1994 JAGUAR XJ6 air condition

Climate Control Systems
New
Drain and discard the transit lubricating oil from a new compressor before it is be fitted. An adjustment must
then be made to avoid over-filling the system, by taking into account;
a) the quantity found in the original compressor.
b) the quantity deposited in the recovery equipment oil separator from the charge recovery operation.
Drained from original compressor
50 ml
Recovered from oil separator 40 ml
Quantity to be put in new compressor 50 + 40 = 90 ml
Typical example:
Please note that the discrepancy between the cumulative figure of recovered and drained oil and the nominal capacity
of
180 ml is caused by normally unrecoverable oil being trapped in components such as the condenser, receiver/ drier
or evaporator.
The previous statements apply even
if a problem has occurred due to oil leakage. The amount of oil lost due to leakage
is generally small, so to avoid over-filling please follow the example.
If however the recovery process has not been necessary because refrigerant has also been lost, then ONLY replace the
quantity drained from the original compressor.
14.9.5
Should a major component such as condenser, receiver / drier or evaporator be renewed then an adjustment to the
system oil level must be made. This may be carried out in the same way as the examples for the compressor except
for the fact that trapped oil within any one of these components cannot normally be drained. Therefore, a nominal
amount of oil should be substituted
in addition to that recovered from the recovery station separator.
Adding Lubricating Oil - Component Related
Condenser Add 40 ml
Evaporator Add 40 ml
Receiver / drier NO adjustment
CAUTION: Always decant fresh oil from a sealed container and do not leave oil exposed to the atmosphere. PAG
oil is very hygroscopic (absoh water) and will rapidly attract atmospheric moisture.
PAG oil must NEVER be mixed with mineral based oils.
Do not re-use oil following a recovery cycle, dispose of it safely.
14.9.6 Adding Refrigerant
In order that the air conditioning system may operate efficiently it must contain a full refrigerant charge. The indica- tions of some system defects, and the results of certain tests, will show that a low charge is the most probable cause
of the fault. In such cases the charge should be recovered from the system, the weight noted, and the correct amount
installed.
Should refrigerant be added in liquid form, initial engine start
-up revolutions must NOT exceed 2000 RPM for a period
of (2) two minutes. If the engine speed is excessive, compressor damage may occur due to the lubricating oil and the
liquid refrigerant being initiallyforced around the system as a 'slug', thus taking oil awayfrom the compressor. These
marginal lubrication conditions in the compressor will cease as the refrigerant becomes gaseous.
Never attempt to 'guess' the amount of refrigerant in a system, always recover and recharge with the correct charge
weight; this is the only accurate method.
CAUTION: If oil was drawn out during the recovery process, the corM amount may be added directly from your
recovery / recycle /recharge station (if so equipped) prior to the 'charging process'. It must be stressed that the need to protect compressor oil from moisture is vital, observe the procedures
in HANDLING LUBRICATING OIL and those concerning excessive engine revolutions.
Issue 1 August 1994 14 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
14.13 SYSTEM CHECKING WITH MANIFOLD GAUGE Sm
14.13.1 Evacuating the Manifold Gauge Set
Attach the centre (service) hose to a vacuum pump and start the pump. Open fully both high anddow valves and allow
the vacuum to remove air and moisture from the manifold set for at least five minutes.
Turn the vacuum pump off and isolate it from the centre service hose but do not open the hose to atmosphere.
CAUTION: It is imperative that the vacuum pump is not subjected to a positive pressure of any degree. Therefore
the pump must be frtted with an isolation valve at the centre (service hose) connection and this valve
must be closed before the pump is switched off. This operation replaces the 'purge' procedure used on
previous systems. Observe the manufacturefs recommendation with regard to vacuum pump oil
changes.
14.13.2 Connecting the Manifold Gauge Set
CAUTION: Only use hoses with connectors which are dedicated to HFC 134A charge ports.
Attachment of the hose quick release connectors to the high and low side system ports is straightfotward, provided
that the high and low valves are closed and the system is NOT operational.
