Engine JAGUAR XFR 2010 1.G Workshop Manual

Symptom Chart

Symptom Possible Causes Action Air conditioning performance poor or
inoperative
Refrigerant undercharged
Refrigerant overcharged
Thermostatic expansion valve
faulty
Receiver drier restricted
Water in refrigerant
GO to Pinpoint Test A. Air conditioning operates briefly and
then switches off
Electric cooling fan inoperative
Air conditioning condenser
airflow obstructed
Test the operation of the electric cooling
fan
Check the air conditioning condenser for
external obstructions Pinpoint Tests

PINPOINT TEST A : PRELIMINARY TESTS TEST CONDITIONS DETAILS/RESULTS/ACTIONS A1: PRELIMINARY TEST 1 NOTES:


This test is performed with the engine not running.
Normal pressure for a correctly charged and switched off system is approximately 4.5 bar on both gauges (system
equalised). 1 Close the valves on the air conditioning station 2 Connect the air conditioning station to the vehicle charging ports 3 Check the pressure values Is a pressure registered on both gauges? Yes
GO to Pinpoint Test B. No
GO to Pinpoint Test D.
PINPOINT TEST B : FUNCTIONALITY TESTS TEST CONDITIONS DETAILS/RESULTS/ACTIONS B1: FUNCTIONALITY TEST 1 NOTES:


Normal pressures for a correctly charged and working system are 1.0 bar to 2.0 bar (low) and 11.0 bar to 15.0 bar (high).
Normal temperature (measured at the center air vent) for a correctly charged and working system is -7°C to -2°C when
ambient temperature is 20°C. 1 Close the valves on the air conditioning station 2 Connect the air conditioning station to the vehicle charging ports 3 Open all doors and the tailgate 4 Start the engine 5 Set the temperature to the lowest setting (all zones) 6 Set the fan speed to maximum 7 Set the recirculate switch to off 8 Insert a temperature probe into the centre air vent 9 Raise engine speed to 1500rpm and maintain this speed for 5 minutes 10 Check the temperature value 11 Check the pressure values Are the pressure readings stable and in the green 'normal' region of the gauge? Yes
Air conditioning system operating normally No
Air conditioning system fault present. GO to Pinpoint Test C.
PINPOINT TEST C : GAUGE TESTS

TEST
CONDITIONS DETAILS/RESULTS/ACTIONS C1: GAUGE TEST 1
NOTE: This test is performed with the engine running and the air conditioning set to on. 1 Check the pressure values Did the gauges register a change in pressure when the air conditioning was switched on? Yes
GO to C2. No
Using the manufacturer approved diagnostic system, check the Automatic Temperature Control Module (ATCM) for related DTCs and refer to the relevant DTC index C2: GAUGE TEST 2
NOTE: This test is performed with the engine running and the air conditioning set to on. 1 Check the pressure values Are the pressure gauge readings fluctuating? Yes
Moisture present in the air conditioning system. Recover the refrigerant. Install a new receiver drier.
Refer to the relevant section of the workshop manual and evacuate and recharge the air conditioning
system. GO to Pinpoint Test B. No
GO to C3. C3: GAUGE TEST 3 NOTES:


This test is performed with the engine running and the air conditioning set to on.
Normal pressures for a correctly charged and working system are 1.0 bar to 2.0 bar (low) and 11.0 bar to 15.0 bar (high). 1 Check the pressure values Are the pressure gauge readings too low? Yes
GO to C4. No
GO to C6. C4: GAUGE TEST 4
NOTE: This test is performed with the engine not running. 1 Stop the engine 2 Using the manufacturer approved refrigerant leak detector, check for a refrigerant leak Was a refrigerant leak detected? Yes
Refer to the relevant section of the workshop manual and recover the refrigerant. Repair as necessary.
Evacuate and recharge the air conditioning system. GO to Pinpoint Test B. No
GO to C5. C5: GAUGE TEST 5
NOTE: This test is performed with the engine not running. 1 Refer to the relevant section of the workshop manual and recover the refrigerant Was the weight of the recovered refrigerant less than specified for the air conditioning system? Yes
Refer to the relevant section of the workshop manual and evacuate and recharge the air conditioning
system. GO to Pinpoint Test B. No
Install a new receiver drier. Refer to the relevant section of the workshop manual and evacuate and recharge the air conditioning system. GO to Pinpoint Test B. C6: GAUGE TEST 6 NOTES:


This test is performed with the engine running and the air conditioning set to on.
Normal pressures for a correctly charged and working system are 1.0 bar to 2.0 bar (low) and 11.0 bar to 15.0 bar (high).

