sensor JAGUAR XJ6 1994 2.G Repair Manual

Body Components & Trim ~
issue 1 August 1994 X300 VSM 21
13.3.17 Fascia Board, Renew
SRO 76.46.01
. Remove
the battery cover and disconnect the battery.
Remove the drivers side and passenger side underscuttle
pads, see sub
-sections 13.3.19 and 13.3.20.
. Remove the drivers airbag module, see section 15.5.
Remove the steering wheel, section 10.
Remove the drivers side and passenger side fascia closing
. Remove the fascia center veneer panel, see subsection
Remove the fascia board for access, see subsection
. Disconnect the air conditioning differential potentiometer
Remove the differential potentiometer assembly.
. Displace and reposition the through panel connectors
from the fascia assembly.
. Displace the fascia vent motor / gearbox assemblies har- ness multi-plug from the mounting bracket.
. Disconnect and reposition the fascia harness to console
harness
multi-plug from the mounting bracket.
. Disconnect the BPU harness multi-plugs.
Remove the tiestraps securing the harness to the fascia.
. Reposition the fascia on a bench.
= Displace and reposition the solar sensor assembly from
Disconnect the solar sensor harness multi-plug.
Remove the solar sensor assembly.
= Undo and remove the defrost vents securing screws.
Displace and reposition the defrost vent assemblies.
. Disconnect the tweeter speaker harness multi-plugs.
. Remove the defrost vent assemblies.
. Displace the fascia harness grommet from the fascia.
. Route the harness through the aperture.
Remove the fascia harness assembly.
. Undo and remove passenger airbag deployment door to
fascia securing bolts ( one bolt is removed with the fascia).
. Displace and remove the deployment door assembly.
. Undo and remove the passenger airbag module to fascia
. Displace and remove the airbag module assembly.
. Undo and remove the airbag module I BPU mounting
bracket assembly to fascia securing nuts 1 bolts.
= Displace and remove the mounting bracket assembly.
. Retrieve the spacing washers.
. Displace and remove the side vent outlets from the fascia.
. Displace and remove the side vent ducts securing clips.
. Displace and remove the side vent ducts.
. Undo and remove the center vent flap assembly to fascia
. Displace and remove the center vent flap assembly.
Undo and remove fascia location bracket securing nuts.
Displace and remove the location bracket.
panels, see
sub
-sections 13.3.22 and 13.3.21.
13.3.23. 13.3.17.
harness multi
-plug.
the fascia.
securing bolts.
securing nuts.

Body Components & Trim -
. Undo and remove the defrost vents clip location bracket
9 Displace and remove the clip location brackets.
Remove the defrost vent spire clips from the fascia.
Place the fascia aside.
. Place a new fascia on the bench.
. Fit and fully seat the defrost vent spire clips.
. Fit and align the defrost vent clip location brackets.
Fit and tighten the location brackets securing screws.
. Fit and align the fascia location brackets to the fascia.
. Fit and align the location bracket securing nuts.
. Fit and align the center vent flap assembly.
. Fit and tighten the flap assembly securing nuts.
. Fit and align the side vent ducts to the fascia assembly.
. Fit and fully seat the side vent ducts securing clips.
Fit and fully seat the side vent outlets to the fascia.
Fit and align the airbag module/BPU mounting bracket as-
. Fit and tighten the airbag module/ BPU mounting bracket
. Fit and align the airbag module to the fascia.
. Fit and tighten the airbag module securing bolts.
. Fit and align the airbag deployment door assembly to the
. Fit but do not fully tighten the door securing bolts.
. Align the door assembly to the fascia.
. Finally tighten the door securing bolts.
. Position the harness. Route the harness speaker / solar
sensor multi-plugs through the aperture in the fascia.
. Fully seat the harness grommet to the fascia aperture.
. Route the tweeter speaker harnesses along the defrost
vent aperture.
. Place the defrost vent assemblies to the fascia.
. Connect the speaker harness multi-plugs to the speakers.
Reposition and fit the vent assemblies to the fascia.
. Fit and tighten the vent securing screws.
Place the solar sensor assembly to the fascia.
. Reconnect the solar sensor harness multi-plug.
. Fully seat the solar sensor assembly to the fascia.
. Reposition the fascia assembly on the bench.
. Secure the harness to the fascia assembly using tiestraps.
. Reconnect the BPU harness multi-plugs.
. Reposition and fit the fascia harness to console harness
. Reconnect the fascia vent motor/gearboxassemblies har-
securing screws.
sembly and align the spacers.
securing nuts
/ bolts.
fascia.
multi
-plug to the mounting bracket.
ness
multi-plug.
X300 VSM Issue 1 August 1994 22