Assessment of system operating efficiency and fault classification may be achieved by using the facilities on your
Re- covery / Recharging / Recycling station, follow the manufacturers instructions implicitly and observe all safety con- siderations.
WARNING: UNDER NO CIRCUMSTANCES SHOULD THE CONNECTIONS BE MADE WITH THE SYSTEM IN
OPERATION OR THE VALVES OPEN. SHOULD THE VALVES BE OPEN AND A VACUUM PUMP OR
REFRIGERANT CONTAINER ATTACHED, AN EXPLOSION COULD OCCUR AS A RESULT OF HIGH
PRESSURE REFRIGERANT BEING FORCED BACK INTO THE VACUUM PUMP
OR CONTAINER.
14.13.3 Stabilizing the System
Accurate test gauge data will only be attained if the system temperatures and pressures are stabilized.
Ensure that equipment and hoses cannot come into contact with engine moving parts or sources of heat.
It is recommended that a free standing air mover is placed in front of the vehicle to provide air flow through the con- denser / cooling system, see illustration below.
Start the engine, allow
it to attain normal working temperature and set at fast idle (typically 1200 to 1500 rpm). Select full air conditioning performance.
With all temperatures and pressures stable, or displaying symptoms of faults; begin relevant test procedures.
Fig.
1
Issue 1 August 1994 20 X300 VSM

SERVKE TOOLS & EQU1PMENT
Illustration I JagusrNumbw I Description I NOtOS
Instrument pack to support panel
to
be issued
11. TORQUE TlGHTENlNG SPEC1FKATIONS
1.8
Fixing
Fascia to console
Fascia to support bracket
(Nm)
I TigM.ningToqrn
I
2.5-3.5
22-28
Instrument pack to fascia
Strut to fascia 2.5-3.5
1.5-2.5
I I 22-28 1 Tunnel bracket to bodv
I Bolster to tunnel bracket I 1.5 I
Fascia support strut to BIW 7-1 0
CPU brackets to fascia 5-7
Fascia demister bracket to fascia 1.5
Fascia and air conditioning location to body 1
Air distribution box duct to air distribution box
Airbag carrier mounting bracket to fascia 1
5-7
instrument pack support bracket to fascia
Airbag bracket to fascia 5-7
1.5-2.5
Air distribution box to fascia
Airbag upper bracket to carrier 1.5-2.5
1.5-2.5
Instrument pack support bracket and strut
Fascia assembly to BIW 5-7
22-28
111. SERVKE MTERlALS
0, Description
Airbag door brackets to fascia
Airbag door bracket to door frame assembly 5-7
5-7
US08 Notes I I
1 to be issued I I
X300 VSM iii Issue 1 August 1994

15.1.13 Spillage and Leakage
If material is spilled or released,contact Jaguar Service for clean up procedures. All other personnel must be kept away
from contaminated area.
Do not dispose contaminated propellant or water into storm or sanitary sewers, ground water or soil.
Spills may be reportable to local state,
and/or federal authorities.
Material should
be disposed of by incineration or chemical oxidation under carefully controlled conditions by specially
trained individuals in accordance with local State and Federal regulations.
0
15.1.14 Scrapping Vehicles With Live Airbag(s)
When scrapping a vehicle with a live airbag, first deploy the
airbag in accordance with following procedures. This
procedure assumes airbag wiring is undamaged.
See Handling
/ Safety information.
If the airbag is
to be removed see Airbag Modules Assembly/ Removal/Service Instructions.
Equipment required: Insulation Displacement Connectors
(IDC) (Scotchloks) (two-off), battery, two-off ten meter
lengths of lmm2 wire fitted with crocodile clips at one end. (See Fig. 1).
WARNING: THE DEPLOYMENT PROCEDURE SHOULD BE PERFORMED OUTDOORS AWAY FROM OTHER
PERSONNEL.
Remove any loose debrisfrom around airbag and ensure no
flammable liquids are present.
Disconnect the vehicle battery. Fig. 1
Link harness conn&ion & deployment method
WARNING:
ALWAYS CONNECT TO AlRBAG FIRST, AS THE BAG WILL DEPLOY IMMEDIATELY ON CONNECTION TO
THE BATTERY.
