air conditioning JAGUAR XJ6 1994 2.G Workshop Manual

GLOSSARY OF TERMS
Introduction
This glossary of terms is intended to cover both general and emissions-related (to SAE J 1930) terminology. It is in- tended to enable the user to ascertain the meaning of standardized terms and acronyms used throughout the Manual.
The required term may be looked-up in the left-hand column, and subsequent columns give the standard abbreviation
or acronym, definitions and previously used terms, as applicable.
As this Manual is a world
-wide publication, and must comply with certain Society of Automotive Engineers Standards, it has been necessary to adopt the terminology etc. demanded by that Standard.
Term(s) Abbreviation Definition Previously used
(if applicable) term(s) (or Eng- lish Eauivalent)
A
throttle pedal
accelerator Dedal AP
AI= measurement across the spanner flats of a
across flats
nut or bolt head
adaptor
AC.
aircon
adapter
after bottom dead center
after
too dead center event
occurring after BDC
event occurring after TDC
ABDC
ATDC ACL
AIC
ACS
Air
Cleaner
Air Conditioning
Air Conditioning Signal air conditioning
compressor clutch
operation is signalled to the PCM which
induces idle speed corrections to
compensate for engine load changes
module controlling air conditioning, heating
and ventilation
wing or similar, designed to obtain some
effect from the flow of air over
it
electrical current whose flow alternates in
direction, in a sinusoidal waveform
NCCM Air Conditioning Control Module
airfoil aerofoil
alternating current ac
aluminium
aluminum
Ambient temperature Temperature
of the air surrounding an object
SI unit of current AmDere A Amp Amp. hour -~ 1 Ampere flowing for one hour
system, usually ele&o&ally controlled (but ~- __. .. . Ampere hour
Anti
-Lock Braking System Ah
ABS can be mechanically) which prevents wheel
lock
-up under braking by sensing lack of
rotation of a wheel(s) and diverting fluid
pressure away from
it (them). Originally Anti-Blockier System (Bosch).
ABS control module
ABS
/ traction control control
module ABS
CM
ABS I TC CM
aerial
antenna (plural, antennae or
antennas)
analog
Analoa Volt-Ohm meter analogue
AVOM unit of pressure
(1.01325 bar)
atmospheres
automatic transmission atm
auto,
auto gearbox
drive shaft
axle shaft shaft
transmitting power to the rear wheel
hubs
.-
Issue 1 August 1994 X300 VSM 7

Engine (AJ16)
Description
Camshaft timing tool
TOOLS & EQUIPMENT
Not- Illustration I JaguarNumber
L L
11. TORQUE TIGHTENING SPECIFICATIONS
not illustrated YA 992
Fixing
Air Cleaner
Air box bracket screw
Air box to bracket
Air box to instrumount
Air cleaner bracket setscrew
Air cleaner support bracket
(4,O liter, supercharged)
Air meter to intake gaiter
(4,O liter, supercharged)
Air temperature sensor to air box
Hose clamp, air box to air meter
Hose clamp, air box to body
Instrument bracket Taptite screw
Trumpet to body
Air Conditioning Compressor Mounting
Belt tensioner assembly to compressor bracket
Compressor bracket to cylinder block
Compressor to bracket
Idler pulley to tensioner assembly
Cooling System
Bypass elbow to thermostat housing
Fan drive unit setscrew
lightening Torque
(Nm)
8,5 - 11,5
9,5 - 12,5
9,5 - 12,5
6,3 - 8,7
8,5- 11,5
1,2 - 1,6
7
-9
1.2
- 1,6
1,2
- 1,6
9,5
- 12,5
9,5 - 12,5
22 - 28
22
- 28
22
- 28
22
- 28
9.5
- 12,5
12 - 16
Front pulley lock
fi
Engine lifting bracket
fi
Engine support beam
fl
'Snap-On' Oil filter
canister removal tool
Issue 1 August 1994 ii X300 VSM

