lock JAGUAR X308 1998 2.G Workshop Manual

10
.
Disconnect the fuel feed and return pipes from the fuel tank
F
it special tool JD-203 around
the pipe as shown. Press
the tool in between the fuel pipe and tank connector to
release the quick-fit tangs. While holding the tool firmly in,
pull out the fuel pipe.
Repeat
for the second pipe.
Plu

g the tank outlet connectors and the fuel pipes.

11
.
From the underside of the vehicl e, release the fuel filler latch
box drain pipe from the clip on the spare wheel well.

12
.
Disconnect and reposition the tr unk harness if it is routed
between the filler tube and the ta nk breather or pressure relief
pipe.
1. Disconnect the lefthand re ar lamp harness connector.
2. Disconnect the fuel flap lock actuator connector.
3. If fitted, disconnect the lefthand side marker lamp
connector and harness fro m the underside of the
vehicle. Withdraw the marker lamp harness and
grommet through the trunk floor access hole.
4. Release the harness securi ng clip from the mounting
bracket.
Wi
thdraw the trunk harness from between the filler tube
and the breather pipe or pressure relief pipe.
13. Disconnect the tank harness connections.

4. Full
y seat the tank into positi
on, ensuring that no harness
wiring is trapped.

5. On non-
ORVR vehicles, reconnec
t the trunk lid lefthand strut
rear pivot.
1. Fit the retaining clip on to the end of the trunk lid strut and fit the strut to the trunk lid pivot. Re-
position retaining clip to secure the strut.
Re
move any temporary trunk lid supports and check that
the lid operates correctly.

6. NOTE
: Make sure the special tool locating peg is correctly
installed to the cam.
Using the special tool, tighten the fuel tank retaining straps.
1. Rotate the cam clockwise to a torque of 6 Nm.
• NOTE: Using an open ended wrench, maintain the torque
on the special tool.
2. Tighten the fuel tank reta ining strap bolt to 25 Nm.

7. Connect the fi
ller neck to the fuel filler latch box seal.
1. Fit the fuel filler latch box seal over the filler neck.
2. Secure with the spring ring
F i
t the fuel filler cap.

8. Connect the vapour outlet pip
e.
Unplug the v
a
pour pipes.
Reconn
ect th
e tank and underfloor vapour pipes via the
quick-fit coupling .
9. Fit the fuel filler latch box drain pipe.
1. Feed the drain pipe th rough the floor grommet.
2. Connect the drain pipe to the fuel filler latch box stub

pipe.
3
. Tie the drain pipe to th
e filler tube using a ratchet
strap. Trim strap.

10
.
Reconnect the trunk harness connections.
1. If fitted, connect the wi ring to the accelerometer.
2. Connect the wiring to the fuel level sensor harness.
3. Connect the wiring to th e fuel pump connector.
4. If fitted, connect the wiring to the pressure sensor connector.

11
.
Reconnect the lefthand side trunk harness if it has been
necessary to move it for access. Route the harness behind both
the filler tube and breather or pressure relief pipe.
1. Fit the harness securing cl ip to the mounting bracket.
2. Connect the fuel flap lock actuator connector.
3. Connect the lefthand rear lamp harness connector.
4. If applicable, feed the side marker lamp harness through the access hole in the floor and reseat the
sealing grommet.
On
the underside of the vehicl
e, fit the side marker lamp
connector and fix the harness to the securing clips.

12
.
On the underside of the vehicle, fit the drain pipe to the
securing clip.
13. On the underside of the vehicle, reconnect the fuel feed and
return pipes.
R
emove the plugs from the tank
and fuel feed and return

Accelerati
on Control - Accelerator Cable Adjustment
Gen
eral Procedures

1.
Load the Approved Jaguar Diagno stic System with power train
data logger.
2. Connect the Approved Jaguar Diag nostic System to the vehicle.

