1997 JAGUAR XJ6 air conditioning

blower at the highest setting. Open the doors
(to make sure the air conditioning system
doesn’t cycle off as soon as it cools the
passenger compartment).
9With the compressor engaged - the clutch
will make an audible click and the centre of
the clutch will rotate. After the system reaches
operating temperature, feel the two pipes
connected to the evaporator at the bulkhead
(see illustration).
10The pipe (thinner tubing) leading from the
condenser outlet to the evaporator should be
cold, and the evaporator outlet line (the
thicker tubing that leads back to the
compressor) should be slightly colder (3 to
10° F). If the evaporator outlet is considerably
warmer than the inlet, the system needs a
charge. Insert a thermometer in the centre air
distribution duct while operating the air
conditioning system - the temperature of the
output air should be 35 to 40° F below the
ambient air temperature (down to approxi-
mately 40° F). If the ambient (outside) air
temperature is very high, say 110° F, the duct
air temperature may be as high as 60° F, but
generally the air conditioning is 30 to 50° F
cooler than the ambient air. If the air isn’t as
cold as it used to be, the system probably
needs a charge. Further inspection or testing
of the system is beyond the scope of the
home mechanic and should be left to a
professional.
11Inspect the sight glass (see illustration).
If the refrigerant looks foamy when running,
it’s low. When ambient temperatures are very
hot, bubbles may show in the sight glass even
with the proper amount of refrigerant. With the
proper amount of refrigerant, when the air
conditioning is turned off, the sight glass
should show refrigerant that foams, then
clears. Note:1993 and 1994 models are
equipped with R-134a refrigerant systems and
do not have a sight glass.Heating systems
12If the air coming out of the heater vents
isn’t hot, the problem could stem from any of
the following causes:
a) The thermostat is stuck open, preventing
the engine coolant from warming up
enough to carry heat to the heater core.
Renew the thermostat (see Section 3).
b) A heater hose is blocked, preventing the
flow of coolant through the heater core.
Feel both heater hoses at the bulkhead.
They should be hot. If one of them is cold,
there is an obstruction in one of the hoses
or in the heater core, or the heater control
valve is shut. Detach the hoses and back
flush the heater core with a water hose. If
the heater core is clear but circulation is
impeded, remove the two hoses and flush
them out with a water hose.
c) If flushing fails to remove the blockage
from the heater core, the core must be
renewed.(see Section 11).
13If the blower motor speed does not
correspond to the setting selected on the
blower switch, the problem could be a badfuse, circuit, control panel or climate control
computer (see Sections 10 and 12).
14If there isn’t any air coming out of the
vents:
a) Turn the ignition ON and activate the fan
control. Place your ear at the heating/air
conditioning register (vent) and listen.
Most motors are audible. Can you hear
the motor running?
b) If you can’t (and have already verified that
the blower switch and the blower motor
resistor are good), the blower motor itself
is probably bad (see Section 10).
15If the carpet under the heater core is
damp, or if antifreeze vapour or steam is
coming through the vents, the heater core is
leaking. Remove it (see Section 11) and refit a
new unit (most radiator shops will not repair a
leaking heater core).
16Inspect the drain hose from the heat/AC
assembly at the right side of the bulkhead,
make sure it is not clogged (see illustration).
If there is a humid mist coming from the
system ducts, this hose may be plugged. In
some early models, the hose may have been
pinched during assembly or blocked with
insulation or underseal.
14 Air conditioning
receiver/drier-
removal and refitting
4
Warning: The air conditioning
system is under high pressure.
Do not loosen any hose fittings
or remove any components until
the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an EPA-approved recovery/
recycling unit by a dealer service depart-
ment or an automotive air conditioning
3•12 Cooling, heating and air conditioning systems
13.16 This drain hose (arrowed) from the
heater/air conditioning unit should be kept
clear to allow drainage of condensation
3261 Jaguar XJ6 13.9 Feel the inlet (small arrow) and outlet (large arrow) pipes at
the bulkhead leading to the air conditioning evaporator (battery
removed here for clarity only)
13.11 The sight glass (arrowed) is located on the top of the
receiver/drier, to the right of the radiator