Engine (AJ16)
3.1.2 ENGlNE/ TRANSMlSSlON UN/& RENEW
SRO 12.41.02/20
The engine/transmission unit on the AJ 16 normally aspirated and supercharged engined vehicles are fitted ontothree
engine mounting/bracket assemblies. The two front engine mountings for the 3.2/4.0 liter normally aspirated and the
4.0 liter supercharged engined vehicles are identical. They are fitted to the front crossmember on either side of the
engine bay. Rubber to metal
engine/transmission rear mounts used for both engine types, are secured to a support
bracket which traverses the two body underframe longitudinal members. For access to remove the engine carry out the following procedures:
WARNING: WHEN WORKING WlTHlN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13
. Remove the air cleaner assembly.
. Depressurize the fuel system, see SRO 19.50.02, section 5.1.
Disconnect the battery.
. In line with the relevant SRO's and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the airconditioning system, see section 14, Charge Recovery (System depressurization).
mounting
arrangements.
CAUTION : Do not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/re- charge equipment.
. Drain the engine oil, see 3.1.3 this section.
. Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTILTHE EXCESS PRESSURE CAN ESCAPE. LEAVETHE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equally spaced to the inlet manifold studs. The engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of the vehicle is jacked
up secure- ly on stands when removing the assembly.
e
0
0
X300 VSM Issue 1 August 1994 2

3.2.2 ENGINE - GEARBOX/ TRANSMISSION
ASSEMBLY, RENEW
SRO 12.37.01/90
The engine /transmission unit on the V12 6.0 liter model is mounted on three engine mounting / bracket assemblies
fitted to the front crossmember on either side of the engine bay. The engine/ transmission rear mount is a mounting
bracket and spring assembly fitted and secured to body underframe longitudinal members. For access to remove the
engine carry
out the following procedures:
WARNING: WHEN WORKING WITHIN THE ENGINE COMPARTMENT, KEEP CLEAR OF THE RADIATOR COOLING
FANS AS THEY COULD START WITHOUT WARNING, EVEN IF THE ENGINE IS NOT RUNNING.
. Remove the hood, see SRO 76.16.01, section 13.
. Remove the two air cleaner assemblies, see SRO’s 19.10.01 & 19.10.02.
. Remove the engine cover, see SRO 12.29.93 (V12 Engine Service Manual).
Depressurize the fuel system, see SRO 19.50.02, section 5.1.
In line with the relevant SRO’s and sections, remove all appropriate obstructing parts, including their fixing and
. Disconnect all mechanical and isolate all electrical linkages leading to and from the engine.
. De-gas the air conditioning system, see section 14, Charge Recovery (System depressurization).
Disconnect
the battery.
mounting arrangements.
CAUTION: Do
not vent refrigerant directly to the atmosphere and always use Jaguar approved recovery/recycle/ra charge equipment.
Drain the engine oil, see 3.2.3 this section.
Drain the coolant, see SRO 26.10.01, section 4.1.
WARNING: DO NOT REMOVE THE HEADER TANK PRESSURE CAP WHILE THE ENGINE IS HOT. IF THE CAP MUST
BE REMOVED, PROTECT THE HANDS AGAINST ESCAPING STEAM AND SLOWLY TURN THE CAP ANTI- CLOCKWISE UNTIL THE EXCESS PRESSURE CAN ESCAPE. LEAVE THE CAP IN THIS POSITION UNTIL ALL
STEAM AND PRESSURE HAS ESCAPED AND THEN REMOVE THE CAP COMPLETELY.
Before
lifting the complete engine/transmission unit with an engine hoist from the engine bay, ensure that two engine
lifting brackets (tool 18G. 1465) are secured equallyspaced to the inlet manifold studs. The four engine lifting brackets
should be positioned towards the front and the rear of the assembly. Ensure the front of thevehicle is jacked
up secure- ly on stands when removing the assembly.
X300 VSM Issue 1 August 1994 2

