General Repair Precautions

The following advice should be noted before ANY repair work is carried out.

- Disconnect the vehicle battery ground lead (disconnect the alternator where electric welding is used) and take note of the reconnection procedures.
- Where structural parts are straightened or renewed, a body alignment / straightening jig must be used.
- Where appropriate, structural sections should be straightened by cold processes. Heat, especially excessive heat, will reduce the strength of steels.
- Repairs may only be carried out successfully, and any warranties protected, if genuine Jaguar replacement parts and Jaguar approved materials are used.
- Tools, procedures and facilities must be right for the job. Do not compromise the quality of the work by using inappropriate methods.
- All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel removal / replacement; this is especially important where hollow sections may contain harnesses, tubes or foam, see section 'Foam Injections' in 'Adhesives. Sealers and Body Protection - Approved Systems.' Service and Repair
- The welding and gas processes detailed 'Body and Frame' are the only ones recommended by Jaguar Cars Ltd.
- Ensure that you have read and understood the safety related procedures in this and other relevant sections.

WARNING: DO NOT WORK IN THE VICINITY OF A LIVE AIR BAG, REMOVE IT COMPLETELY. Air Bag Systems

WARNING: ANY SEAT BELT WHICH HAS BEEN WORN IN AN ACCIDENT MUST BE RENEWED. PLEASE SEE SEAT BELTS FOR IMPORTANT INFORMATION REGARDING 'TEAR LOOP' SEAT BELTS / BUCKLES AND ANCHORAGE LOCATIONS. Seat Belt Systems

CAUTION: Electric arc welding should not be used on Jaguar vehicles. The high voltages produced by this process will cause irreparable damage to the electrical control and microprocessor systems.

Welding and Gas Processes Special Notes:

Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated, metal.

The flanges of panels which are to be welded together must be clean, corrosion free and treated as appropriate, with either weld-through primer or inter-weld sealer; use only materials and processes in accordance with the 'Body Sealing and Preservation Manual' and relevant application areas in 'Adhesives, Sealers and Body Protection - Approved Systems,' in Service and Repair, Body and Frame.

NOTE: See 'Zinc Coated Panels' in 'Body Structures'. Description and Operation

Generally, the resistance spot welding equipment used in the motor vehicle repair industry does not produce a weld of equivalent strength to that of the manufacturer. Therefore, the expression 'single row of resistance spot welds' means that the spots should be spaced on a pitch of 19 to 25 mm. This will usually result in more spot welds than found in the original factory joint.

To remove resistance spot welds, a resistance spot weld cutter should be used.

If the new joint is to be MIG plug welded, the old resistance spot welds should be cut from the panel which is to be retained and those holes used for plug welding.

Suitable holes may also be drilled or punched; 8,0 mm dia. for sections up to 1,6 mm, and 10,0 mm dia. for thicker sections.



Plastics - Explanatory Notes:

Plastic component and trim materials:






This table, in conjunction with the Images in 'Plastics' will enable rapid identification of the particular material of any major plastic part. Application and ID

NOTE: Not all plastic components are nominated, only those suitable for economic reclamation.

Plastics - Handling Notes:


NOTE: With reference to the following conditions, consider the properties of those plastic components which may be affected by a repair or rectification procedure.

- As mentioned elsewhere, the exterior panel temperature of the vehicle must not exceed 95°C at any time and may only be held at this upper limit for a maximum of 2 (two) hours.
- Interior vehicle temperature must not exceed 86°C, the time limit being (two) hours.
- Temperatures above those specified in 1 and 2, may result in distorted or permanently damaged components. If there is any doubt whatsoever, remove those components which may be affected by the application of heat.
- Certain items may be manufactured from 'blended' materials; these must NOT be recycled with pure materials. For example do not mix PC / ABS (wheel trim) with ABS ('B' pillar upper trim).
- Should plastic components become greasy, they may be cleaned with an 'SBP spirit wipe, or equivalent.