Body Components & Trim -
13.3.39 Roof lining (Headlining), Description
The roof lining is a one piece construction of 6mm thick polyurethane foam, covered with brush finish, suede effect,
knitted polyester.
13.3.40 Roof lining; Renew
. Position front seats fully rearwards and recline the passen-
. Disconnect vehicle battery ground lead.
. Remove:
ger
seat squab.
0 Sliding roof flange (where fitted).
0 Front passenger door.
0 Rear console (where fitted).
0 Center console.
0 Sunblind and bezel.
0 Combined grab handle and coat hook.
0 Rear quarter upper trim pad LH & RH.
0 Cantrail crash roll.
0 Illuminated sun visor.
0 Roof console.
9 Release multi-plug connectors from clips at roof console
Remove roof console retaining clip from headlining.
. Remove security sensors (where fitted) and disconnect
. Release roof lining to body tags and lower roof lining.
. Remove the roof lining:
Position the roof lining with the rear corner through the
passenger side rear door and the opposite cornerthrough
the driver side rear door.
. Position the roof lining across the car with the roof console
cut-out straddling 'B'-'C' post.
. Tip the roof lining forward against bottom of fascia with
rear edge of roof lining diagonally across door aperture.
. Carefully feed the roof lining out of the passenger side
front door, easing the edge cut-outs over the door aper- ture and any other obstruction.
aperture.
multi
-plugs.
. To
refit, carry out reversal of the above procedure.
X300 VSM 37 Issue 1 August 1994

Climate Control Systems
Manual Inputs
Automatic inputs
outputs
14.5 AIR CONDITIONING CONTROL MODULE (A/CCM)
14.5.1 Description
Theclimate control system peripheralscommunicate with theA/CCMvia three main devicecategories, plusthevehicle
power supply and ground connections.
Control panel Face Vent Temperature Control
Temperature and solar sensors
Flap
servo motor potentiometers
Circulation pump
& coolant flow valve
Power
transistor(fan speed control)
Compressor lock sensor
(12 cylinder only)
Instrument pack (coolant temp
& road speed) (engine revolutions via engine control module)
Blower motors (Left
& Right) & associated relays
Flap
servo motors
Heated front
/ rear screens & exterior mirror relays
Motorized in
-car aspirator
Compressor clutch request to engine control module (not
heater-only cars)
Circulation pump relay
Coolant flow valve
X300 VSM Issue 1 August 1994 7

Climate Control Systems
. Centre vent flap
Foot flap
Defrost flap
I I
14.5.2 Control Module Interfaces
. Recirculation switch
. Air con onloff switch
. System onloff switch
. Auto. / Man. select
. Set temperature
. Air flow outlet mode set
. Heated front screen switch
. Heated rear screen &
. External temp. display
. FahrenheiVCentigrade
heated mirror switch
switch
switches
. Solar sensor
. Motorized in-car aspirator
. Ambient temp. sensor
9 Evaporator temp. sensor
. Heater matrix temp. sensor
. Compressor lock sensor
. Face differential temp. control
. Refrigerant pressure switch
. Engine speed signal
. Engine coolant temperature
Vehicle speed signal
Circulation pump
. Coolant flow valve
. Power transistor (fan speed
= Servo motor potentiometers:
signal
control)
LH air inlet flap
RH air inlet flap
Centre vent flap
Foot flap
Defrost flap
Air by
-pass flap
CONTROL PANEL
4
-
4
4
4
4
4
4
A 1 CCM
e I . External temp. display
. Coolant recirculation valve
. Coolant recirculation pump
Cool air by-pass
Air Flow Speed Control
. LH blower motor & power transistor
. RH blower motor & power transistor
. LH high speed relay
. RH high speed relay
. LH air inlet
. RH air inlet
. Compressor
- . Front screen heater (to EMS)
- . Heated rear screen
and door mirrors
Fig.
1 Schematic view AI CCM Inputs & Outputs
0
0
0
0
Issue 1 August 1994 8 X300 VSM