Cooling System (AJl6) m
4.1.1 COOLING SYSTEM DESCRIPTION
4.1.1.1 Major Components
o Main engine crossflow radiator, incorporating a concentric tube cooler for the power steering fluid mounted in
the right
-hand radiator side tank. Vehicles with automatic transmission have a transmission fluid cooler
mounted in the left
-hand radiator side tank; for 4,O liter supercharged engines a six-plate cooler is fitted; other
vehicles have
a tube-type cooler. Adouble-action temperature switch, for controlling the radiator cooling fans,
is mounted in the left
-hand radiator side tank.
0 Two electrically operated radiator cooling fans, mounted behind the main radiator.
0 Coolant circulating pump, belt driven from the engine crankshaft.
0 Coolant header tank with pressure relief cap and coolant level probe.
o Engine thermostat.
4.1.1.2
0 Heater matrix.
o Electrically operated coolant circulating pump, mounted on the left-hand side of the engine bulkhead.
o Solenoid operated valve, located adjacent to the coolant circulating pump.
Components for Climate Control System
4.1.1.3 Components for Supercharged Engine
0 0 Supercharger crossflow radiator, mounted in front of the main radiator. The supercharger radiator is reverse- circuited, i.e. the coolant inlet is at the bottom of the radiator.
0 Electrically operated coolant circulating pump, located at the left-hand side of the main radiator.
4.1.1.4 Operation
The configuration of the cooling system for normally aspirated and supercharged (4,O liter) engines is shown in Sub- section 4.1.2.
The cooling system is pressurized, which allows the system to operate at a higher temperature without overheating.
The header tank is fitted with a pressure relief cap to protect the system against overpressure.
Under cold start conditions, coolant is forced by the engine driven water pump through the cylinder block and cylinder
head to the thermostat housing. The thermostat is closed to give rapid engine warm up, hence the coolant is returned
directly to the water pump inlet. When normal engine operating temperature is reached, the thermostat opens and
coolant is diverted through the radiator before returning to the water pump inlet. In vehicles fitted with
a supercharger,
coolant is circulated through the supercharger radiator and intercooler by the supercharger water pump. The super- charger cooling circuit uses the same coolant header tank as the main engine cooling system.
The radiator cooling fans operate in series and parallel under the control of the double
-action radiator mounted tem- perature switch. The fans are also controlled by the climate control system on vehicles fitted with air conditioning.
Under hot operating conditions, the fans may continue to operate after the engine has been switched off. The fans
stop automatically when the coolant temperature has been reduced sufficiently.
The system also provides the coolant supply for the climate control system, which is described in Section
14.
X300 VSM 1 Issue 1 August 1994

Automatic Transmission (AJI 6)
8.1.3 TRANSMISSION CONTROL MODULE, RENEW
0 (4, OL)
SRO 44.15.32
. Raise the trunk lid and disconnect the battery.
. Remove the passenger side dash liner for access.
Displace and remove the air conditioning footwell outlet
duct.
. Release and remove the footwell carpet securing fastener:
displace and reposition the carpet for access.
Release the Transmission Control Module
(TCM) bracket
to body bracket securing nut
(1 Fig. 1).
. DisplacetheTCM mounting brackettang (2 Fig. 1)fromthe
body bracket and mounting stud.
= Reposition the TCM, release the TCM multi-pin plug lever
lock and disconnect the multi
-pin plug (3 Fig. 1).
. Release and remove the TCM mounting bracket securing
bolts and remove the TCM.
= Fit and align the new TCM to the mounting bracket.
. Fit and tighten the TCM securing bolts.
. Connect the TCM harness multi-pin plug and secure the
Position the TCM to body mounting bracket, ensuring that
Fit and tighten the TCM securing nut.
. Position the footwell carpet and fit the carpet fastener.
. Fit and align the footwell outlet duct to air conditioning
. Position and fit the duct fastener to the blower motor slot.
. Refit the dash liner.
. Reconnect the battery.
multi-pin plug lever lock.
the tang locates
in the bracket slot and stud.
unit.
1
i
J44-703 U
Fig. 1
Issue 1 August 1994 X300 VSM 7

