Air Vent Cover JAGUAR X308 1998 2.G User Guide

the
intake elbow provide connections for vacuum actuators and are also used to redirect emissions into the engine.
On the right-hand side of the elbow a la rge diameter pipe connects to the brake servo. The smaller pipe provides a vacuum
feed to the fuel rail pressure regulator and throttle cruise control system. On the le ft-hand side of the elbow the front pipe
supplies vacuum control for the evaporative emissions system valves.
Emissions from the engine part load breather (bank 2) and pu rged fuel vapor from the EVAP valve are drawn via a common
T piece into the left-hand side of the intake elbow. Re-cir culated exhaust gas enters the intake elbow via the EGR valve
which is mounted directly on the rear of the elbow : where the EGR system is not used, a blanking plate is fitted.
The fuel system, throttle and emission control system s are described more fully in the relevant sections.
Intake Manifold

Filtered air from the vehicle's intake ducting is metered by th e electronic throttle and distributed to the two cylinder banks
via an integral intake manifold.
The intake manifold is manufactured in plastic with integral plastic fuel rails and metal-thread inserts; the very smooth
internal surfaces give excellent air flow.
Individual ducts lead off a central chamber to the inlet valves of each cylinder.
Silicon-rubber gaskets, loca ted in channels in the intake manifold, seal th e joints between the ducts and the cylinder heads.
Engine Ventilation

The e
ngine is ventilated through two brea
thers; a part-load breather and a full-load breather, one on each camshaft cover.
The outlet hose for the part-load breather is connected between the bank 2 camshaft cover and the intake elbow. The full-
load outlet hose is connected from the bank 1 camshaft cover to the intake duct between the MAF sensor assembly and the
throttle body.
Constructed in plastic, the hoses incorporate O-ring seal s and quick-release connectors; refer to Section 303-01.
I
ntake Air Distribution and Filtering - Supercharged Vehicles
Ai
r is supplied to the supercharger via an
intake cleaner/duct, throttle assembly and intake elbow which are similar to those
used for normally aspirated engines. The su percharger delivers pressurized air to two separate charge air cooler units, each
unit being mounted on the cy linder bank which it supplies. Pr essurized cooled air is fed from the charge air coolers directly
into each inlet port.

Intake Air Distribution and Filtering - Supercharger Outlet Pipe
Remo
val and Installation
Remov
a
l
1.
Re
move air cleaner cover / intake
assembly; refer to 19.10.30.
2. Drain radiator coolant; refer to operation (SC) 26.10.01.

3. Disc
onnect coolant hoses and vacuum pipe from supercharger
outlet duct.
Pl a
ce absorbent rags under
the two coolant hoses which
are connected to the outlet duct.
1. Remove vacuum pipe.
2. Disconnect hoses.
Plu g
hoses and outlet duct stub pipes to prevent spillage.

4. CAUTIO
N: Take care to avoi
d any coolant from dripping
into supercharger.
Remove supercharger outlet duct. 1. Remove three bolts.
2. Remove four bolts.
Di
scard rubber seals from bolts.
3. Remove outlet duct.
Discard ou
tlet duct gasket.
5.
Bla
nk supercharger outlet with
body tape, or similar, to
prevent ingress of foreign matter.

6. Remove charge air c oo
ler inlet assembly.
1. Remove two bolts.
2. Remove two bolts.
3. Remove charge air cooler inlet assembly.
7. Remove ducts from charge air cooler inlet assembly.
1. Remove two clamp plates.
2. Discard two ducts.

Evaporative E
missions - Evaporative Emissions
Description an
d Operation

To reduce the emission of fuel vapour, th e fuel tank is vented to atmosphere through activated charcoal adsorption canister
(s) which collects the fuel droplets. The ch arcoal is periodically purged of fuel when the EVAP Canister Purge Valve opens
the vapour line between the canister(s) and the air intake induct ion elbow. This action allows manifold depression to draw
air through the canister atmospheric vent, taking up the deposited fuel from the charcoal adsorber and burning the resulting
fuel vapour in the engine.
The EVAP Canister Purge Valve is controlled by the engine management system ECM. Purging is carried out in accordance
with the engine management fu eling strategy (see below).
The fuel tank vapour outlet is via a removeable flange assemb ly on the top surface of the tank. The vapour storage canister
or canisters are fitted on the underside of the vehicle below the rear seats.
There are three variants of the evaporativ e system. All systems use the charcoal adsorber storage canisters and purge valve
and operate as described above. The specific features of each system are described below. The evaporative systems are
designated as :
sin g
le canister system
ru
nn
ing loss system
ru
nn
ing loss with On-board Re-fueling Vapour Recovery (ORVR) system
EVAP Canister Purge Valve