3. W
ith 'Disable Network Integrity Test - YES/ NO' displayed on
the screen select YES.
4. With new menu displayed on the screen, select ' Engine
Management'.
5. Turn the ignition to ON.
R
emove any previously selected data logger parameters.
6. On data logger select PPS11 an d PPS2 (Pedal demand sensors
1 and 2).
7. On Sedan models only, remove the bulkhead covers on both
sides and the engine compartment rear cover.
8. Cut, remove and discard the ra tchet strap which retains the
throttle cable to the abutment bracket.
9. Ensure there is no tension on the throttle cable by releasing
the throttle cable adjustment nut from the abutment bracket.
10. Record the voltages for both sensors, PPS11 and PPS2.
11. Partially insert the throttle cable adjustment nut into the
abutment bracket.
12. Recheck the voltages for both sensors, PPS11 and PPS2.
13. Where the voltages at step 12 are higher than the voltages
taken at step 10, contin ue to step 15 below.
14. Where the voltages at step 12 are the same as the voltages
taken at step 10, contin ue to step 16 below.
15. Rotate the adjustment nut clockwise (as viewed from the
front of the vehicle) until the same voltages are indicated as in
step 10. Continue to turn thro ugh a part revolution until the
sides of the nut are vertical. Tu rn through a further 90 degrees,
then fully insert the nut into the abutment bracket.
16. Rotate the adjustment nut anti-clockwise (as viewed from the
front of the vehicle) until the indicated voltage starts to
increase. Then rotate the nut clockwise through a part
revolution until the sides are ve rtical. Turn through a further 90
degrees, then fully insert the nut into the abutment bracket.
17. Fit a new ratchet strap to secure the throttle cable adjusting
nut to the abutment bracket.
18. Operate the throttle pedal through 20 full cycles to settle the
cable. Check the voltages now shown, remain the same as in
steps 15 and 16.
19. Check and where necessary adjust the kickdown switch. For
additional information, refer to Section 307
-05A Automatic Transmissi
on/Transaxle External Controls
Sectio
n
307
-05
B
Au

tomatic Transmission/Tra
nsaxle External Controls
.
20
.
On Sedan models only, refit the engine compartment rear
cover and the bulkhead co vers on both sides.
21. Switch the ignition OFF and disconnect the Approved Jaguar
Diagnostic System.

Probable
causes of faults may be found by comparing actual
system pressures, registered on your manifold gauge set or
recovery / recharge / recycle station, and the relevant pressure to temperature relationship graph. The following chart
shows the interpretation that ma y be made by this difference.
• NOTE: The A/CCM will disengage the compressor clutch should the evaporator temperature fall to 0°C.
• NOTE: Graphs are typical for HFC 134A
The 'Normal' condition is that which is relevant to the prevailing evaporator temperature.
System Pressure Fault Classification
• NOTE
: If erratic or unusual gauge move
ments occur, check the equipment against a known (calibrated) manifold gauge
set.
This table should be used in conjunction with the graphical representations of 'High side' pressure / ambient temperature
and 'Low side' pressure / evaporator temperature.
Leak
Test
F
a
ults associated with low re
frigerant charge weight and low pressure ma y be caused by leakage. Leaks traced to
mechanical connections may be caused by to rque relaxation or joint face contamination. Evidence of oil around such areas
is an indicator of leakage.
Models that have fluorescent tracer dye incorporated into the refrigeration system can be checke d for non-apparent leaks by
scanning with a high intensity ultraviolet lamp. The location of leaks can be pinpointed by the bright yellow glow of the
tracer dye.
CAUTION: Observe ALL safety precautions associated with ultraviolet equipment.
Should a leak be traced to a joint, check that the fixing is secured to the correct tightening torque before taking any other
action.
When examining the system for leaks, chec k the compressor shaft seal and evaporator.
Charge Re
covery (system depressurization)
The process of
charge r
ecovery will depe
nd on the basic characteristics of your chosen recovery / recycle / recharge
equipment, therefore, follow the manu facturer's instructions carefully.
Remember that compressor oil may be drawn out during this process, take note of the quantity recovered so that it may be
Lo
w side
gauge reading
High s i
de
gauge reading
Fau l
t
Cause
No
r
mal
No
r
mal
Di
sc
harge air initially cool then
warms up
Mois
ture in system
N
ormal
to low
No
r
mal
As aboveAs above
LowLowD
i
scharge air slightly cool
Ref
r
igerant charge low
LowLowDi

scharge air warm
Refr
igerant charge very low
LowLowDi

scharge air slightly cool or frost
build up at expansion valve
Expansion valve st
uck closed
LowLowDi

scharge air slightly cool,
sweating or frost after point of restriction
Restri
ction in High side of system
HighLowCompressor noisyDe
fe
ctive compressor reed valve
HighHighD
i
scharge air warm and high side
pipes hot
Refri
gerant charge high or inefficient condenser
cooling due to air flow blockage or engine cooling fans
not working
HighHighD i
scharge air warm / Sweating or
frost at evaporator
Expans ion valve st
uck open

re
placed.
E

vacuating the System
This process, the removal
of un
wanted air and moisture, is crit ical to the correct operation of the air conditioning system.
Moisture in the system can be highly de structive and may cause internal blockages due to freezing; water suspended in the
lubricating oil will dama ge the compressor. Once the system has been dismantled, or the refrigerant charge recovered, all
traces of moisture must be removed before recharging.
Specific procedures will vary depending on the individual characteristics of the recovery / recycle / recharge equipment, and
must be carried out exactly in accordance with the manufacturer 's instructions. However, it is recommended that initially
only the high-side valve be opened at the start of the procedure. After a short time a small depression should be seen on
the low-side, at which point the low-side valve may be opened and the evacuation process completed. If a vacuum is not
registered on the low-side, it may indicate that the expansion valve is permanently closed or that the system is blocked.
This simple check may save time and effort when the system is recharged.