Body Components & Trim e
Remove the battery cover. Disconnect the battery.
. Remove the console ashtray, see subsection 13.3.28.
. Remove console veneer panel, see subsection 13.3.24.
. Remove the gear selector ident plate securing screws.
. Carefully reposition the radio console assembly from the
mounted position.
. Disconnect the assembly harness multi-plugs.
. Disconnect the antenna co-axial connector.
Undo and remove the ground lead to radio securing nut.
. Reposition the ground lead from radio stud.
. Disconnect the radio harness multi-plugs.
. Reposition the radio harness from the center console.
. Displace the radio console assembly.
. Remove the radio assembly from the console.
. Remove the radio retaining plate.
Undo and remove the air conditioning control module se
-
curing screws.
. Displace and remove the module.
. Undo and remove switch/clock module securing screws.
. Displace and remove the module assembly.
. Place the radio console aside.
. Place the new radio console to the front.
. Fit and fully seat the switch /clock module to the console.
. Fit and tighten the module securing screws.
. Fit and fully seat air conditioning module to the console.
. Fit and tighten the securing screws.
. Fit and fully seat the radio mounting plate to the console.
. Place the radio console to the center console position.
. Place the radio to the center console position.
* Route the radio harness / multi-plugs through the radio
. Connect the radio harness multi-plugs.
8 Connect the radio console harness multi-plugs.
. Route the radio ground and antenna leads through the
. Fully seat the radio console in the mounted position.
Reposition the ground lead to radio securing stud.
Fit and tighten the securing nut.
Connect the antenna co-axial to the radio.
. Reposition the excess harness / leads into the radio
mounting hole, ensuring that the harnesses are posi- tioned to allow the radio to be pushed fully home.
console
into the center console position.
radio console.
Fit and tighten the securing screws.
. Fully seat the radio into the console.
. Reposition and fit the selector ident plate.
. Fit and tighten the ident plate securing screws.
. Refit the console veneer panel. I
13.3.10 Radio Console, Renew
SRO
76.25.15
Issue 1 August 1994 16 X300 VSM

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
. Reposition and fit the motor/gearbox assemblies harness
. Fully seat the through panel connectors to the fascia.
. Place the air conditioning differential potentiometer to the
fascia and route the differential potentiometer harness
through the vent aperture.
. Reconnect the differential potentiometer harness multi-
Plug.
Refit the fascia board.
. Refit the center veneer panel.
. Refit the fascia closing panels.
. Refit the steering wheel.
. Refit the drivers airbag module.
. Refit the underscuttle pads.
. Reconnect the battery and refit the battery cover.
multi
-plug
to the mounting bracket.
X300 VSM 23 Issue 1 August 1994

Body Components & Trim
13.3.19 Underscuttle Pad - Drivers Side, Remove For
Access And Refit
SRO 76.46.11/90
Motor the drivers seat fully rearwards.
Undo and remove the underscuttle pad securing screws (1
Using special tool JD 188 (2 Fig. I), displace securing clip.
Displace and reposition the underscuttle pad assembly (3
Disconnect the air conditioning aspirator multi-plug.
Remove the underscuttle pad.
Place the underscuttle pad assembly in position.
Connect the air conditioning aspirator multi-plug.
Reposition the underscuttle pad.
Secure the underscuttle pad with clip and align the secur-
Fit and tighten the underscuttle pad securing screws.
Motor the seat to the original position.
Fig.
1).
Fig 1).
ing screw
holes.
13.3.20 Underscuttle Pad - Passenger Side, Remove For
Access And Refit
SRO 76.46.15/90
Motor the passenger seat fully rearwards.
Undo and remove the underscuttle pad securing screws.
Using special tool JD 188, displace the securing clip.
Displace and remove the underscuttle pad.
Place the underscuttle pad assembly in position.
. Secure the underscuttle pad with clip and align the secur-
Fit and tighten the underscuttle pad securing screws.
Motor the seat to the original position.
ing screw holes. Fig.
1
X300 VSM Issue 1 August 1994 26