Climate Control Systems
14.10 FAULT DIAGNOSIS
14.10.1 Introduction
It is very important to positively identifythe area of concern before starting a rectification procedure. A little time spent
with your customer to identify the conditions under which a problem occurs will be beneficial. Relevant criteria are:
Weather conditions, ambient temperature, intermittent or continuous fault, airflow fault, temperature control fault, dis
- tribution fault and air inlet problem.
14.10.2 Functional Check
This simple 'first line check' will allow you to ascertain whether the system is operating within its design parameters,
without recourse to (JDE). Please carry out the following, in order.
0 Start engine and attain normal running temperature.
0 Presss AUTO to display selected temperature and illuminate AUTO & AJC state lamps.
0 Rotate FAN to increase or decrease lower speed, verify bar graph representation.
0 Operate AJC to toggle on or off. Because the compressor can be inhibited by the engine management system,
ensure that the engine temperature is normal and that the ambient is above 5O C.
0 Operate RECIRC, state lamp should be lit and the flap behind the blower grille open.
0 Operate distribution buttons in turn, verify correct air distribution and relevant state lamp.
0 Operate DEFROST, check max fans and air to front screen.
0 Cycle TEMPERATURE to 'Hi' and 'Lo' to verify demanded variations and display operation. Note that extremes
will provide max heat or cold independent of in-car temperature.
0 Operate EX to toggle between ambient and control temperatures.
0 Operate HFS and HRW to note timer and mirror operation.
0 Initiate System Self Test to check for, and extract, stored faults should any of the above not perform as stated.
14.10.3 System symptoms
There are five basic symptoms associated with air conditioning fault diagnosis. The following conditions are not in order of priority.
No Cooling
0 Is the electrical circuit to the compressor clutch functional?
0 Is the electrical circuit to the blower motor(s) functional?
0 Slack or broken compressor drive belt.
0 Compressor partially or completely seized.
0 Compressor shaft seal leak.
0 Compressor valve or piston damage (may be indicated by small variation between HIGH &LOW side pressures
relative to engine speed).
0 Broken refrigerant pipe (causing total loss of refrigerant).
0 Leak in system (causing total loss of refrigerant) - possible code 23.
0 Blocked filter in the receiver drier.
0 Evaporator sensor disconnected - possible code 13.
0 Pressure switch faulty - possible code 23.
X300 VSM Issue 1 August 1994

