climate control system JAGUAR XJ6 1994 2.G User Guide

WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE CAP IN THIS POSITION UNTIL
ALL THE STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
WARNING: WHEN DRAINING THE COOLANT WITH THE ENGINE HOT, PROTECT THE HANDS AGAINST CONTACT
WITH HOT COOLANT.
WARNING
: WHEN WORKING WITHIN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE ENGINE DRIVEN RADI- ATOR COOLING FAN WHEN THE ENGINE IS RUNNING.
4.2.3.2 Working Practices
Whenfilling thesystem with coolant,ensurethatthevehicle isstanding on a level surfaceand thatthecoolant is poured
in slowly so that airlocks are not introduced into the system. Airlocks can seriously affect the operation of the climate
control system and can cause damage to the heater circuit pump.
Hose clips should always be positioned
so that there is proper access for tightening and that the clip does not foul or
interfere with the operation of any components.
4.2.3 SERVICE PROCEDURES
4.2.3.1 Safety Precautions
The anti-freeze specified in Appendix A1 must be used wherever possible. It is designed to afford the maximum cor- rosion protection to all metals found in the engine cooling system, as well as having the frost protection properties
necessary during the winter months. Should it not be available, then anti-freeze conforming to Ford Motor Company
specification
ESBM97B49-A may be used. To provide optimum temperature and corrosion protection, the specified
anti-freeze concentration must always be used. Once coolant has been drained from the system, it must be discarded
and not reused. Anti-freeze is harmful to the environment. Always dispose of used coolant safely and never pour it down a drain connected to the public sewer.
CAUTION: Never fill or topup the system with water only.
CAUTION
: Anti-freeze is harmful to paintwork. Coolant spillages must be wiped up immediately and the affected
area washed to remove all traces of coolant.
CAUTION: To prevent the possibility of damage to the heater circuit
pump, the pump should be electrically isolated if the ignition has to be turned ON while the cooling system is drained.
The drive belt must always be tensioned to the specified value and the tension checked at the correct point on the belt.
This information is given in Sub-section IV in the preliminary pages.
When tightening components, the torque figures given in Sub
-section II in the preliminary pages should always be
used for the fastenings listed.
When fitting a replacement thermostat, ensure that the jiggle-pin is to the top of the thermostat housing.
4.2.3.3 Coolant Change
The coolant must be changed at intervals of four years. The system should be drained from the radiator drain plug,
flushed and filled with fresh coolant. Flushing should be carried out thoroughly to remove all the old coolant from the
engine and heater matrix. (The heatervalve isopen with the ignition OFF). AfterfilIing,checkthecoolant concentration
with a hydrometer. For specified anti-freeze and coolant concentration, see in Appendix Al.
X300 VSM 3 Issue 1 August 1994

€3 Cooling System (V12)
4.2.4 DRAIN AND FILL PROCEDURES
4.2.4.1 Radiator, Drain
. Place a drain tray in position under the radiator drain plug
. Remove the headertank pressure cap. Release thecaptive
Tighten the radiator drain plug.
(Fig.
1).
radiator drain
plug and drain the coolant.
CAUTION: This procedure does not drain the heater cir- cuit.
m: DO NOT REMOVE THE HEADER TANK PRES- SURE CAP WHILE THE ENGINE IS HOT. IF THE
CAP MUST BE REMOVED, PROTECT THE
HANDS AGAINST ESCAPING STEAM AND
SLOWLY TURN THE CAP
ANTI-CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE.
LEAVE THE CAP IN THIS POSITION UNTIL ALL
THE STEAM AND PRESSURE HAS ESCAPED
AND THEN REMOVE THE CAP COMPLETELY.
WARNING: WHEN DRAINING THE COOLANT
WITH THE
ENGINE HOT, PROTECT ME HANDS AGAINST
CONTACT WITH HOT COOLANT.
Fig. 1
4.2.4.2 Radiator, Fill
. Add coolant until the level in the header tank is steady at MAX. (Do not fit the header tank cap).
. Switch on the ignition. (The climate control system must be OFF).
. Start the engine and add coolant to the header tank if required to ensure that it does not empty.
. Run the engine until thetemperature gauge reads normal. (The enginespeed may be raised to reduce warm uptime).
. Switch off the ignition and wait for one minute.
Check that the coolant level in the header tank is between MAX and
10 mm above MAX. Add coolant as necessary.
. Fit the header tank cap.
4.2.4.3 Complete System, Fill
. Add coolant until the level in the header tank is steady at MAX. (Do not fit the header tank cap).
= Switch on the ignition. (The climate control system must be OFF).
. Start the engine and add coolant to the header tank if required to ensure that it does not empty.
. Run the engine until the temperature gauge reads normal, (The engine speed may be raised to reduce the warm up
. Turn the climate control system ON. Set the temperature to HI. Manually select a fan speed of approximately 50%.
. Run the engine for four minutes. Ensure that the climate control system outlet air temperature is hot to very hot and
that there is no noise from the heater coolant circulating pump. (The engine speed may be raised to assist with heat- ing).
time).
8 Switch
off the ignition and wait for one minute.
. Check that the coolant level in the header tank is between MAX and 10 mm above MAX. Add coolant as necessary.
. Fit the header tank cap.
4.2.4.4 System, Air Bleeding
After filling the system with coolant, any air present must be purged before effective cooling is possible. Provided the
correct fill procedure has been followed, purging of the system takes place automatically as follows:
The air entrained by the coolant, rises to the top of the radiator and to the highest point on each side of the engine (the
thermostat housings). While the thermostats are closed, the radiator is under reduced pressure due to the pump suc
- tion and air is bled through the jiggle-pins in each thermostat. Purged air is returnedvia the bleed system to the header
tank. When normal operating temperature is reached, the thermostats open and the system operates normally. ~~
Issue 1 August 1994 4 X300 VSM