1 Check the pressure values Are the pressure gauge readings too high? Yes
GO to C7. No
Test inconclusive. GO to Pinpoint Test B. C7: GAUGE TEST 7
NOTE: This test is performed with the engine not running. 1 Stop the engine 2 Refer to the relevant section of the workshop manual and recover the refrigerant Was the weight of the recovered refrigerant more than specified for the air conditioning system? Yes
Refer to the relevant section of the workshop manual and evacuate and recharge the air conditioning
system. GO to Pinpoint Test B. No
Install a new thermal expansion valve. Refer to the relevant section of the workshop manual and
evacuate and recharge the air conditioning system. GO to Pinpoint Test B.
PINPOINT TEST D : NITROGEN LEAK TESTS TEST
CONDITIONS DETAILS/RESULTS/ACTIONS D1: NITROGEN LEAK TEST
CAUTION: When charging the system with nitrogen, the pressure should be regulated to 7.0 bar.
NOTE: This test is performed with the engine not running. 1 Charge the air conditioning system with nitrogen 2 Isolate the nitrogen supply 3 Monitor the pressure gauge and check for leaks Has the source of the leak been identified?
Yes
Rectify the leak as necessary. Install a new receiver drier. Refer to the relevant section of the workshop
manual and evacuate and recharge the air conditioning system. GO to Pinpoint Test B. No
Refer to the relevant section of the workshop manual and evacuate and recharge the air conditioning system. GO to Pinpoint Test B.
DTC Index

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Climate Control Module (HVAC) (100-00 General Information, Description and Operation).

Published: 11-May-2011
Climate Control System - General Information - Electronic Leak Detection
General Procedures


1. WARNING: Good ventilation is necessary in the area where A/C leak
testing is to be carried out. If the surrounding air is contaminated with
refrigerant gas, the leak detector will indicate this gas all the time.
Odors from other chemicals such as antifreeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can cause the same problem. A fan,
even in a well ventilated area, is very helpful in removing small traces of
contamination from the air that might affect the leak detector. Failure to
follow this instruction may result in personal injury.

Attach an R-134a manifold gauge set or use a UL-approved
recovery/recycling device such as an R-134a A/C refrigerant center (which
meets SAE Standard J 1991). For additional information, refer to the
manufacturers equipment instructions.
Both gauges should indicate 413-551 kPa (60-80 psi) at 24°C
(75°F) with the engine off.
If little or no pressure is indicated, carry out the air conditioning
(A/C) system recovery, evacuation and charging procedure.
For additional information, refer to Air Conditioning (AC) System Recovery, Evacuation and Charging in this section.
2. Use an R134-a Automatic calibration halogen leak detector to leak test
the refrigerant system. For additional information, refer to the
manufacturers equipment instructions.

3. If a leak is found, carry out the air conditioning (A/C) system recovery
procedure.
For additional information, refer to Air Conditioning (AC) System Recovery, Evacuation and Charging in this section.

Published: 15-Nov-2013
Climate Control System - General Information - Air Conditioning (A/C)
Compressor Commissioning
General Procedures

Activation

CAUTION: Failure to follow this instruction may result in damage to the component.

1. Set the ignition to the on position, make sure the air conditioning (A/C)
is in the off position.

2. Start the engine and allow to run for a minimum of 5 minutes.

3. Set the heater controls to 22°C, with the fan speed set to 75%.

4. Switch on the A/C system.

5. Open all air vents in the dashboard.

6. Run the A/C system for a minimum of 5 minutes, while the engine is still
at idle speed.

7. Once this is achieved the compressor is stabilized, with the oil being
distributed evenly throughout the system.

7 RH (right-hand) outer face level register 8 RH inner face level register 9 LH (left-hand) inner face level register 10 LH outer face level register 11 Face/Feet distribution stepper motor 12 RH temperature blend stepper motor 13 Windshield (defrost) distribution stepper motor 14 LH temperature blend stepper motor


Face Level Registers System Operation

Operation of the face level registers is controlled by the ATC module, using LIN bus messages to the integral stepper motors. The four registers operate together in both the opening and closing phases.

The face level registers can be selected to run in one of two modes; 'automatic' or 'always open'. The mode is selected on the
climate control screen of the TSD.
Refer to: Navigation System (415-01 Information and Entertainment System, Description and Operation).

In the automatic mode, operation of the face level registers is synchronized with the engine START/STOP button. When the
engine starts the ATC module opens the registers. When the engine stops, the ATC module closes the registers.
If a face level register is fouled, when it receives an open or close request, the register concerned makes a number of
attempts to reach the requested position. If the register still does not move, it is left in the fouled position. The remaining
registers will continue to open and close as normal.

The automatic mode is disabled when the climate control system is off. The ATC module closes the registers if they are open in the automatic mode and the climate control system is selected off.

