charging JAGUAR XFR 2010 1.G Repair Manual

Published: 11-Jul-2014
Climate Control System - General Information - Climate Control System
Diagnosis and Testing

Principles of Operation

For a detailed description of the Climate Control System, refer to the relevant Description and Operation sections in the
Workshop Manual. REFER to:

Air Distribution and Filtering (412-01 Climate Control, Description and Operation), Air Distribution and Filtering (412-01 Climate Control, Description and Operation), Air Distribution and Filtering (412-01 Climate Control, Description and Operation), Heating and Ventilation (412-01 Climate Control, Description and Operation), Heating and Ventilation (412-01 Climate Control, Description and Operation), Heating and Ventilation (412-01 Climate Control, Description and Operation), Air Conditioning (412-01 Climate Control, Description and Operation), Air Conditioning (412-01 Climate Control, Description and Operation), Air Conditioning (412-01 Climate Control, Description and Operation), Control Components (412-01 Climate Control, Description and Operation), Control Components (412-01 Climate Control, Description and Operation), Control Components (412-01 Climate Control, Description and Operation), Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation), Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation), Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation).
Inspection and Verification


WARNING: Servicing must be carried out by personnel familiar with both vehicle system and the charging and testing
equipment. All operations must be carried out in a well ventilated area away from open flame and heat sources.


CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.


NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
1. Verify the customer concern

2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical Electrical
Coolant level
Hose(s)
Coolant pump
Control flap(s)
Duct(s)
Vent(s)
Cabin air filter
Drive belt
Air conditioning compressor
Thermostatic expansion valve
Evaporator
Receiver drier
Air conditioning condenser
Refrigerant pipes Auxiliary
drive belt
Fuel fired booster heater
Fuel fired booster heater fuel pump
Fuel fired booster heater fuel pipes
Fuse(s)
Wiring harness
Electrical connectors
Blower
Air conditioning compressor
Electric cooling fan
Automatic Temperature Control Module (ATCM)
Refrigerant pressure sensor
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index

5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required

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

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 - Air Conditioning (A/C) System
Recovery, Evacuation and Charging
General Procedures


1. WARNING: Servicing must be carried out by personnel familliar with both
vehicle system and the charging and testing equipment. All operations
must be carried out in a well ventilated area away from open flame and
heat sources.


NOTE: The receiver drier need only be changed under the following
circumstances: There is dirt in the refrigerant circuit ( eg. compressor
seizure ), the system is leaking and refrigerant has been lost to
atmosphere, or the refrigerant circuit has been open more than 24 hours,
due to repair.
Refrigerant recovery.

2. Remove the dust covers from the high and low pressure
connections.



























3. Connect the high and low pressure lines to the appropriate connections.

4. Open the valves on the connections.

5. Turn the valves on the station to the correct positions.

6. Turn the process switch to the correct position.

7. Turn the main switch to 'ON'. www.JagDocs.com

8. WARNING: Refrigerant must always be recycled before re-use to ensure
that the purity of the refrigerantis high enough for safe use in the air
conditioning system. Recycling should always be carried out with
equipment which is design certified by Underwriter Laboratory Inc. for
compliance with SEA J1991. Other equipment may not recycle refrigerant
to the required level of purity. R143a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant.Refrigerant R134a from domestic and comercial sources must
not be used in motor vehicles air conditioning systems.
Allow the system to recover the refrigerant from the system.

9. Close the valves on the refrigerant station.

10. Turn the main switch 'OFF'.

11. Close the valves on the connections.

12. Disconnect the high and low pressure connections.

13. Install the dust covers to the connectors.

14. Open the tap at the rear of the station to drain the refrigerant oil.

15. Measure and record the quantity of refrigerant oil recovered from the
system.

16. Close the tap at the rear of the station.

17. Evacuation.

18. Remove the dust covers from the high and low pressure connections.

19. Connect the high and low pressure lines to the appropriate connections.

20. Open the valves on the connections.

21. Turn the valves on the station to the correct positions.

22. Turn the process switch to the correct position.

23. Turn the main switch to 'ON'.

24. Allow the station to evacuate the A/C system.


25. CAUTION: The system must be evacuated immediatley before
recharging commences. Delay between evacuation and recharging is not
permitted
Recharging

26. Close the valves on the refrigerant station.

Published: 11-May-2011
Climate Control System - General Information - Air Conditioning (A/C) System
Flushing
General Procedures

1. WARNINGS:


Use extreme care and observe all safety precautions related to the
use of refrigerants. Due to refrigerant hazards, always wear safety
goggles and non-penetrable gloves when working on or flushing air
conditioning (A/C) systems. Failure to follow this instruction may result
in personal injury.


When flushing the A/C system, refer to the manufacturers
equipment instructions for additional information. Failure to do so may
result in system damage or personal injury.


The A/C refrigerant analyzer must be used before the recovery of
any vehicle's A/C refrigerant. Failure to do so puts shop bulk refrigerant
at risk of contamination. If the vehicle A/C refrigerant is contaminated,
refer the customer to return to the repair facility that performed 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 refrigerant. All contaminated A/C refrigerant must be disposed of as
hazardous waste. For additional information, refer to the manufacturers
equipment instructions. Failure to follow this instruction may result in
personal injury.


Prior to using the A/C flushing equipment for the first time, follow
the operating instructions. Failure to follow this instruction may result in
personal injury.


CAUTION: Prior to flushing, remove and discard the desiccant sack.
Depending on the equipment used, other A/C components may have to
be removed prior to flushing. For additional information, refer to the
manufacturers equipment instructions before flushing the A/C system.
Recover the refrigerant.
For additional information, refer to Air conditioning (A/C) System Recovery, Evacuation and Charging in this section.
2. Remove the desiccant sack.
For additional information, refer to Section 412-03 Air Conditioning.
3. Flush the system. For additional information, refer to the manufacturers
equipment instructions.

4. Install new refrigerant lines if blocked with debris.

5. Install a new desiccant sack.
For additional information, refer to Section 412-03 Air Conditioning.
6. Add the required amount of oil to the A/C system depending on the
repair procedure.
For additional information, refer to Refrigerant Oil Adding in this section.
7. Evacuate and charge the A/C system.
For additional information, refer to Air conditioning (A/C) System Recovery, Evacuation and Charging in this section.
8. Carry out fluorescent dye leak detection test.

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.

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.

pressure/temperature regimes. Larger diameter pipes are installed in the low pressure/temperature regime and smaller
diameter pipes are installed in the high pressure/temperature regime.
Low and high pressure charging connections are incorporated into the refrigerant lines for system servicing.

Published: 11-May-2011
Climate Control - Desiccant Bag V6 3.0L Petrol/V8 5.0L Petrol/V8 S/C 5.0L
Petrol
Removal and Installation

Removal


NOTE: Removal steps in this procedure may contain installation details.


1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).

3. Refer to: Radiator Splash Shield (501-02 Front End Body Panels, Removal and Installation).

4. www.JagDocs.com