4.2.5.2 Diagnostic Procedures
1
I Symptom ..
Overheating
herheating at
dle
roo cold ~~~
Possible Cause
Thermostat(s) stuck
closed
Incorrect thermostat rating
Faulty temperature gauge
Faulty temperature transmitter
Radiator core blocked
Radiator grille obstructed
Concentration of anti
-freeze
too high
Drive belt slack
Drive belt broken
Water pump seized
lnsuff icient coolant
Internally collapsed hoses
Incorrect ignition timing
Fuel
/ air mixture too weak
Incorrect valve timing
Cylinder head
gasket(s) leak-
ing
Brakes binding
Electric cooling
fan(s) not op- erating
Thermostat(s) stuck open
Incorrect thermostat rating
Thermostatb) not fitted
Electric cooling
fan(s) operat-
ing continuously
Faulty temperature gauge
Faulty temperature transmitter
Check
Cooling System (V12)
4.2.5 FAULT DIAGNOSIS
4.2.5.1 Introduction
The following diagnostic procedures are provided to assist properly qualified persons to identify and rectify the faults in the system which are most likely to be encountered. Reference is made to the Electrical Diagnostic Manual (EDM), which should be consulted for all electrical faults. When investigating faults relating to temperature, the prevailing
ambient temperature conditions should be taken into account. The climate control system is dealt with in Section 14.
Test thermostat(s)
Check thermostat operating
temperature
Refer to EDM
Refer to EDM
Check for
hotspots in radiator
Check grille for obstruction
Check strength of coolant
Check belt tension
Visual check Slacken drive belt and turn
water pump pulley by hand.
Check belt for damage
Check coolant level
Pressure test system and
check for deformation of hoses
Refer to EDM
Refer to EDM
Check valve timing
Pressure
-test system. (Check
for contamination of coolant in
header tank)
Check brake calipers for stick
- ing pistons and seized brake
pad pins
..
Refer to EDM
Test
thermostat(4
Check thermostat operating
temperature
Remove thermostat housing
and inspect
Refer to EDM
Refer to EDM
Refer to EDM
Remedy
Renew thermostat(s)
Renew thermostat(s1
Renew gauge
Renew transmitter
Flush or renew radiator
Remove obstruction from
grille
Drain and
fill with coolant of
correct concentration
Adjust belt to correct tension
or renew belt
if worn
Renew belt
Renew water pump. Renew
drive belt
if required
Top
-up coolant
Renew hoses as required
Rectify as required
Rectify as required
Correct valve timing
Renew head
gasket(s)
Rectify as required
Rectify as required
Renew
thermostat(s1
Renew thermostatb)
Fit thermostat(s)
Rectify as required
Renew gauge
Renew transmitter
Issue 1 August 1994 X300 VSM 5