Diagnostics

If a fault occurs with the face level registers, a DTC (diagnostic trouble code) is stored in the ATC module. The DTC can be read using the Jaguar approved diagnostic system. The Jaguar approved diagnostic system can also initiate a self test routine
to check the operation of the face level registers.
Refer to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).


Air Ducts Component Description

The air ducts distribute air from the heater assembly to the registers and vents in the instrument panel and the center floor
console. Air ducts also direct air from the heater assembly into the front and rear footwells.

Registers and Vents

The registers control the flow and direction of air from the air ducts. The instrument panel contains four face level registers;
one at each end and two mounted centrally. For the rear seat occupants, two registers are installed in the rear face of the
center floor console. All of the registers incorporate vertical and horizontal directional vane adjustment and full air flow
adjustment down to zero.

The four face level registers in the instrument panel each contain an integral stepper motor. The stepper motors enable the
registers to rotate between the open and closed positions. In the open position, the registers have normal appearance and
functionality. In the closed position, the registers present a smooth surface flush with the surrounding instrument panel.

The vents are fixed outlets. There are four vents in the upper surface of the instrument panel; one in each end to direct air
onto the side windows and two along the front edge to direct air onto the windshield.
Central Face Level Registers
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Touch screen display (TSD) 6 Integrated control panel 7 Information control module 8 ATC (automatic temperature control) module 9 Face/Feet distribution stepper motor 10 RH (right-hand) temperature blend stepper motor 11 LH (left-hand) temperature blend stepper motor 12 Windshield (defrost) distribution stepper motor 13 Blower control module 14 RJB (rear junction box) 15 Blower
System Operation
Operation of the heating and ventilation system is controlled by the ATC module. Refer to: Control Components (412-01 Climate Control, Description and Operation).
The system can be operated in automatic or manual mode, with temperature settings selected using the switches on the
integrated control panel.

When the engine is running, coolant is constantly circulated through the heater core by the engine coolant pump and the
auxiliary coolant pump. Where fitted, the auxiliary coolant pump is energized by the CJB on receipt of medium speed CAN bus signals from the ATC module. The CJB broadcasts auxiliary coolant pump status over the medium speed CAN bus for use by other vehicle systems.

The blower is supplied with power by the blower relay on the RJB and connected to ground via the blower control module. The blower control module regulates the voltage across the blower motor to control blower speed. The voltage set by the blower
control module is controlled by a PWM (pulse width modulation) signal from the ATC module. The ATC module uses a feedback signal from the blower control module to monitor blower speed.
Refer to: Control Components (412-01 Climate Control, Description and Operation).


Heater Assembly Component Description

The heater assembly controls the temperature and flow of air supplied to the air distribution ducts. The heater assembly is
mounted on the vehicle centerline, between the instrument panel and the engine bulkhead.

The heater assembly consists of a casing that contains an A/C (air conditioning) evaporator, a heater core, two air distribution
control doors and two temperature blend control doors. On 2.7L diesel vehicles, the heater assembly also contains an electric
booster heater.
Refer to: Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation).
Mounted on the heater casing are four stepper motors. Each of the stepper motors is connected to either an air distribution
control door or a temperature blend control door.
The A/C evaporator is part of the A/C system. Refer to: Air Conditioning (412-01 Climate Control, Description and Operation).
The heater core provides the heat source to warm the air supplied to the passenger compartment. The heater core is an
aluminum two pass, fin and tube heat exchanger, and is installed across the width of the heater housing. Two aluminum tubes
attached to the heater core extend through the engine bulkhead and connect to the engine cooling system. For additional
information, refer to:
Engine Cooling (303-03A, Description and Operation),
Engine Cooling (303-03B Engine Cooling - V6 3.0L Petrol, Description and Operation), Engine Cooling (303-03C, Description and Operation).

Air Inlet Duct

The air inlet duct connects the fresh air inlet in the engine bulkhead to the heater assembly. The air inlet duct is installed
behind the instrument panel on the passenger side.

The air inlet duct consists of a casing that contains a pollen filter, an air inlet door, a blower and a blower control module. A
recirculation air inlet is incorporated into the casing. A servo motor is mounted on the casing and connected to the air inlet
door, to allow selection between fresh and recirculated air.
Refer to: Control Components (412-01 Climate Control, Description and Operation). The pollen filter is part of the air distribution and filtering system.
Refer to: Air Distribution and Filtering (412-01 Climate Control, Description and Operation).
The blower regulates the volume of air flowing through the air inlet duct to the heater assembly. The blower consists of an
open hub, centrifugal fan and an electric motor.
The blower control module regulates the power supply to the blower motor. The blower control module is installed in the air

1 Evaporator 2 Thermostatic expansion valve 3 High pressure servicing connection 4 Refrigerant pressure sensor 5 Engine cooling fan 6 Condenser 7 Receiver/Drier 8 A/C compressor 9 Low pressure servicing connection 10 Blower NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow.