Ite
m
Par
t
Number
De
scr
iption
1—EVAP canister purge v
alve
2—Valve s
olenoid connector
3—Vapour outlet to indu
ction elbow
4—Vapour
inlet from canister(s)
5—Vacuum contro
l pi
pe from induction elbow
6—Vacuum contro
l pi
pe to vapour pressure control va
lve - applicable to single canister systems only
7—Vacuum
control connection to EVAP valve

Climate Co
ntrol System - General In
formation - Climate Control System
Description an
d Operation
CAUTION: Observe all relevant safety requirements. Wear suitable eye and skin protection Do not mix HFC 134A and
CFC 12 refrigerants. Do not vent refrigerant directly to atmosphere and always use Jaguar approved recovery, recycle and
recharge equipment. Note the amount of recovered refrigerant; it will indicate the state of the system.
Working Practices
Be aware o
f, and comply with al
l health and safety requirements , whether they be legislative or common sense. This applies
to conditions set both for the operator and workshop.
Before commencing any repair or service procedure, disconnect the vehicle battery ground lead and protect the vehicle,
where appropriate, from dirt or damage.
Work in a well ventilated, clean and tidy area.
Keep all components and tools clean.
Recovery, recycle and recharge equipment must meet, or ex ceed, the requirements detailed in the Specification sub-
section.
Handling Refrigerant

We
ar eye protection at all times. Use gloves and keep all
skin covered that may come into contact with refrigerant.
Should refrigerant come into co ntact with eyes or skin, wash the affected area with cool water and seek medical advice; do
not attempt to treat the condition yourself.
Avoid breathing refrigerant vapor; it may cause irritation to the respiratory system.
CAUTION: Never use high pressure comp ressed air to flush out a system. Under certain ci rcumstances a combination
of HFC 134A refrigerant, compressed air and a source of combus tion (welding and brazing operations in the vicinity), may
result in an explosion and the release of potentially toxic compounds.

HFC 134A and CFC 12 refrigerants must neve r come into contact with each other. They will form an inseparable mixture
which can only be disposed of by incineration.
Do not vent refrigerant directly to atmo sphere; always use Jaguar approved recove ry equipment. Never depress the charge
or discharge port valves to check for the pr esence of refrigerant.
HFC 134A refrigerant is fully recycleable and it may be 'cleaned' by the recovery equipment and therefore re-used following
removal from a system.

Sym
ptom #2
Sy
mptom #2
Sym

ptom #3
Sy
mptom #3
No
cooling
Compressor sei
zed
Compressor seal failure
Compressor valve or piston damage
*
*
*
R
enew compressor
*
Compressor cl
utch / circuit faulty
*
R
efer to PDU
*
D
rive belt slack / broken
*
Adjust or r
enew
*
B
lower motor / circuit faulty
Pressure switch / circuit fault
*
*
R
efer to PDU
*
Total l
oss of refrigerant caused by broken pipe or joint
*
Repair / renew. Check code 2
3
*
P
artial loss of refrigerant caused by leaking joint or pipe
*
R
epair / renew, check fault code #23
*
Conden
ser damage
*
Re
new, check fault code #23
*
Bl
ocked receiver / drier filter
*
R
enew receiver / drier
*
Evaporator senso
r / circuit faulty
*
R
efer to PDU, check fault code #13
*
Bl
ocked pollen filter (if fitted)
*
Cle
an or renew
*
• NOTE: Should a leak or low refrigerant be established as the cause of INSUFFICIENT COOL ING, follow the procedures
Recovery / Recycle / Recharge, this section, and ob serve all refrigerant and oil handling instructions.
Sy
mptom
Possib
le Sources
Acti
on
Insuffi

cient
cooling
Compre
ssor clutch slipping
*
R
enew clutch assembly
*
Fl
aps or vents closed / seized
*
Check f
ault codes #41 to 46
*
Bl
ower circuit fault
*
R
efer to PDU
*
Bl
ocked condenser matrix / fins
*
Check hig
h / low side pr
essures / renew. Check /
clean fins
*
Bl
ocked evaporator matrix
*
Check hig
h / low side
pressures / renew
*
Bl
ocked pollen filter (if fitted)
*
Cle
an or renew
*
Evaporator temp
erat
ure sensor faulty
*
R
efer to PDU
*
P
artial loss of refrigerant caused by leaking joint

