The new Jaguar XJ had to prove its driveability and reliability during hundreds of laps through the 73 corners of the former Formula One circuit at Nürburgring in Germany.  Jaguar´s new German test centre also extensively tested and fine-tuned the XJ´s advanced electronic systems, including its Dynamic Stability Control (DSC), self-levelling air suspension and the enhanced CATS adaptive damper systems.

The new XJ is the most rigorously tested Jaguar ever produced. Following the equivalent of two motoring lifetimes of simulated testing in extreme climate chambers, XJ prototypes were put to the test in California´s Death Valley and inside the Arctic Circle.

The aerospace derived build process of the single shell aluminium body uses 88 Ethernet controlled robots to precisely execute the rivet bonding technology. No spot welding takes place at any stage.  The entire revolutionary process is designed to ensure that the exceptionally strong and rigid XJ body shell will give years of quiet, rattle-free, squeak-proof service.

In contrast to the computer and robot controlled body shell and paint processes, your specified XJ is built on the assembly line almost exclusively by hand.  All the most advanced production aids, such as laser camera systems, hydraulic lifting and positioning equipment are utilised, but it is the operator´s eyes and hands that guide, install, check and sign every component as each body is customised and then united with its designated chassis and powertrain.

The soft grain leather used on Sovereign and Super V8 models comes in to Browns Lane as hides specified by colour and Jaguar leather top finish. Skilled leather workers then carefully mark the faults and scars to be found on any natural hide. Cutters then use their skill and experience to hand cut the many elements of the leather trim with a minimum amount of wastage, ensuring the leather for each car comes from the same hide. No mechanical or laser cutters are used. Skilled seamstresses then finish and finely stitch each piece, which is then fitted by hand in the trim section.

The high quality burr walnut veneers for the XJ come from the growths at the base of 75-year old American walnut trees. These ´burls´ with their rich distinctive patterning are dug out, roughly planed and shipped to Britain for cutting into fine veneers. Jaguar craftsmen ´mirror-match´ the veneers for facias and door inserts. This means flipping the veneer of consecutive sheets to achieve a perfect mirror image pattern. The veneer and laminates are then built up with alternate grains over a metal substrate and heat bonded. After lacquering, they go through progressive stages of polishing until each individual set is packed and matched with the individually specified Jaguar it is being made for.

Every XJ that comes off the production line faces a battery of quality tests to guarantee the durability and reliability of all new Jaguars. These include rolling-road tests, instrument testing and simulated monsoon conditions to test all-weather integrity and performance. When it finishes its final factory test, every XJ - with seats, sills and brake discs protected by heavy polythene - is taken for an 8-mile road test by an experienced Jaguar test driver. Every function and reaction is tested before returning to the factory for a final wash, paintwork inspection and heavy protective waxing before delivery to the dealer or to the docks for shipping overseas.