repair facility. Always wear eye protection
when working near air conditioning system
fittings.
1Have the refrigerant discharged and
recovered by an air conditioning technician.
2Disconnect the refrigerant lines (see
illustration)from the receiver/drier and cap
the open fittings to prevent entry of moisture.
3Remove the three nuts holding the
receiver/drier to the radiator support and
remove the receiver/drier. Note:On 1993 and
1994 models, the receiver/drier is a long
tubular style mounted to the top-front of the
radiator support. The grille must be removed
for access on these models (see Chapter 11
for grille removal).
4Refitting is the reverse of removal.
5Have the system evacuated, charged and
leak tested by the workshop that discharged
it. If the receiver/drier was renewed, have
them add new refrigeration oil to the
compressor, about 28 cc (one ounce). Use
only the refrigerant oil compatible with the
refrigerant of your system (R-12 or R-134a).
15 Air conditioning
compressor-
removal and refitting
4
Warning: The air conditioning
system is under high pressure.
Do not loosen any hose fittings
or remove any components until
the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an EPA-approved
recovery/recycling unit by a dealer service
department or an automotive air
conditioning repair facility. Always wear
eye protection when disconnecting air
conditioning system fittings.
1Have the refrigerant discharged by an
automotive air conditioning technician.2Disconnect the battery negative cable.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
3Remove the drivebelt from the compressor
(see Chapter 1).
4Detach the electrical connector and
disconnect the flexible refrigerant lines (see
illustration).
5Unbolt the compressor and lift it from the
vehicle (see illustration).
6If a new or rebuilt compressor is being
installed, drain the fluid from the new unit by
opening the drain plug and by tilting the
compressor to the rear so that any remaining
oil will come out the ports in the back normally
covered by the plate and hard lines. Refit the
drain plug and end-plate and add 199 cc
(7 fluid ounces) of new oil of a type compatible
with the type refrigerant in your system.
7Refitting is the reverse of removal. Renew
any O-rings with new ones specifically made
for the type of refrigerant in your system and
lubricate them with refrigerant oil, also
designed specifically for your refrigerant.
8Have the system evacuated, recharged and
tested by the workshop that discharged it.
16 Air conditioning condenser-
removal and refitting
4
Warning: The air conditioning
system is under high pressure.
Do not loosen any hose fittings
or remove any components until
the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an EPA-approved
recovery/recycling unit by a dealer service
department or an automotive air con-
ditioning repair facility. Always wear eye
protection when disconnecting air
conditioning system fittings.
1Have the refrigerant discharged and
recovered by an air conditioning technician.
2Remove the radiator cowl panel as
described in Section 5.
3Using two spanners to avoid twisting the
fittings, disconnect the inlet and outlet lines
from the condenser (see illustration).
4Pull the condenser straight up and out of
the vehicle.
5Refitting is the reverse of removal. When
refitting the condenser, be sure the rubber
Cooling, heating and air conditioning systems 3•13
3
15.5 Remove the lower mounting bolts
and the adjuster bolt (arrowed)16.3 Disconnect the two lines, then pull up
on the condenser (arrowed)
3261 Jaguar XJ6 14.2 After the system has been discharged, unbolt the two
refrigerant lines (left arrows) from the top of the receiver/drier and
cap them - use two spanners when loosening or tightening these
lines - right arrows indicate the two top mounting bolts
15.4 Disconnect the electrical connector (small arrow) at the
compressor, then disconnect the bolt (large arrow) at the
retaining plate that holds the two hoses in place

cushions fit on the mounting points and that
any foam insulator strips are still in place or
transferred to the new condenser.
6Reconnect the refrigerant lines, using new
O-rings. If a new condenser has been
installed, add 84 cc (3 fluid ounces) of new
refrigerant oil. Note:The oil and O-rings must
be compatible with the type of refrigerant you
are using.
7Refit the remaining parts in the reverse
order of removal.
8Have the system evacuated, charged and
leak tested by the workshop that discharged
it.
17 Air conditioning evaporator
and expansion valve-
removal and refitting
4
Warning 1: The air conditioning
system is under high pressure.
Do not loosen any hose fittings
or remove any components until
the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an EPA-approved
recovery/recycling unit by a dealer service
department or an automotive airconditioning repair facility. Always wear
eye protection when disconnecting air
conditioning system fittings.
Warning 2: Later model vehicles
are equipped with airbags. To
prevent the accidental
deployment of the airbag, which
could cause personal injury or damage to
the airbag system, DO NOT work in the
vicinity of the steering wheel or instrument
panel. The manufacturer recommends
that, on airbag-equipped models, the
following procedure should be left to a
dealer service department or other repair
workshop because of the special tools and
techniques required to disable the airbag
system.
1Refer to Chapter 11 for removal of the glove
compartment, under-dash panels and
console. Note:The removal of the
heater/evaporator housing is difficult and
time-consuming, much more so than the
removal of the heater core (see Section 11).
For some home mechanics, the job is better
left to a Jaguar dealership or other qualified
repair workshop.
2Disconnect the air conditioning lines from
the backside of the expansion valve (at the
bulkhead, just to the right of the engine), usingtwo spanners (see illustration). Cap the open
fittings and expansion valve after dismantling
to prevent the entry of air or dirt.
3Refer to Section 11 for moving the climate-
control computer aside and disconnecting the
heater core pipes.
4From the engine side of the bulkhead, near
the expansion valve, remove the nut retaining
the heat/air conditioning assembly housing
(see illustration). Another mounting nut is on
the left side, under the wiper motor (see
illustration 11.2).
5Disconnect the defroster ducts on the left
and right side of the evaporator housing (see
illustration).
6Identify all of the vacuum motor lines with
masking tape and a felt pen, then disconnect
the lines. Note:Most vacuum lines are colour-
coded. Make notes on which ones go to
which devices.
7Tag and disconnect the wiring plugs
connected to the heating/air conditioning
housing.
8At the bottom left and bottom right of the
housing, pull off the rubber drain tubes that go
into the flooring.
9Remove the four rod-type support braces.
Two support the dash, and two connect the
case to the floor of the car (see illustrations).
3•14 Cooling, heating and air conditioning systems
17.5 Left duct (large arrow) can be removed
by pulling off the clip (small arrow) - right
duct pulls out without a clip17.9a Unbolt the four support braces
(small arrows) from the case (large arrow)
and floor17.9b Black case-support rods are held
with nuts (arrowed), the gold dash-support
rods are retained by a bolt/nut to the dash
3261 Jaguar XJ6 17.2 Use two spanners when disconnecting the air conditioning
lines (arrowed) at the bulkhead, on the backside of the expansion
valve - one spanner holds the body of the expansion valve
17.4 Remove the housing retaining nut (arrowed) on the engine
side of the bulkhead, near the expansion valve - another nut is on
the right, near the heater core pipes