or pipe
*
R
epair / renew
*
Blocked expan
sion valve
*
Check hig
h / low side
pressures / renew
*
Expans
ion valve fault
*
Chec
k system pres
sure differential
*
C
ollapsed air conditioning hose hose
*
Check hig
h / low side
pressures / renew
*
Moi
sture or air in the system
*
Chec
k system pressures
*
Low r
efrigerant charge
*
Initiate recovery
procedure, check fault code #23
*
Coo
lant flow valve open
*
Chec
k operation
*
Sy
mptom
Possib
le Sources
Acti
on
Int

ermittent cooling
Compre
ssor clutch slipping
*
R
enew clutch assembly
*
Compressor cl
utch circuit faulty
Blower(s) circuit faulty
*
*
R
efer to PDU
*
Motorized in-car aspirator faulty

*
R
efer to PDU, check fault code #11
*
Evaporator temp
erature sensor faulty

*
R
efer to PDU, check fault code #13
*
Bl
ocked condenser matrix / fins
*
Check hig
h / low side pressures / renew. Check / clean fins

*
Bl
ocked evaporator matrix
*
Check hig
h / low side
pressures / renew
*


Sym
ptom #1
Sy
mptom #1
Sy

mptom
Possib
le Sources
Acti
on

Cl
imate Control System - General Info
rmation - Contaminated Refrigerant
Handling
Gen
eral Procedures

1.
CAUTION: If contaminated re frigerant is detected DO
NOT recover the refrigerant into your R-134a OR R-12
recovery/recycling equipment. Take the follow actions:
Repeat the test to verify contam inated refrigerant is present.
2. Advis
e the customer of the contaminated A/C system and any
additional cost to repair the system. The customer may wish to
return to the repair facility performing the last A/C repair.
3. Recover the contaminated refrigerant using suitable recovery
only equipment designed for capturing and storing
contaminated refrigerant. This equipment must only be used to
recover contaminated refrigerant to prevent the spread to other
vehicles. As an alternative, contact an A/C repair facility in your
area with the proper equipment to perform the repair.

Climate Control System - General Infor
mation - Refrigerant System Tests
Gen
e
ral Procedures
WARNING: USE EXTREME CARE AND OBSERVE ALL SAFETY PRECAUTIONS RELATED TO THE USE OF REFRIGERANTS.
FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY.
CAUTION: The A/C refrigerant analyzer mu st be used before the recovery of any vehicle' s A/C refrigerant. Failure to
do so puts workshop bulk refrigerant at risk of contamination. If the vehicle A/C refrigerant is contaminated, refer the
customer to return to the repair facility that carried out the last A/C repair. If the customer wishes to pay the additional
cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrige rant. All contaminated A/C
refrigerant must be disposed of as hazardous waste. To prevent possible pe rsonal injury, for all equipment, follow the
equipment manufacturer's procedures and instructions.
• NOTE: Jaguar Cars Ltd. supports the effi cient usage, recovery and recycling of the refrigera nt used in passenger car air
conditioners. Jaguar Cars Ltd. recommend s the use of UL-approved recovery/recycling equipment during any A/C system
repair and recharge procedure which requ ires that the system be evacuated.


1. Us
e UL-approved recovery/recycling equipment to evacuate
and recover the A/C system.
Follow t h
e equipment manufacturer's procedures and
instructions for use of equipment.

Air Distribution and Filtering - Center Registers
Removal and Installation
Removal
Installation

1.
Remove battery cover and disconnect ground cable from battery
terminal. Refer to 86.15.19.
2. Remove passenger airbag deployment door for access. Refer to
Section 501-20.
3. Remove major gauge module veneer panel for access. Refer to
76.47.24.
4. Carefully withdraw fascia centre veneer panel.

5. Slacken and remove four screws securing centre vent assembly
to fascia.
6. Withdraw centre vent assembly for access, disconnect clock
harness multiplug, release clock retaining tangs and remove clock
from vent assembly.

7. Remove and discard the four veneer panel to fascia securing
clips.
1. Fit and fully seat new veneer panel retaining clips to fascia.
2. Fit clock to centre vent assemb ly, ensuring retaining tangs are
fully seated.
3. Position centre vent assembly at fascia and connect clock
harness multiplug.
4. Fully seat vent assembly in fascia and fit and tighten securing
screws.
5. Fit and fully seat centre veneer panel.
6. Fit major gauge module veneer panel. Refer to 76.47.24.
7. Fit passenger airbag deployment door. Refer to Section 501-20.
8. Connect ground cable to battery terminal and fit battery cover.
Refer to 86.15.15.