Climate Control Systems
SECTION CONTENTS
Subsection Title SRO Page
i to iii ............ Preliminary Pages ................................................................ i to iii
14.1
............. Working Practices .................................................................... 1
Working Practices. General ............................................................ 1 14.1.1 ............
14.1.2. ........... Working Practices. Handling Refrigerant ................................................. 1
14.1.3 ............ Working Practices. Handling Lubricating Oil ............................................. 2
14.1.4
............ Working Practices. System Maintenance ................................................. 2
14.2
............. Climate ControlSystem ............................................................... 3
14.2.1
............ Climate Control System. Description .................................................... 3
14.2.2.
........... Climate Control System. Features ....................................................... 3
14.3
............. ClimateControl Panel ................................................................ 4
14.4
.............
14.4.1 ............ Temperature Control. Coolant Circuit .................................................... 6
14.5 ............. Air Conditioning Control Module ....................................................... 7
14.5.1 ............ Air Conditioning Control Module. Description 7
14.5.2. ........... Air Conditioning Control Module. Interfaces .............................................. 8
14.6
............. Control Module Fault & Condition Self-Analysis .......................................... 9
14.6.1
............ Control Module Fault & Condition Self-Analysis. System Health ............................. 9
14.6.2.
........... Control Module Fault & Condition Self-Analysis. System Protection .......................... 9
14.7
............. Air Distribution ..................................................................... 10
14.8
............. Refrigeration Cycle .................................................................. 12
14.9
............. General System Procedures ........................................................... 13
14.9.1
............ General System Procedures. Leak Test .................................................. 13
14.9.2
............ General System Procedures. Charge Recovery (System Depressurization) .................... 13
14.9.3.
........... General System Procedures. Evacuating the System ....................................... 13
14.9.4.
........... General System Procedures. Adding Lubricating Oil (Compressor Related) ................... 13
14.9.5.
........... General System Procedures. Adding Lubricating Oil (Component Related) ................... 14
14.9.6.
........... General System Procedures. Adding Refrigerant .......................................... 14
14.10
............ Fault Diagnosis ..................................................................... 15
14.10.1
.......... Fault Diagnosis. Introduction .......................................................... 15
14.10.2
.......... FaultDiagnosis. FunctionalCheck ..................................................... 15
14.10.3
14.11
............ Systemself- Test .................................................................... 17
14.1 1.1 ........... System Self- Test. Interrogation Procedure via the Control Panel ............................ 17
14.1 1.2 ........... System Self- Test. Control Panel Fault Code Key ......................................... 17
14.1 1.4 ........... System Self- Test. Panel Communication Check .......................................... 18
14.13
............ System Checking With Manifold Gauge Set ............................................. 20
14.7 3.1 .......... System Checking With Manifold Gauge Set. Evacuating the Gauge Set ...................... 20
14.13.2 .......... System Checking With Manifold Gauge Set. Connecting the Manifold Gauge Set .............. 20
14.13.3
.......... System Checking With Manifold Gauge Set. Stabilizing the System ......................... 20
14.14
............ Pressure / Temperature Graph (High Side / Ambient Temperature) ........................... 21
14.15
............ Pressure / Temperature Graph (Low Side / Evaporator Temperature) ......................... 22
14.16
............ System Pressure Fault Classification ................................................... 23
Temperature
Control
.................................................................. 6
............................................ a
.......... Fault Diagnosis. System Symptoms ..................................................... 15 a
14.1 1.3 ........... System Self- Test. Associated Faults .................................................... 18
14.12
............ Manifold Gauge Set ................................................................. 19
X300 VSM ~ i Issue 1 August 1994

Climate Control Systems
Illustration 1 JaguarNumber I Deription Not-
not i II ustrated
11. TORQUE TIGHTEN1 NG SPEC1 FICATIONS
Recovery 1 Recycling 1 Recharging
station See
standards
fixing
Blower assembly to body
Condenser to receiver
1 drier (tube nut)
lightening Torque
I (Nm)
4-7
14
- 18
Hoses to evaporator plate
Liquid line to receiver
1 drier (tube nut)
I Discharge hose to condenser (tube nut) I 22 - 28 I
7 - 10
14- 18
I Heater 1 cooler case to body I 5-7 I
I Hoses to compressor I 7-10 I
I Mountina strut to heater / cooler case I 5-7 I
X300 VSM Issue 1 August 1994 ii