Climate Control Systems
lnsufficent Cooling
0 Sluggish blower motor(s).
0 Restricted blower inlet or outlet passage
0 Blocked or partially restricted condenser matrix or fins.
0 Blocked or partially restricted evaporator matrix.
0 Blocked or partially restricted filter in the receiver drier.
0 Blocked or partially restricted expansion valve.
0 Partially collapsed flexible pipe.
0 Expansion valve temperature sensor faulty (this sensor is integral with valve and is not serviceable).
0 Excessive moisture in the system.
0 Air in the system.
0 Low refrigerant charge - possible code 23.
0 Compressor clutch slipping.
0 Blower flaps or distribution vents closed or partially seized - possible codes 41 or 46.
0 Coolant flow valve not closed.
0 Evaporator sensor incorrectly positioned
m: Should a leakor low refrigerant be established as the cause of /NSUff/C/€NTCOOL/NG,followthe procedures
Recovery / Recycle / Recharge, this section, and observe all refrigerant and oil handling instructions.
lntermiffent Cooling
0 Is the electrical circuit to the compressor clutch consistent?
0 Is the electrical circuit to the blower motor(s) consistent?
0 Compressor clutch slipping?
0 Motorized in-car aspirator or evaporator temperature sensor faulty, causing temperature variations - possible
codes 11 or 13.
0 Blocked or partially restricted evaporator or condenser.
Noisy System
0 Loose or damaged compressor drive belt.
0 Loose or damaged compressor mountings.
0 Compressor oil level low, look for evidence of leakage.
0 Compressor damage caused by low oil level or internal debris.
0 Blower motor(s) noisy.
0 Excessive refrigerant charge, witnessed by vibration and 'thumping' in the high pressure line (may be indicated
by high HIGH & high LOW side pressures).
0 Low refrigerant charge causing 'hissing' at the expansion valve (may be indicated by low HIGH side pressure).
0 Excessive moisture in the system causing expansion valve noise.
0 Air-lock in water pump*.
lnsufficent Heating
0 Coolant flow valve stuck in the closed position.
0 Motorized in-car aspirator seized.
0 Cool air by-pass damper stuck or seized - possible code 43.
0 Blocked or restricted blower inlet or outlet.
0 Low coolant level.
0 Blower fan speed low.
0 Coolant thermostat faulty or seized open.
0 Water pump inoperative or blocked
0 Air-lock in matrix*.
m: * Please see Sections 4.1 and 4.2 for specific coolant fill / bleed procedures.
Electrical faults may be more rapidly traced using
(JDE), please refer to the (EDM).
Issue 1 August 1994 16 X300 VSM

Climate Control Systems
Action
Simultaneously hold AUTO and RECIRC - Switch
ignition to ON
Press AUTO
Press FACE
Simultaneously press FACE and HRW
Press
RECIRC (Press FAN to skip actuator check)
Press FAN
14.11 SYSTEM SE1 F-TEST
14.11. I Interrogation Procedure via the Control Panel
Result
Display element check
Any stored fault NUMERIC code
(If ZERO appears there are
no stored codes)
Scroll through stored faults (maximum of
5)
Clear stored fault codes (may need to be repeated for each
fault)
Initiate actuator check (Actuator codes
20 through 27*)
Exit error check mode
Fault Code
0
11
12
13
14
15
21
22
0
23
14.1 1.2 Control Panel Fault Code Key
Item Description
Normal Operation No
fault codes present, wait 30 seconds for system self-
check.
Motorized In
-car Aspirator Open /short in sensor circuit. Panel fault codes are not stored
for motorized in
-car aspirator motor failure.
Ambient Temperature Sensor Open
/ short circuits.
Evaporator Temperature Sensor Open
/ short circuits.
Water Temperature Input Instrument pack output.
Heater Matrix Temperature Sensor Open
/ short circuits.
Solar Sensor Open
/ short circuits.
Compressor Lock Signal
- 12 cylin- Open /short circuits. Low gas charge, low compressor oil,
der and supercharged
6 cylinder loose belt.
engines only.
Refrigerant Pressure Switch Open /short circuits. Low gas charge*
31
32
33
34
35
36 0
I 24 1 Face Vent Demand Potentiometer. 1 Open / short circuits
LH Fresh
/ Recirc. Potentiometer
RH Fresh / Recirc. Potentiometer
cool ~i~ by-pass potentiometer
Defrost Vent Potentiometer
Centre Vent Potentiometer
Foot Vent Potentiometer Open
/short circuit
in potentiometer. feed.
w: and log further faults. Cycling the ignition two or three times
after rectification of the fault will cure this.
In certain circumstances, the motor can over-travel
43
44
I Defrost Vent Motor
I Cool Air by-pass Motor
I 41 I LH Fresh / Recirc. Motor I
Check for short / open circuits in motor drive lines. Motor flap
sticking
/ jammed.
1 42 I RH Fresh / Recirc. Motor I
1 45 I Centre Vent Motor I
46 I Foot Vent Motor
w: In ambient temperatures below Oo C, the system may log fault code 23 because the low ambient causes a tem-
porary low gas pressure. Where the ambient temperature rise above 40" C, and if the engine is close to over- heating, feed to the compressor clutch may be cut and code 23 registered.*
X300 VSM 17 Issue 1 August 1994