Remove passenger side and driver side under-scuttles / knee bolster.
. Disconnect the airbag connector under the facia.
. Look for the yellow harness connectors and cut the wires originating from the airbag just above the mating plug.
w: The harness connected between the driver's airbag and the yellow connector has one red/purple feed wire and
one pinkbrown return wire.
The harness connected between the passenger's airbag and the yellow connector has two
red/purple feed
wires and one pinwpurple return wire.
Pass a 10 meter (33ft) link harness containing two lmm2 wires through the window aperture, and connect using an
. Close all doors, leave window with lead open.
. Ensure no personnel are in the car or in the area around the car.
. Move back 10 meters (33ft) and connect harness crocodile clips to battery: the airbag will immediately deploy.
Allow the unit to cool for at least 20 minutes. Cooling modules should be continuously monitored to ensure heat
(continued next page)
Insulation Displacement Connector (IDC) and two crocodile clips, to the airbag wires.
generated does not create
a fire with spilled liquids or other debris.
X300 VSM 5 Issue 1 August 1994

31
30
29
28 27
26
4 26 24 21 23 22 7 20 19 18 18 17 8
a
10
11
12
13
14
1s
1M-137
1. Tachometer 2. Speedometer
3. Battery Condition 4. FuelGauge 5. Oil Pressure 6. Coolant Temperature 7. Odometer /Trip Computer Display 8. Primary Warning Indicators (RED) 9. Exhaust Temperature 10. Low Oil Pressure 11. Seat Belt Not Fastened 12. Boot Open 13. DoorOpen 14. Coolant Level 15. Air Bag Fault 16. Status / Warning Lamps
17. Hand Brake On (RED) 18. Brake System Fault (RED)
19. Main Beam On (BLUE) 20. Direction Indicator Right (GREEN) 21. Status / Warning Lamps 22. Direction Indicator Left (GREEN) 23. Traction Control Off (GREEN) 24. Transmission Sport Mode (GREEN) 25. Charging Fault (RED) 26. Check Engine (AMBER)
27. Low Fuel Level (AMBER) 28. Anti - Lock Fault (AMBER) 29. Traction Control Fail (AMBER) 30. Bulb Fail (AMBER) 31. Washer Fluid Level (AMBER) 32. Transmission Fault (AMBER)
Fig.
1 Instrument Panel, Front Mew
w: The 'Premium Unleaded Fuel Only' caution is added to the Federal Market vehicles, also 'PARK BRAKE and
'BRAKE' replace international symbols used in all other markets.
m: Six cylinder vehicle version shown; the tachometer red-line on 12 cylinder vehicles starts at 6000 RPM.
The front of the
PECUSprogrammable instrument panel features 6 analog gauges, 22 warning lamps /tell tales and
a Liquid Crystal Display (LCD), the rear of the panel accommodates two PCB mounted connectors, one 24-way
connector, one 48-way connector, one instrument panel identification label and 14 light bulbs arranged in groups of
seven on either side. Three power inputs and two ground inputs are provided for 'POWER UP' and 'POWER DOWN'
sequence, the three power inputs comprising battery, ignition and auxiliary. The instruments are protected by a
housing
/ lens assembly.
15.2.7 Gauges
The two major gauges are tachometer and speedometer, and the four minor gauges indicate battery condition, fuel
level, oil pressure and coolant temperature.
Each gauge is contained
in a sealed non-serviceable can and must be renewed as a complete unit in case of any
damage.
CAUTION: Extreme care should be exercised when renewing instrument pand components to avoid damago to the delicate indicator needles.
X300 VSM 9 Issue 1 August 1994

Black
Black
Black All
models
All Models
All Models
Black
Black All
Models
All Models
Black/
White Stripe
Black/
White Stripe
Black Non
Aircon.
Models
only
Non Power
Wash Models
only
Optional
0 Key to Fig. 1, hgine Compartment Relays, page 14.
Number v12 Color
All Models
SRO
B6.55.04
Rdaw
Horn
Location
Engine
compartment,
inside the left
hand side fuse box.