Climate Control Systems
Description U-
HFC 134A - ICI Klea or
equivalent
Polyalkyleneglycol (PAG) Compressor lubricant
Refrigerant
111.
Notes
Recyclable. NOT
compatible
with CFC 12
Absorbs water readily. NOT
compatible with mineral based
oils
SERVICE MATERIALS
Standard for Recovery I Recycle 1 Recharge Equipment.
Recovery rate
Cleaning capability
Oil separator
.Moisture indicator
Vacuum pump
Filter Replaceable with moisture indicator
Charge Hoses
Feature Requirement
0,014 - 0,062 m3 / min. (1,36 kg in 20 minutes)
15 parts per million (ppm) moisture; 4000 ppm oil; 330 ppm non condensable gases
in air
With hermetic compressor and automatic oil return
Sight glass type, sensitive to 15 ppm minimum
2 stage 0,07 - 0,127 m3 I min.
Selectable charge weight and automatic delivery
Dedicated HFC 134A port connections.
Iv. SERVICE DATA
Application
Charae weight
Lubricant capacity
Compressor pressure relief valve
Drive belt 12 cylinder
Drive belt tension
All figures apply to a cold belt
Special note
Drive belt tension measuring point
Drive belt 6 cyclinder
Drive belt tension
All figures apply to a cold belt
Drive belt tension measuring point
Specification
160 - 200 ml
Opening point 34 Bar. Closing point 27,6 Bar.
Maximum leakage rate of 113 liters 1 minute @ 41 Bar
7 rib Poly
-vee; 1450 mm long
Burroughs method
- New belt 790 N; If tension falls
below 270 N reset at 630 N
Clavis method
- New belt 114 to 120 Hz; If tension falls
below 70 Hz reset at 87 to 93 Hz
For new belt; rotate engine 3 revolutions minimum and
retension
Mid-way between crankshaft and compressor pulley ~
4
rib Poly-vee X 1010 mm long
Burroughs method
- New belt 556 to 578 N; If tension
falls below 245 N reset at 378 to 400
N
Clavis method - New belt 167 to 173 Hz; If tension falls
below 85 Hz reset at 127 to 133 Hz
Mid
-way between crankshaft and compressor pulley on
the upper run
1 Charge pressure I Heating element to increase pressure
Issue 1 August 1994 X300 VSM iii

Climate Control Systems
14.1 WORKING PRACTICES
14.1.1 General
o Be aware of, and comply with all health and safety requirements, whether they be legislative or common sense.
This applies to conditions set both for the operator and workshop.
o Before commencing any repair or service procedure, disconnect the vehicle battery ground connection and
protect the vehicle where appropriate, from dirt or damage.
0 Work in a well ventilated, clean and tidy area (Fig. 1).
0 Keep all components and tools clean.
0 Recovery / Recycle and Recharge equipment must comply with, or exceed the standard detailed in the
preliminary pages.
Fig.
1
14.1.2 Handling Refrigerant
0 Wear eye protection at all times. Use gloves, keep skin that may come into contact with HFC 134A covered.
Should refrigerant come into contact with your eyes or skin; wash the affected area with cool water and seek
medical advice, do not attempt to treat yourself.
o Avoid breathing refrigerant vapour, it may cause ir- ritation to your respiratory system.
0 Never use high pressure compressed air to flush out
a system. Under certain circumstances HFC 134A +
compressed air + a source of combustion (welding
and brazing operations in the vicinity), may result in
an explosion and the release
of potentiallytoxiccom-
pounds.
0 HFC 134A and CFC 12 must never come into contact
with each other (Fig. 21, they will form an inseparable
mixture which can only be disposed of by inciner
-
ation.
0 Do not vent refrigerant directly to atmosphere, al- ways use Jaguar approved recovery equipment. Re-
member, HFC 134A is costly but recycleable.
continued
1 Issue 1 August 1994 X300 VSM

