air condition JAGUAR XFR 2010 1.G Workshop Manual

Speed Control Module
Speed Control Sensor
Speed Control Switch4: Electrical
412: Climate Control System
412-00: Climate Control System - General InformationSpecificationDiagnosis and TestingClimate Control SystemGeneral ProceduresAir Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
Air Conditioning (A/C) System Flushing
Contaminated Refrigerant Handling
Electronic Leak Detection
Fluorescent Dye Leak Detection
Inspection and Assembly Requirements
Manifold Gauge Set Connection
Refrigerant Oil Adding - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol
Refrigerant System Tests
Air Conditioning (A/C) Compressor Commissioning412-01: Climate ControlSpecificationDescription and Operation
Air Distribution and FilteringComponent Location
Overview
System Operation and Component DescriptionHeating and VentilationComponent Location
Overview
System Operation and Component DescriptionAir ConditioningComponent Location
Overview
System Operation and Component DescriptionControl ComponentsComponent Location
Overview
System Operation and Component DescriptionRemoval and InstallationAmbient Air Temperature Sensor
Blower Motor

Blower Motor Control Module
Center Registers
Climate Control Assembly
Climate Control Module
Defrost Vent/Register Blend Door Actuator
Driver Side Register
Evaporator
Floor Console Register
Footwell Vent/Duct Blend Door Actuator
Heater Core
Heater Core and Evaporator Core Housing
Instrument Panel Register Trim Panel
In-Vehicle Temperature Sensor
Passenger Side Register
Pollen Filter
Recirculation Blend Door Actuator
Sunload Sensor
Thermostatic Expansion Valve
Desiccant Bag - V6 3.0L Petrol/V8 5.0L Petrol/V8 S/C 5.0L Petrol412-02: Auxiliary Climate ControlSpecificationDescription and OperationComponent Location
System Operation and Component DescriptionRemoval and InstallationAuxiliary Coolant Flow Pump
Electric Booster Heater412-03: Air ConditioningSpecificationDiagnosis and TestingAir ConditioningRemoval and InstallationAir Conditioning (A/C) Compressor - V8 5.0L Petrol/V8 S/C 5.0L Petrol
Condenser Core - V8 S/C 5.0L Petrol
Pressure Cutoff Switch (82.10.32)413: Instrumentation and Warning Systems
413-01: Instrument ClusterSpecificationDescription and OperationComponent Location
Overview
System Operation and Component Description

Air Conditioning A/C Accelerator Pedal Position APP
Is a multitrack sensor which inputs the drivers demand into the engine
control module (ECM) After Bottom Dead Center ABDC Event occurring after bottom dead center After Top Dead Center ATDC Event occurring after top dead center Anti-lock Brake System ABS
System which prevents wheel lock-up under braking by sensing lack of
rotation of a wheel(s) and diverting fluid pressure away from it (them) Alternating Current ac Amplitude Modulation AM Automatic Temperature Control ATC Automatic Transmission Fluid ATF Ampere A SI unit of current Ampere hour Ah Barometric Pressure BARO Pressure of surrounding air at any given temperature and altitude Battery positive voltage B+ The positive voltage from a battery or any circuit connected directly to it Before Bottom Dead Center BBDC Event occurring before bottom dead center Before Top Dead Center BTDC Event occurring before top dead center Bottom Dead Center BDC Lowest point of piston travel in a reciprocating engine Battery Junction Box BJB Brake Pedal Position BPP Brake Horsepower BHP
Effective horsepower developed by an engine or motor, as measured by a
brake applied to its output shaft British Standard BS Standard specification issued by the British Standards Institution Brake Traction Control System BTCS

