2010 JAGUAR XFR Electrical

19.

































20.
CAUTION: Note the fitted position of the component
prior to removal.


NOTE: Make sure that the component is installed to
the position noted on removal.




























CAUTIONS:


Make sure that the clips are correctly located.


Note the fitted position of the component prior to
removal.
NOTES:


Make sure that this component is installed to the
noted removal position.


Federal vehicles only.

Torque: 9 Nm

21. WARNING: The SRS electrical connectors are unique.
DO NOT force, or attempt to connect electrical connectors
to the wrong sockets.


CAUTION: Note the fitted position of the component
prior to removal.
NOTES:


Make sure that the component is installed to the
noted removal position. www.JagDocs.com

Pedestrian Protection System - Pedestrian Protection System
Diagnosis and Testing

Principles of Operation Published: 09-Dec-2013

For a detailed description of the Pedestrian Protection System, refer to the relevant Description and Operation section in the
workshop manual.
REFER to: Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation) / Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation).
Inspection and Verification

WARNINGS:


TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED
BEFORE REPAIRING OR REPLACING ANY PEDESTRIAN PROTECTION SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER
SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT TWO MINUTES. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN PERSONAL INJURY.


Do not use a multimeter to probe the pedestrian protection system actuators. It is possible for the power from the
multimeter battery to trigger the activation of the actuator. Failure to follow this instruction may result in personal injury.


CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.
NOTES:


If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the installation of a new module/component.


When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.


Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.


It is advisable not to use a cellular phone or to have a cellular phone in close proximity when working on the pedestrian
protection system or components


Given the legal implications of a restraints system failure, harness repairs to pedestrian protection system circuits are
not acceptable. Where the text refers to "REPAIR the circuit", this will normally mean the replacement of a harness.


After 5 hood deployment events, a new Pedestrian Protection System Control Module (PPSCM) and wiring harness must be
installed.
1. Verify the customer concern

2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical Electrical
Hood
Hood hinge
Hood deployment controls
Fuses
Wiring harnesses and connectors
Pedestrian Protection System Control Module (PPSCM)
Impact sensors
Hood deployment controls
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for

- 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

Item
Description 1
Rubber strip 2
Window frame 3
Adhesive 4
Window glass Removing and installing bonded windows

Safety measures

The following safety measures must always be followed to prevent personal injury:
- Wear protective gloves and arm protection.
- Wear protective goggles.

Preparations

Before cutting out a bonded window, undo and remove any attached parts in the cutting area that are at risk, e.g. trim
panels and decorative strips, as well as all electrical connections.
Mask any painted areas that are adjacent to the window.
Cut off any surplus adhesive, as this makes it easier to cut out the window.
Secure vertical windows against dropping out.
Cutting out the window

Cut into the adhesive bead at easily accessible points using the cutting tool.
Carefully guide the cutting tool around the window, cutting through the adhesive bead.
Avoid touching the window frame and the body flange.
Use cup suction tools to lift the cut-out window out of the window aperture.
General preparations for bonding

Follow the manufacturer's instructions.
Cut back the remaining adhesive bead on the metal flange to a residual height of about 1mm. Do not touch or clean the
cut surface afterwards.
Carefully rectify any paint damage (apply primer and top coat).
Renew the window stops as necessary.
Bonding the window glass
Apply an even bead of adhesive to the window or to the body flange.
Insert the window glass into the window aperture and centre it (2 technicians required).
Check the gaps.

NOTE: Open the windows and doors while the window is left to dry and do not move the vehicle (slamming doors
creates excess pressure which could cause the window to become loose).
Use adhesive tape to prevent the window from falling out or slipping.

Finishing operations

Reconnect all electrical connections and check that the components operate correctly.
Install the attached parts and check that the fit is accurate and secure.
- Carry out a visual inspection to Make sure that the gaps and joints are even.
Thoroughly clean the window glass.

Protective equipment and safety at work

Various safety measures and legal requirements must be met when carrying out repairs. All regulations relating to
health and safety at work must be followed. Adhesive bonding of bonded windows

NOTE: The illustration may indicate either hand of the service panel, the opposite hand will be similar.