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

Symp
tom #5
Sy
m
ptom #5


Low r
e
frigerant charge
*
Check f or 'hissi
ng' at expansion
valve; may be witnessed by low
HIGH side pressure. Recover / recharge
*
Moi
s
ture or air in the system
*
Chec k syst
em pressures
*
Heat er ci
rcuit air-lock
*
R e
fer section 303-03 for fill / bleed procedure
*
Suct ion
pipe touching bank 1 (A)
cylinder head (rubber isolator
missing)
*
Check the pi
pe cluster for correct fitti
ng
*
• NOTE: Electrical faults may be more rapidly traced using PDU
Sym
ptom
Possib
l
e Sources
Acti
o
n
Insuffi
ci
ent
heating
Coo l
ant flow valve stuck 'closed'
Coolant flow valve stuck 'open' allowing recirculation of
coolant at engine idle
*
*
Re
new v
alve
*
Motorized in-car aspirator sei zed
*R e
new aspirator
*
Coo l
air bypass damper stuck open

*
Re new,
check fault code #43

*
B l
ocked air inlet / pollen filter
*
Chec k / cl
ean / renew
*
B l
ower speed low
*
Check performance range
*
Low cool ant
level
*
Adjust as req u
ired (verify and correct
reason for loss)
*
Engine
t
hermostat faulty
*
Check engine r u
nning temperature
*
Heater water pump seized
*Chec k op
eration
*
Heater ma trix
blocked
*
Re new m
atrix
*
Heater circui t
air-lock
*
R e
fer section 303-03 for fill / bleed
procedure
*

Sym
p
tom #4
Sym
ptom #4
Sy
m
ptom
Possib
l
e Sources
Acti
o
n
No
i
sy
system
Loose or damaged compressor drive
belt
*Adjust or r
e
new
*
Loose compressor mountings
*Check f o
r damage, tighten to specification if OK
*
Compressor oil level l
ow
*
Look for evidence of l
eakag
e and rectify as required
*
Compressor internal dama ge
*Check f o
r debris, renew compressor and receiver drier
*
B l
ower motor noise
*
Re new m
otor (assuming no fan interference)
*
Excessive refrige rant charge
*Check f o
r vibration or 'thumping'
in high pressure line; may be
witnessed by high pressure on both HIGH and LOW sides.
Recover / recharge
*

Clima
te Control System - General Inform
ation - Manifold Gauge Set Connection
Ge
neral Procedures
Mani
fol
d.
Low Side Pressure Gauge.
High Side Pressure Gauge.

1.
The 'ma
nifold gauge set' is a most important tool for tracing faults and
system efficiency assessment. The relationship between HIGH and LOW
pressures and their correlation to AMBIENT and EVAPORATOR
temperatures must be compared to determine system status (see
Pressure / Temperature graphs).
Because of the heavy reliance upon this piece of equipment for service
diagnosis, ensure that the gauges are calibrated regularly and the
equipment is treated with care.

2.
Parts
List
ItemDescri
ption1LOW side
serv
ice hose

- BLUE
2LOW side
ha
nd valve -
BL
UE3LOW
pres
sure
compound
gauge _ BLUE
4HI GH

pressure
gauge _ RED
5HI GH
side
hand valve -
RED6HI GH
side
service hose
- RED
7Sys t
em
service hose
- Neutral color,
commonly YELLOW
1. The manifold is designed to control refrigerant flow. When connected into
the system, pressure is registered on both gauges at all times. During
system tests both the high and low side hand valves should be closed
(rotate clockwise to seat the valves). The hand valves isolate the low and
the high sides from the center (service) hose.
1. This compound gauge, is designed to register positive and negative
pressure and may be typically calibrate d - Full Scale Deflection, 0 to 10
bar (0 to 150 lbf / in2) pressure in a clockwise direction; 0 to 1000 mbar
(0 to 30 in Hg) FSD negative pressu re in a counter clockwise direction.
1. This pressure gauge may be typically calibrated from 0 to 30 bar (0 to
500 lbf / in2) FSD in a clockwise direction. Depending on the
manufacturer, this gauge may also be of the compound type.

Air
Particle Filter

The air particle filter system (where fitted) is located in the plenum below the windshield .
• NOTE: Refer to 'Filter Compensation', Section 412-04.
The filter elements are retained by adhesive strip which is atta ched to the filter moulding; the filter is fitted with the light,
flocked surface towards the engine.
Loca
tion of Air Distribution Ducts
LHD s
hown