Item Description 1 Drill 2 x 8mm holes to form basis of slot 2 Mill out to form 20mm x 8mm slot 3 Slots spaced at 30mm intervals
NOTE: Mig brazing is carried out at a temperature of 650°C to 950°C. To avoid degradation of the ultra high strength
steel material properties, the temperature must be below 950°C.
Mig braze the slot(s) using a Fronius Trans Plus Synergic 2700 4 R/Z/AL MIG Welder, with CuSi3 (DIN 1733) 1.0mm filler wire
with setting parameters 4, which is 92 Amps, Wire feed 4.6 m/min. Shielding gas L1 = pure Argon (DIN 439).
Dress the surface of the weld cap (brazed slot) with 60/80 grit belt sanders.
Accident damage and diagnosis
General notes
Exact diagnosis of the extent of the damage enables proper repair planning.
All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual.
The stability and strength properties of the body must be taken into account during body repairs. The body has exact
defined deformation patterns that must not be affected by any repair work. Roof panel
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.
