during welding. The soot produced
prevents satisfactory cavity protection.
Procedure

The paint layer must be removed for a width of 30 mm from the line of the weld using a rotating tress wire brush.
This operation must be carried out on both the new and the old parts of the bodywork.
Depending on the bodywork component, a 10 mm width of the underlying zinc layer must also be removed along the
weld line. www.JagDocs.com