Item Description 1 Front bumper cover 2 Front bumper 3 Front fender 4 Hood 5 Hood hinge 6 Hood latch panel 7 Hood latch panel mounting bracket 8 Front fender support bracket 9 Fender apron panel front extension 10 Fender mounting plate 11 Hood strut mounting bracket 12 Front wheelhouse section 13 Front bumper mounting 14 Front side member 15 Front side member section 16 Front side member closing panel 17 Front side member closing panel section 18 Front side member & suspension top mount assembly 19 Fender apron panel 20 Fender apron panel front section 21 Fender apron panel closing panel Time schedules, front end

The following information shows the total time taken to replace single panels and complete assemblies. This time includes
removal of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panels are not included).

The times shown were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide
only.

Single panel times
Panel Description Hours Hood 7.4 Front bumper cover 7.8 Front fender L/H 8.9 Front Fender R/H 9.1 Hood latch panel 6.6 Instrument panel console remove and install 5.3 Engine and suspension assembly remove and install 9.3 Combination panel replacement times

The following panel combination times show the total time to remove/install body panels, MET items and paint times based on
Metallic Clear Over Base Paint process, (blends to adjacent panels are not included).

Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender Hood latch panel Hood latch panel mounting bracket Front fender support bracket Total Time L/H 23.5
R/H 23.6 Combination panel times
Panel Description Hours Hood Hood hinge L/H and R/H Front bumper cover Front bumper Front fender L/H and R/H Hood latch panel Hood latch panel mounting bracket L/H and R/H Front fender support bracket L/H and R/H Total Time 26.8 www.JagDocs.com

Published: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Closing Panel Front Section
Removal and Installation

Removal


1. NOTE: The fender apron closing panel front section is
manufactured from mild steel.

The fender apron closing panel front section is cut from the
fender apron panel closing service panel.










2. The fender apron closing panel front section is replaced in conjunction
with:
Front bumper cover
Hood
Front fender
Hood latch panel
Fender apron panel front extension
Fender apron panel front section

3. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

4. Remove the fender apron panel front section.
For additional information, refer to: Fender Apron Panel Front Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).

5. Disconnect the generator electrical connectors.


6. NOTE: Make sure the section is cut to cater for the extent
of damage and to allow a minimum 50mm staggered joint
with the fender apron panel front section.

Cut the front section from the fender apron panel closing
service panel.

Front End Sheet Metal Repairs - Fender Apron Panel
Removal and Installation

Removal Published: 11-May-2011


1. NOTE: The fender apron panel is manufactured from mild
steel.

The fender apron panel is serviced as a separate weld-on
panel.










2. The fender apron panel is replaced in conjunction with:
Front bumper cover
Front fender
Fender apron panel closing panel
Hood
Hood hinge
Hood strut mounting bracket
Fender mounting plate

3. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

4. Remove the hood.
For additional information, refer to: Hood (501-02 Front End Body Panels, Removal and Installation).

5. Remove the hood hinge.

6. Remove the fender apron panel closing panel.
For additional information, refer to: Fender Apron Panel Closing Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).

7. Disconnect the generator electrical connectors.

8. Remove the windshield wiper motor and linkage.
For additional information, refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).

9. Remove the ECM (engine control module).
For additional information, refer to: Engine Control Module (ECM)
(303-14A, Removal and Installation) /
Engine Control Module (ECM) (303-14B Electronic Engine Controls - V6 3.0L Petrol, Removal and Installation) /
Engine Control Module (ECM) (303-14C, Removal and Installation). www.JagDocs.com

Published: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Panel Closing Panel
Removal and Installation

Removal


1. NOTE: The fender apron panel closing panel is
manufactured from mild steel.

The fender apron panel closing panel is serviced as a
separate weld-on panel.










2. The fender apron panel closing panel is replaced in conjunction with:
Front bumper cover
Front fender

3. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

4. Remove the front fender.
For additional information, refer to: Front Fender (501-27 Front End Sheet Metal Repairs, Removal and Installation).

5. Disconnect the generator electrical connectors.

6. Remove the pedestrian protection hood actuator.
For additional information, refer to: Pedestrian Protection Hood Actuator LH (501-20C Pedestrian Protection System, Removal and Installation) / Pedestrian Protection Hood Actuator RH (501-20C Pedestrian Protection System, Removal and Installation).

7. Remove the secondary bulkhead panel.
For additional information, refer to: Secondary Bulkhead Panel LH - 3.0L NA V6 - AJ27 (501-02 Front End Body Panels, Removal and Installation) / Secondary Bulkhead Panel RH - 3.0L NA V6 - AJ27 (501-02 Front End Body Panels, Removal and Installation).

8. Remove the pedestrian protection actuator bracket.

9. Release and position the fuse box to one side.

10. Release and position the wiring harness to one side.