Heating and Ventilation - Heater Core and Evaporator Core Housing
Removal and Installation
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Recover refrigerant from air co nditioning system; refer to
82.30.30.
3. Drain radiator coolant only; refer to 26.10.01 or (SC)
26.10.01.
4. Remove instrument panel for access, refer to 76.46.01.

5. From under the hood: Disconnect air conditioning pipes at the
evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.

6. Disconnect heater hoses from heater matrix pipes.
1. Release spring band clips and disconnect heater hoses.
2. Install suitable blanking plugs.

7. From inside the vehicle: re move driver footwell duct.
Remove screw.
Remove duct.
8. Remove upper steering column lower fixings.
1. Remove nut.
2. Remove bolt.

Repair Procedure
• CAUTIONS: Do not use crimping pliers, insulation strippers, butt splice connectors, heat sh rink sleeves or pre-terminated wiring
harness(s) that are not supplied with the Jagu ar wiring harness repair kit. Each part has been designed to be used only with
the other parts in this wiri ng harness repair kit.
Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to
the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not
over heat the glue lined heat shrink sleeve so that the wiring harness insulation becomes damaged.
It is not correct to make more than five repair joints on the wiring harness to any electrical connector and if more damage is
found at the same electrical connector then a new wiring harness must be installed.
Remove the faulty terminal from the elec trical connector using the extractor tool and correct tip. Make sure that any
anti-backout device is released befo re trying to remove the terminal.
CAUTION: : A number of electrical connector terminals ar e gold plated or gold flashed. When defective, they
must be installed with a gold pre-terminated wiring harnes s(s) from the wiring harness repair kit. It is not always
easy to identify the female as gold but the male pins are visually easier, therefore always check both male and
female terminals to identify those which are gold. Under no circumstances are gold and tin terminals to be mixed as
this will lead to early failur e of the electrical contact.
• NOTE: Never use a harness lead with a smalle r diameter than the original harness lead.
Select the correct size and ty pe of pre-terminated wiring harness and butt splice connector from the wiring harness
repair kit.
Using the wire cutter on the stripping tool, cut the pre-terminated wiring harness and the harness cable to the
required length.
• NOTE: See illustration: Stripping Insulation
From the Relationship Table, find the correct length of insulation to be stripped from the pre-terminated wiring
harness and set the adjustable cable length stop to the correct length. Place the pre-terminated wiring harness in
the wire stripper and remove the insulation.
Put the cable identification sleeve(s) on to the wiring harness with the main cable colour nearest to the terminal. During this next step do not overtighten. Place the selected butt splice connector in the crimping tool, matching the
aperture and the butt connector colours. Make sure that the window indentation in the butt connector is resting over
the guide bar on the lower jaw. Partially close the grip until the butt connec tor is securely held in the aperture. This
will give support to the butt conn ector while the pre-terminated wiring harness is inserted into it.
• NOTE: See illustration: Spice Correctly Located
Insert the pre-terminated wiring harnes s into the butt connector and make sure that the wire is against the wire
stop. Close the grip firmly, crimping the lead to the butt connector. When the handles have been completely closed
the butt connector will be fre ed from the tool as the handles are released. If the handles have not been completely
closed then the jaws will hold the butt connector and it cannot be removed from the tool until the crimp is fully made
by closing the handles completely. Make sure that the harness cable has been squarely cut and the correct length of insulation removed. If more than
one splice is needed the butt connectors must be not be crimped to the wiring harness at the same distance from
the connector. The splices must be staggered to prevent a bulk of splices in the same area of the wiring harness.
It is preferable to cover the butt splice joint with heat shrink sleeve. This is desirable not essential, except where the
electrical connector is a sealed electrical connector. Use the smaller diameter sleeve for red and blue pre-terminated
wiring harness(s) and the large diameter sleeve for the yellow pre-terminated wiring harnes s(s). It is advisable to
place the heat shrink over the completed joint but in some instances the sleeve will not pass over the terminal.
Check, and if required, place the correct size sleeve onto the harness cable or pre-terminated wiring harness before
crimping the butt splice to the wiring harness.
Place the harness cable into the butt splice with the spli ce window over the guide bar. Make sure that the cable
harness wire is agains t the stop in the butt splice, crimp the butt splice connector to the wiring harness.
Gently pull the harness cables each side of the butt sp lice to make sure that a secure joint has been made.
AMP 6.3 flatDD
Econoseal III 250 seriesBF