General Information
Body Repairs - General Information - Body Repairs
Description and Operation
General Information
Introduction
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. 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.
Contents
This document includes technical data and information for the all new Jaguar XJ aluminium range. The information contained within is valid at the time of production and incorporates:
- Who should use this information?
- Category A and B definition
- Accident damage and diagnosis
- Impact effects on the body
- Planning a repair
- Estimating
- Identifying the correct Jaguar Approved Body Repair Facilities
- Obtaining spare parts
- Equipment
- Aluminium information
- Galvanic corrosion and housekeeping
- Panel replacement times
- Fixings
- Bonding
- Materials
- Aluminium Welding
- Tolerances and gap specification
- Body alignment
The methods described for panel replacement operations have been obtained from a study of physical repair operations.
In line with Jaguars continuous improvement programme, information and data contained will be updated periodically.
All activities described within are based on the use of genuine Jaguar Parts, tools and approved materials.
Who should use this information?
The information and repair methods listed are designed as an aid for Jaguar Approved Body Repair Facilities achieving the Jaguar approved Bodyshop Operating Standards. The relevant section should be read completely before commencing any repairs. Only technicians who have successfully completed the approved XJ aluminium range training programme should work on the model. Jaguar Approved Bodyshop Operating Standards require that the skills of technicians be regularly assessed and that any training needs identified are addressed within a reasonable time. This information complements the Jaguar training programme.
The authorised repair network is divided into category A and B. The following describes the process required to identify category A or B damage.
Definition of category A and B
Category A
- NOTE: Specific equipment and facilities are required to carry out Category A repairs, see the equipment section.
Damage that requires panel(s) to be replaced with any one or combination of the following procedures:
- Welded panel
- Bonded panel
- Panel secured with fixings
The following list identifies Category A procedures:
Category A procedures
- Fender apron closing panel front section
refer to: Fender Apron Closing Panel Front Section.
- Fender apron panel
refer to: Fender Apron Panel.
- Fender apron panel closing panel
refer to: Fender Apron Panel Closing Panel.
- Fender apron panel front section
refer to: Fender Apron Panel Front Section.
- Front side member
refer to: Front Side Member.
- Front side member and suspension top mount assembly
refer to: Front Side Member and Suspension Top Mount Assembly.
- Front side member closing panel
refer to: Front Side Member Closing Panel.
- Front side member closing panel section
refer to: Front Side Member Closing Panel Section.
- Front side member section
refer to: Front Side Member Section.
- Front side member to deformation element bracket
refer to: Front Side Member To Deformation Element Bracket.
- Suspension top mount
refer to: Suspension Top Mount.
- Roof panel
refer to: Roof Panel.
- A-pillar outer panel
refer to: A-Pillar Outer Panel.
- A-pillar reinforcement
refer to: A-Pillar Reinforcement.
- Rocker panel rear section
refer to: Rocker Panel Rear Section.
- Back panel
refer to: Back Panel.
- Quarter panel
refer to: Quarter Panel.
- Quarter panel lower extension
refer to: Quarter Panel Lower Extension.
- Rear floor side extension
refer to: Rear Floor Side Extension.
- Rear side member closing panel section
refer to: Rear Side Member Closing Panel Section.
- Rear side member section
refer to: Rear Side Member Section.
- Rear wheelhouse outer
refer to: Rear Wheelhouse Outer.
- Spare wheel well
refer to: Spare Wheel Well.
Category B
Damage associated to bolt on panel(s) that are replaced, or light surface damage to exterior cosmetic panels.
The following list identifies Category B procedures:
Category B procedures
- Front bumper cover
- Front bumper
- Side member deformation element
refer to: Side Member Deformation Element.
- Hood
- Hood hinge
refer to: Hood Hinge. Service and Repair
- Hood latch panel
refer to: Hood Latch Panel. Service and Repair
- Hood latch panel mounting panel
refer to: Hood Latch Panel Mounting Bracket. Service and Repair
- Front fender
refer to: Front Fender. Service and Repair
- Front door
- Rear door
- Luggage compartment lid
- Luggage compartment lid hinge
- Rear bumper cover
- Rear bumper