Climate Control Systems
0 Because HFC 134A is fully recycleable it may be 'cleaned' by the recovery equipment and re-used following
removal from a system.
0 Leak tests should only be carried out with an electronic analyzer which is dedicated to HFC 134A. Never use a CFC 12 analyzer or naked flame type.
0 Do not attempt to 'guess' the amount of refrigerant in a system, always recover and recharge with the correct
charge weight. In this context do not depress the charge or discharge port valves to check for the presence of
refrigerant.
14.1.3 Handling Lubricating Oil
0 Avoid breathing lubricant mist, it may cause irritation to your respiratory system.
0 Always decant fresh oil from a sealed container and do not leave oil exposed to the atmosphere for any reason
other than to fill or empty a system. PAG oil is very hygroscopic (absorbs water) and will rapidly become con-
taminated by atmospheric moisture.
PAG oil is
NOTcompatible with previously used mineral based oils and must NEVER be mixed (Fig. 1). Do not
re
-use oil when it has been separated from refrigerant, following a recovery cycle. Dispose of used oil safely.
14.1.4 System Maintenance
0 When depressurizing a system do not vent
refrigerant directlyto atmosphere, always use Jaguar
approved recovery equipment.
0 Always decant compressor oil from a sealed con- tainer and do not leave oil exposed to the atmosphere
for any reason other than to fill or empty
a system.
PAG oil is very hygroscopic and will rapidly become
contaminated by atmospheric moisture.
0 Plug pipes and units immediately after disconnection
and only unplug immediately priorto connection. Do
not leave the system open to atmosphere.
0 It is not necessary to renew the receiver drier when- ever the system has been 'opened' as previously ad-
vised - see note this page. However,if a unit or part
of the system is left open for more than five minutes,
it may be advisable to renew the receiver drier. This
guidance is based on
U.K average humidity levels;
therefore, locations with lower humidity will be less
critical to moisturecontamination of the unit.
It must
be stressed that there is not
a 'safe' period for workto
be carried out in: ALWAYS plug pipes and units im-
mediately after disconnection and only remove plugs
immediately prior to connection.
J82-387
Fin. 1
U: The receiver / drier MUST be renewed if the compressor has failed or if it is suspected that debris may be in
the system.
0 If replacement parts are supplied without transit plugs and seals DO NOT use the parts. Return them to your
supplier.
0 Diagnostic equipment for pressure, mass and volume should be calibrated regularly and certified by a third
party organization.
0 Use extreme care when handling and securing aluminium fittings, always use a backing spanner and take
special care when handling the evaporator.
0 Use only the correct or recommended tools for the job and apply the manufacturer's torque specifications.
Issue 1 August 1994 2 X300 VSM

Climate Control Systems
CL /MATE CONTROL SYSTEM 0 14*2 14.2.1 Description
The climate control system in the 1995 model year saloon has a centre mounted heater / cooler unit with separate
blower assemblies, one LH and one RH. Heating temperature control is effected by means of a coolant flow valve and
circulation pump.
For models fitted with air conditioning, cooling is provide by passing air through the evaporator, which is situated im
- mediately behind the heater / cooler case inlet ducts.
Electric motors with integral potentiometers are used to position
all flaps.
W: There are no vacuum operated components in the system.
14.2.2 Features
o Self diagnostic control system with error codes.
0 Actuator 'self check'.
0 Display element check.
m: These features will be helpful for initial trouble shooting and where Jaguar Diagnostic Equipment (JDE) is not
available.
0 'Soft touch' logic controls. 0
0 Serial link from panel to control module (NCCM).
0 LCD display for temperature, status and fan speed.
0 Variable fan speed, whether in automatic or manual mode.
0 Manual air flow distribution over-rides.
0 Compensated air flow with regard to vehicle speed.
0 Rear footwell outlets.
0 Rear face outlets.
0 Scavenge system closed circuit temperature control.
0 Heated front screen (where fitted).
x300 VSM 3

Climate Control Systems
14.3 CLIMATECONTROL PANEL
12 13 14 15 16
Fig. 1 Control layout (see key listing below)
The following description of the various control panel functions is provided as a brief over
-view to assist in function
checking. Further information concerning the control panel to component interface may be found in the fault finding
procedures (this section) or the Electronic Diagnostic Manual (EDM).
Iynfe: The system may be activated by any one of four commands. a) AUTO button item 1 1; b) DEFROST button item 12; c) NC button item 10; d) OFF switch item 1.
1. Combined push for OFF and rotary FAN SPEED control. The speed of the two fans is changed by clockwise (to
increase) or anti-clockwise rotation of the knob. Operation of the control, (push) OFF or (rotate) FAN over-rides
the AUTO selection and cancels the 'AUTO' display.
2. RECIRCULATE AIR push-on / push-off button and state lamp, used to prevent outside air being drawn into the
cabin. There are two modes:
a) Press and immediate release; provides timed recirculation of five
(5) minutes. b) Press and hold for two (2) seconds; 'latches' the mode until operator over-ride.
3. Temperature scale SELECTOR for Celsius or Fahrenheit.
4. FANS SPEED display bar graph.
5. TEMPERATURE numeric display for demand and exterior.
6. Selected temperature SCALE temperature numeric display.
7. EXTERIOR temperature option display.
Issue 1 August 1994 4 X300 VSM