Electrical rl
15.2 INSTRUMENTS
15.2.1 General Description
The instruments measure, monitor and display data relevant to the vehicle’s performance. Data is received from
sensors positioned at various locations around the vehicle via two multi-pin sockets located at the rear of the
instrument panel and is than presented using three different visual display methods described as follows:
15.2.2 Analog Display
This is used to display road speed, engine speed, oil pressure, battery condition, fuel level and coolant temperature.
15.2.3 Indicator Lamps
These indicate the presence of any hazard /fault conditions or operational actions.
15.2.4 LCD (Liquid Crystal Disp/ay)
This single line, six digit seven segment display is normally used to display the odometer reading but can also be used
to display vehicle condition messages associated with particular warning lamps and trip computer information.
15.2.5 Transducers
These devices listed as follows transmit vehicle condition to the instruments:
0 Engine Coolant Temperature Transmitter
0 Low Coolant Level Probe
0 Oil Pressure Transmitter - AJ16N12
0 Fuel Gauge Tank Unit - AJlW12
Fault conditions and their causes displayed by the instruments and warning lamps are covered in more detail
by further information contained within the
Electrical Diagnostic Manual.
15.2.6 Instrument Panel, General
2 I I 3 1
1. 24 Way Connector 3. Identification Label 2. 4% Way Connector 4. Bulb Holder
Fig.
1 Instrument Panel, Rear View
X300 VSM Issue 1 August 1994 8
c

15.6
15.6.1
The single windscreen wiper blade is controlled by a windscreen wiper/washer switch located on the right-hand side
of the steering column switchgear (see Fig.
1).
POWER WASH & SCREEN WASH/ WlPE
Windscreen Washers & Wipers, General Description
The windscreen wiper motor, part of the wiper motor
assembly operates at slow or fast speeds and drives the
lever assembly, a single arm and blade via a crank.
On
V12 engined vehicles the wiper motor assembly is
mounted to the front of the bulkhead with the motor
protruding into the plenum chamber, whilst on AJ16 engined vehicles the wiper motor assembly is mounted into
the same position, but with the motor protruding into the
engine compartment.
For wipe and wash operation
a mixture of water and special
'Jaguar Windscreen Fluid' is drawn from the PVC reservoir
assembly by
two electrically controlled pumps and is then
distributed via flexible feeder hoses interconnected using
'TEE' pieces to the screen wash jets and to heated power
wash jets (where fitted). The ends of power wash hoses are
fitted with 'quick
fit' fluid connectors.
The
two pumps, one for screen wash and one for headlamp
power wash are externally fitted to the reservoir located at
the front right
-hand side of the engine compartment.
Contained within the reservoirs pull-up neckis a serviceable
filter.
The screen wash jets with independently adjustable
eyeballs are mounted on the plenum chamber finisher and
the temperature of the fluid passing through the jets is
controlled from an ambient temperature sensor fitted near
the inlet of the right
-hand side air duct. Fig.
1
The
fluid temperature for each of the headlamp wipe wash operation is controlled by self regulating, heated power
wash jets mounted on to either side of the bumper.
Each powerwash jet is protected by
a cover supplied with an integral cover-to-bumperseal. The cover snap fixes into
the bumper.
15.6.2
This switch only operates with the ignition switch in position '11' and has the following functions:
windscreen Wiper and Washer Switch
Position 0 The wind screen wiper is switched 'OFF' and parked.
Position 1: Normal speed wiper operation is obtained by pushing the switch lever up one position.
Position 2: High speed wiper operation is obtained by pushing the switch lever fully up.
Position D: To obtain intermittent wiper operation the switch lever is pushed down and released.
The delay period will vary with vehicle speed. To cancel the function repeat the procedure.
15.6.2.1 Single Wipe Operation
To obtain a single sweep of the wiper blade, the lever is pulled towards the steering wheel and released.
W The intermittenmick wipe operations are both at slow speed and they are controlled by a Central Control
Module (CCM), which also controls the headlamp power wash operation.
Issue 1 August 1994 X300 VSM