Engine
compartment,
behind left hand head
lamp assembly.
see starter
motor
solenoid. All
Models
1 ~~
All
Models 5 Starter Motor
Solenoid
4 All Models
All Models 18.30.34 Air-conditionin
g Water Pump
Wiper Motor
On
/Off
2 see starter
motor
solenoid.
see starter
motor
solenoid. All
Models
3 Wiper Fast /
Slow
18.30.71 Engine
compartment, behind right
hand head
lamp assembly. 8 EMS Engine
Management
System
Control
Black
I
All Models 9 Ignition Coil
PI Main Relay see
EMS
control.
see EMS
control. Black
I
All
Models 8
Air Pump 7 see EMS
control.
see EMS
control. Black
Air Injection
Black Air Con
- Model Air
Injection
only
All Models
18.30.34
86.55.08 Air
Conditioning
Compressor
Clutch
Relay Case
Engine
compartment,
on the right
hand side inner
wing valance.
Relay
Case Non Power
Wash
Models
only
11
10
12
Power Wash
Screen Wash Optional
All Models
All Models
Black
All Models
Ignition Relay
Engine
compartment,
inside
right
hand fuse box.
X300 VSM 33 Issue 1 August 1994

I SRO I Rdw* AJ16 v12
Automatic Automatic
Models only Models only
Automatic Automatic
Models only Models only
UK
& ROW -
Manual Seat
only
UK
& ROW -
Manual Seat
onh/
UK & ROW -
Manual Seat
only
Manual Seat
only
UK
& Manual -
Seat only
UK
& Manual -
Seat only
UK
& ROW -
Optional
Optional
Optional Optional
Keylock
Number
13
14
15
16
34
35
17
36
37
38
Driver's Seat Height
Control (Upward)
Driver's Seat Height
Control (Downward)
Passenger Seat
Height Control (Upward)
Passenger Seat
Height Control
(Downward)
Driver's Seat Heater
All Models
All Models
All Models
Passenger Seat
Heater
RH Front
Screen
Heater
LH Front Screen
Heater
Ignition All Models
25
All Models 26
All Models 23
Ignition
Air
-conditioning
Isolate
LH Blower
RH Blower
LH Blower
high
speed
RH Blower high
speed
Deadlock front
lefthear right All
Models All Models
20
Below gear selector 'J' gate.
Not NAS or
Japan
UK
& Europe
only
All Models
All Models
USA
&
Canada only
All Models
All Models
All Models
All Models
Below
gear selector
'J' gate.
Not NAS or
30
UK & Europe 31
All Models 28
All Models 29
USA & 27
All Models 24
All Models 33
All Models 22
All Models 32
Japan
only
Canada only
On
seat panel below
driver's seat.
86.55.78
86.55.74
On seat panel below
driver's seat.
Deadlock front
righthear left
Door Lock
Door Unlock
Driver's Door
Unlock
Mirror Heater
Puddle Lamps
Cigar Lighter
Fuel Flap Lock On
seat panel below
passenger's seat.
On seat panel below
passenger's seat.
On seat panel below
driver's seat.
On seat panel below
passenger's seat.
Left hand side footwell on
front
'A' post, behind cover.
Left hand side footwell on
front
'A' post, behind cover.
Fuse box assembly
RH side heelboard.
Fuse box assembly
LH side heelboard.
Behind
RH side heelboard.
Behind
RH side heelboard.
Behind RH side heelboard.
Behind
RH side heelboard.
Behind
RH side heelboard.
Behind LH side heelboard.
Behind LH side heelboard.
Behind LH side heelboard.
Behind LH side heelboard.
Behind LH side heelboard.
Behind
RH side heelboard.
Behind LH side heelboard.
Behind
RH side heelboard.
Behind LH side heelboard.
Color
Blue
Blue
Violet
Violet
Violet Violet Blue Blue
Blue
Blue
Blue
Blue
Blue
Blue
Blue Blue
Blue
Violet
Violet
Violet
Violet
Violet
Violet Blue
Blue
Violet All
Models All Models
All Models All Models
All Models All Models
18
X300 VSM 35 Issue 1 August 1994