2010 JAGUAR XFR Workshop Manual

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Page 2705 of 3039

JAGUAR XFR 2010 1.G Workshop Manual 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

Page 2706 of 3039

JAGUAR XFR 2010 1.G Workshop Manual

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

Page 2707 of 3039

JAGUAR XFR 2010 1.G Workshop Manual For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques or
methods are used in these areas then this can pose a fundamental threat to vehicle saf

For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques or
methods are used in these areas then this can pose a fundamental threat to vehicle safety.
Hidden damage

As well as looking at external indicators like flaked off paint, it is vital to check for hidden body damage or deformation
that is not visible from the outside. Large attached parts like bumpers and inner fenders often need to be removed to
allow accurate assessment of damage to underlying body parts.
Gap dimensions

Gap dimensions offer another alternative for diagnosis by visual inspection. If any changes or misaligned edges are apparent,
then this usually indicates that the dimensions of the affected part are incorrect.
Changes in gap dimension

Item
Description 1
Gap too wide 2
Gap too small Impact effects on the body

NOTE: Vehicle components like drive shafts and trailer attachments transfer forces. If a vehicle is subjected to a rear
impact then all connected body parts and mechanical components (e.g. transmission mountings) should be thoroughly checked.
Electronic components should be checked to make sure that they still operate correctly.

Furthermore it is possible to deduce the overall extent of damage from the direction and magnitude of the impact forces. This
does however require extensive body-specific knowledge.

If, for instance, an impact occurs at the front left-hand side member, then the right-hand side member is usually also affected
as a result of the rigid body-shell design (crossmember). Often the length of this side member will not have changed, but
because of the rigid body-shell design it may have moved from its original position (often only by a very small amount). If any
deviations are present this can usually be detected by checking the gap dimensions between door and fender or by checking for
changes in dimension.

In the case of more severe impacts, the front part of the body cannot absorb all of the impact energy, and the passenger cell
is also deformed. Here the impact energy is transferred via the side member to the A-pillar (see diagram). This results in
deformations in the area of the roof and the door rocker panel.

The body reacts quite differently to side impacts where there is hardly any crumple zone. As the passenger cell is extremely
stable, there are comparatively few local deformations at the site of the impact. However, the impact forces are transferred to
the entire vehicle floor, which often results in so-called "banana damage", where the vehicle is bent into a banana shape.

Page 2708 of 3039

JAGUAR XFR 2010 1.G Workshop Manual

Item
Description 1
Deformation area - roof rail 2
Deformation area - roof 3
Deformation area - door rocker panel Body measurements

Measuring options

Comparison measurements can als

Page 2709 of 3039

JAGUAR XFR 2010 1.G Workshop Manual
NOTE: It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell
intact.

Which body parts need to be renewed?
Which body parts can be repaired?
Obta

NOTE: It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell
intact.

Which body parts need to be renewed?
Which body parts can be repaired?
Obtaining spare parts

The availability of spare parts often determines how easily the body repairs can be carried out. The following procedure is
recommended:

Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine identification letters,
initial registration etc.
Establish all of the metal parts that need to be renewed.
Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.
Straightening repairs

WARNING: The use of heat when pulling to straighten body panels, (such as side members), is not recommended.
Longitudinal pulling, (hot or cold), is also not recommended. A small amount of side to side pull is permissible, (cold).

When any type of pulling or straightening operation is performed it is important to observe for any movement in adjacent
panels.
A panel must retain its strength and integrity, if there is any doubt the panel must be renewed.
Straightening repairs are often required to restore the body to its original shape after an accident. This can be done with:
Alignment jigs.
Universal straightening and measuring jigs.
Welding jig system.

The following points must be followed to Make sure that the repairs are carried out professionally and that all the dimensions
are correct after the repairs have been carried out.
Structure:
- The repair sequence depends on the individual repair plan (taking any necessary disassembly work into
account).
- Clean the attachment areas.
- Anchor the vehicle free of stress on the relevant system.
- Support the aggregates to take strain off the body.
- Decide on at least three measuring/mounting points that are undamaged and as far apart as possible (for basic
adjustment).
- Check the dimensions of the measuring/mounting points.
Straightening:

NOTE: Check dimensions and gaps continuously during straightening.

- A body is always straightened in the opposite direction to that of the impact. Always carry out straightening
repairs with the complete body shell assembled (do not cut out any parts beforehand). Carry out the
straightening work in several stages. This prevents the risk of over stretching or of welded joints tearing out.
During the individual straightening steps, relieve tension by striking with an aluminium hammer while the part is
subjected to a tensile load (in the area of pre-determined folding points, dents, welded joins etc.).
Special features:
- Ultra high strength steel cannot be straightened due to its brittleness and must always be replaced. www.JagDocs.com

Page 2710 of 3039

JAGUAR XFR 2010 1.G Workshop Manual Cutting out body parts

Depending on how the parts are joined/connected, different tools are suitable for cutting/separating body parts.

NOTES:

All other parts like interior equipment, w

Page 2711 of 3039

JAGUAR XFR 2010 1.G Workshop Manual Body saws are particularly versatile and are therefore very suitable for making severance cuts on body parts.

Reciprocating saw

In addition to the short stroke saw, the reciprocating saw can

Page 2712 of 3039

JAGUAR XFR 2010 1.G Workshop Manual
NOTE: Any attached body parts that require accurate alignment and fitting must be incorporated in this step; for
instance bumpers, seals, headlamps, rear lamps and lock assembly components. If this

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