1 Pressure relief valve 2 Outlet port 3 Inlet port 4 Solenoid valve 5 Electrical connector 6 Pulley The A/C compressor circulates refrigerant around the system by compressing low pressure, low temperature vapor from the evaporator and discharging the resultant high pressure, high temperature vapor to the condenser.

The A/C compressor is a permanently engaged variable displacement unit which is driven by the engine accessory drive belt. To protect the system from excessive pressure, a pressure relief valve is installed in the outlet side of the A/C compressor. The pressure relief valve vents excess pressure into the engine compartment.

control switch on the integrated control panel or the + and - soft buttons on the touch screen display (TSD). The ATC module also adjusts blower speed to compensate for the ram effect on inlet air produced by forward movement of the vehicle. As
vehicle speed and ram effect increases, blower motor speed is reduced, and vice versa.

Air Distribution Control

Two air distribution doors are used to direct air into the passenger compartment. The doors are operated by stepper motors,
which are controlled by the ATC module using LIN bus messages.
When the A/C system is in automatic mode, the ATC module automatically controls air distribution into the passenger compartment in line with its 'comfort' algorithm. Automatic control is overridden if any of the TSD air distribution soft buttons
are selected. Air distribution in the passenger compartment will remain as selected until the 'Auto' switch is pressed or a
different manual selection is made.

A/C Compressor Control

When A/C is selected the ATC module maintains the evaporator at an operating temperature that varies with the passenger compartment cooling requirements. If the requirement for cooled air decreases, the ATC module raises the evaporator operating temperature by reducing the flow of refrigerant provided by the A/C compressor. The ATC module closely controls the rate of temperature increase to avoid introducing moisture into the passenger compartment.

If the requirement for cooled air increases, the ATC module lowers the evaporator operating temperature by increasing the flow of refrigerant provided by the A/C compressor.
When A/C is off, the compressor current signal supplied by the ATC module holds the A/C compressor solenoid valve in the minimum flow position, effectively switching off the A/C function.
The ATC module incorporates limits for the operating pressure of the refrigerant system. If the system approaches the high pressure limit, the compressor current signal is progressively reduced until the system pressure decreases. If the system falls
below the low pressure limit, the compressor current signal is held at its lowest setting so that the A/C compressor is maintained at its minimum stroke. This avoids depletion of the lubricant from the A/C compressor.
A/C Compressor Torque

The ATC module transmits refrigerant pressure and A/C compressor current values to the ECM (engine control module) over the medium speed then high speed CAN bus, using the CJB as a gateway. The ECM uses these values to calculate the torque being used to drive the A/C compressor. The ECM compares the calculated value with its allowable value and if necessary forces the ATC module to inhibit the A/C compressor by transmitting the 'ACClutchInhibit' CAN message. This forces the ATC module to reduce the drive current to the A/C compressor solenoid valve, which reduces refrigerant flow. This in turn reduces the torque required to drive the A/C compressor.
By reducing the maximum A/C compressor torque, the ECM is able to reduce the load on the engine when it needs to maintain vehicle performance or cooling system integrity.

Cooling Fan Control

The ATC module determines the amount of condenser cooling required from the refrigerant pressure sensor, since there is a direct relationship between the temperature and pressure of the refrigerant. The cooling requirement is broadcast to the ECM on the medium speed CAN bus. The ECM then controls the temperature of the condenser using the cooling fan.
Programmed Defrost

The programmed defrost DEF switch is located on the integrated control panel. When the switch is pressed, the ATC module instigates the programmed defrost function. When selected, the ATC module configures the system as follows:
Automatic mode off.
A/C on. Selected temperature unchanged.
Air inlet set to fresh air.
Air distribution set to windshield.
Blower speed set to level 6.
Windshield heater (where fitted) and rear window heater on.
The programmed defrost function can be cancelled by one of the following:
Selecting any air distribution switch on the TSD.
Pressing the AUTO switch on the integrated control panel.
A second press of the DEF button.
Switching the ignition OFF.
The blower speed can be adjusted without terminating the programmed defrost function.

Rear Window Heater

Rear window heater operation is only enabled when the engine is running. The ATC module controls operation of the rear window heater using a relay in the RJB. When rear window heater operation is required, the ATC module broadcasts a message to the RJB on the medium speed CAN bus. On receipt of the message, the RJB energizes the relay by providing a ground path for the relay coil. This allows a battery feed to flow across the relay to power the rear window heater element.