Bus Topology of a
communication
network Coast Clutch Solenoid CCS Camshaft Position CMP Indicates camshaft position Carbon dioxide CO² Colorless gas with a density of approximately 1.5 times that of air Carbon monoxide CO Poisonous gas produced as the result of incomplete combustion Chlorofluorocarbon CFC Catalytic converter
In-line exhaust system device used to reduce the level of engine exhaust
emissions Celsius C
SI term for the Centigrade scale, with freezing point at zero and boiling point at 100 degrees Compact Disc CD Cylinder Head Temperature
Sensor CHT Sensor A sensor for measuring the temperature of the cylinder head Central Junction Box CJB Crankshaft Position CKP Indicates crankshaft position Clutch Pedal Position CPP Indicates clutch pedal position Controller Area Network CAN
A communication system which allows control modules to be linked together Constant Velocity CV Cubic centimeter cm³ Central Security Module CSM Electronic module to support security system functionality Data Link Connector DLC
Connector providing access and/or control of the vehicle information, operating conditions, and diagnostic information Driver Door Module DDM Electronic module to support driver door functionality Driver Seat Module DSM Electronic module to support driver seat functionality Daytime Running Lamps DRL Deutsche Institut fur Normung DIN German standards regulation body Diagnostic Trouble Code DTC
An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic (OBD) system Direct current dc
Current which flows in one direction only, though it may have appreciable pulsations in its magnitude Domestic Data Bus D2B Digital Versatile Disc DVD Electronic Automatic Temperature Control EATC
Exhaust Gas Recirculation EGR Exhaust Gas Recirculation Temperature Sensor EGRT Sensing EGR function based on temperature change Electronic Brake Force
Distribution EBD
Engine Control Module ECM Electronic module to support engine functionality Electronic Crash Sensor ECS Sensor to measure severity of impact Engine Coolant Temperature ECT Engine Oil Pressure EOP European On-Board Diagnostic EOBD Electronic Pressure Control EPC Electrically Erasable
Programmable Read-Only Memory EEPROM
Erasable Programmable
Read-Only Memory EPROM
Evaporative Emission EVAP
System designed to prevent fuel vapor from escaping into the atmosphere. Typically includes a charcoal filled canister to absorb fuel vapor Flash Electrically Erasable
Programmable Read-Only Memory FEEPROM
Front Electronic Module FEM Flash Erasable Programmable
Read-Only Memory FEPROM
Frequency Modulation FM Fuel Pump Driver Module FPDM Fuel Rail Pressure FRP Generic Electronic Module GEM Ground GND
Electrical conductor used as a common return for an electrical circuit or
circuits, and with a relative zero potential Global Positioning System GPS Global System for Mobile
Communication GSM
Gross Vehicle Weight GVW Heated Oxygen Sensor HO2S Electrically heated oxygen sensor which induces fuelling corrections

General Information - Health and Safety Precautions
Description and Operation Published: 11-May-2011

The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with
their use, and safety measures to be taken. Some of these chemicals may be included in the following list either in their own
right or as an ingredient in a sealer or adhesive.

Acids and Alkalis

See also Battery Acids.
e.g. caustic soda, sulphuric acid.

Used in batteries and cleaning materials.

Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath
mists.
Ensure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags

See also Fire, Chemical Materials - General

Highly flammable, explosive – observe No Smoking policy.
Used as a part of the Supplemental Restraint System (SRS), mounted in various positions around the vehicle.
The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500° C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely
consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure
to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste
site.
Following any direct contact with gas generant.

Wash affected areas thoroughly with water
Seek medical assistance if necessary


WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted
before repairing or replacing any SRS components. To deplete the backup power supply energy, disconnect the battery negative
cable and wait for one minute. Failure to follow this instruction may result in personal injury.


NOTE: The storage, transportation, disposal and/or recycling of air bag modules must be carried out in accordance with all
applicable federal, state and local regulations including, but not limited to, those governing building and fire codes,
environmental protection, occupational health and safety and transportation.
Air Bags - Do's

Do store in an air bag safe when not installed to the vehicle.
Do store modules in an upright position
Do keep modules dry
Do carry modules with the cover side pointing away from the body
Do place modules with their cover side upwards
Do carefully inspect modules for damage
Do stand to one side when connecting modules
Do make sure all test equipment is properly calibrated and maintained
Do wash you hands after handling deployed air bags
Do wear safety glasses when carrying out repairs to the SRS or when handling an air bag module
Only carry out a system test with the air bag modules fully installed
Do inspect the condition of the impact sensor mounting bracket and sensor flylead if the vehicle has been involved in
an impact. Replace if damaged, even if there has been no deployment.
Air Bags - Do Nots

Do not store highly flammable material together with modules or gas generators
Do not store gas generators at temperatures exceeding 80° C

Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.

Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a
doctor.

If liquids are swallowed inadvertently, consult a doctor giving the information on the container or label. Do not induce vomiting
unless this action is indicated on the label.

Fluoroelastomer

See Viton.

Foams - Polyurethane

See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not
work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.

Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory
protection. Do not remove the respirator immediately after spraying, wait until the vapor/mists have cleared.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the
use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat
cutting of cured foams or partially cured foams should be conducted with extraction ventilation.

Freon

See Air Conditioning Refrigerant.

Fuels

See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)

Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs e.g. through vomiting, is a very
serious hazard.

Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes
severe pain.

Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of
gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache,
depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious
consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.
Gas - oil (Diesel Fuel)
See warnings and cautions in relevant manual sections.
Combustible.
www.JagDocs.com

Highly flammable, flammable - observe No Smoking policy

Pressurized Equipment

See High Pressure Air, Lubrication and Oil Test Equipment.

Solder

Solders are a mixture of metals such that the melting point of the mixture is below that of the constituent metals (normally
lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these
should be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give
toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Solvents

See also Chemical Materials, Fuels (Kerosene), Fire.
e.g. acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and de-waxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some
can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches
and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be
adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not
use in confined spaces.

When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction ventilation or personal respiratory
protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.

Sound Insulation

See Fibre Insulation, Foams.

Suspended Loads


CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load e.g.
suspended engine, etc.

Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are adequate and suitable for the job,
in good condition and regularly maintained.

Transmission Brake Bands

See Asbestos.

Underseal

See Corrosion Protection.

Viton

In common with many other manufacturers' vehicles, some components installed to the Jaguar range have 'O' rings, seals or
gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets
and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and
Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400º C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.

'O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.
DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal
or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may
be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement
of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a
limewater (calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final
cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding (and cutting).
Resistance Welding (Spot Welding)
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Arc Welding
This process emits a high level of ultraviolet radiation which may cause arc-eye and skin burns to the operator and to other
persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn,
and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is
believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens
is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied
coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly
in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined
spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases,
with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultraviolet emission is much less than that from arc welding,
and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may
be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.

Do not empty fuel while working in a workshop or a pit
Ensure that working area is well ventilated
Ensure that any work on the fuel system is only carried out by experienced and well qualified maintenance personnel
Ensure that fume extraction equipment is used where appropriate


Fume extraction equipment must be in operation when solvents are used e.g. Trichloroethane, white spirit, sbp3,
methylene chloride, perchlorethylene. Do not smoke in the vicinity of volatile degreasing agents.

Whenever possible, use a ramp or pit whilst working beneath a vehicle, in preference to jacking. Position chocks at the wheels
as well as applying the parking brake. Never rely on a jack alone to support a vehicle. Use axle stands, or blocks carefully
placed at the jacking points, to provide a rigid location. Check that any lifting equipment used has adequate capacity and is
fully serviceable. Ensure that a suitable form of fire extinguisher is conveniently located. When using electrical tools and
equipment, inspect the power lead for damage and check that it is properly earthed. Disconnect the earth (grounded) terminal
of the vehicle battery. Do not disconnect any pipes of the air conditioning refrigeration system unless you are trained and
instructed to do so. A refrigerant is used which can cause blindness if allowed to come into contact with the eyes. Ensure that
adequate ventilation is provided when volatile degreasing agents are being used.

Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from naked
flames and other sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as causing
damage to protective coatings, there is a risk of damage from stray heat to electronic equipment and brake lines. Do not leave
tools, equipment, spilt oil etc. around the work area. Wear protective overalls and use barrier cream when necessary.

Environmental Protection

In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into water courses. The burning of
used engine oil in small space heaters or boilers is not recommended unless emission control equipment is installed. Dispose
of used oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation
trade. If in doubt, contact the Local Authority for advice on disposal facilities.

General Information - How To Use This Manual
Description and Operation

Workshop Manual Organization Published: 08-Dec-2012

This manual covers descriptive, diagnostic (including OBD), and repair aspects to service the vehicle effectively.

The manual is arranged in sections, each section dealing with a specific part of a vehicle system. For example, Section 412-03
[Air Conditioning] covers air conditioning, which is part of the climate control system.
The first digit of the section number indicates the group (in the above example this being Electrical). There are five groups:
General Information.
Chassis.
Powertrain.
Electrical. Body
and Paint.

The second and third digits of the section number indicate the vehicle system (12 in the above example being Climate
Control).

The last two digits of the section number indicate the part of the system covered by the section (03 in the example denotes
Air Conditioning).