10With everything disconnected, pull the
heat-air conditioning housing back and out
from under the dash.
Caution: Do not force anything. If the unit
gets stuck, determine where the inter-
ference is before a duct, wire or hose is
broken.
11Pry off the series of black metal clips
connecting the main housing to the evaporator
case, then separate the evaporator case and
pull out the evaporator core. Note:When
refitting the evaporator core into the case, be
sure to refit the foam insulation in the same
way it was installed originally.
12The evaporator core can be cleaned with a
“fin comb” and blown off with compressed air.13The expansion valve is located on the
right side of the bulkhead on the engine side.
To renew it, remove the battery (Chapter 5) for
better access. Disconnect the lines from the
back of the valve as in Step 2. Disconnect the
high and low-pressure hoses from the frontof
the expansion valve (see illustration).
14If the evaporator core is renewed, make
sure the technician adds 1.4 ounces of new
refrigerant oil (of a type compatible with your
type of refrigerant) to the system.
15The remainder of the refitting is the
reverse of the removal process. Be sure to
use new O-rings, and new gaskets on the
expansion valve.
16Have the system evacuated, charged and
leak tested by the workshop that discharged
it.
Cooling, heating and air conditioning systems 3•15
3
17.13 Disconnect the lines at the front of
the expansion valve - always use two
spanners to avoid twisting a line - one
spanner holds the body of the valve
3261 Jaguar XJ6

selector towards the rear of the vehicle. Pull
up on the rear half of the radio trim bezel while
gently detaching the clips securing the front,
then remove the bezel from the vehicle.
6Remove the radio and heater control
assembly (see Chapter 12).
7Remove the dashboard centre trim panel
(see Section 26), then remove the centre air
conditioning duct from the vehicle (see
illustration).
8Remove the retaining screws located in the
air conditioning duct opening (see illustration).
9Remove the plastic screws securing the
lower front section of the console (see
illustration).
10Unplug any electrical connectors that will
interfere with the removal of the console.
11Pull the console towards the rear of the
vehicle, then lift the console up over the shift
lever and remove it from the vehicle.
12Refitting is the reverse of removal.
Overhead console
13Remove the plastic screw securing the
overhead console, then carefully pull the
console out of the headliner (see illustration).
14Disconnect the electrical connectors from
the lights.
15Refitting is the reverse of removal.
25 Instrument cluster housing-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering column or instrument panel.
The manufacturer recommends that, on
airbag equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.
1Disconnect the negative battery cable. Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Remove the drivers side knee bolster (see
Section 26).
3Place the steering wheel in the full rearward
position. If the vehicle is equipped with a tilt
column, place the steering wheel in the lowest
position.
4Remove the instrument cluster housing
screws (see illustration).
5Pull the instrument cluster housing outward
to access the electrical connections on the
backside (see illustration).
6Disconnect all electrical connections from
the backside of the cluster housing and
remove the housing from the vehicle.
7Refitting is the reverse of removal.
11•12 Bodywork and fittings
24.3b Pull the ash tray towards the rear of
the vehicle to remove it - don’t pull it
straight up24.4 Working through the ash tray opening,
remove the radio trim bezel wingnuts
(arrowed) located under the trim bezel24.7 After removing the centre trim panel,
detach the air conditioning duct
24.8 Remove the retaining screws in the
air conditioning duct opening24.9 Remove the plastic screws (arrowed)
from each side of the console24.13 Remove the plastic screw, then pull
the overhead console down and unplug
the electrical connectors
3261 Jaguar XJ6
25.4 Working in the knee bolster opening,
remove two retaining screws from each
end of the instrument cluster housing25.5 Pull outward on the instrument
cluster housing and unplug the electrical
connectors from the backside

26 Dashboard trim panels-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering column or instrument panel.
The manufacturer recommends that, on
airbag equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery
Knee bolster
1Knee bolsters are located on the lower half
of the instrument panel on the driver and
passenger sides of the vehicle. The removal of
these covers will allow access to a variety of
electrical, heating and air conditioning
components.
2Detach the retaining screws along the
edges of the knee bolster (see illustration).
3Pull outward on the lower edge of the knee
bolster and detach it from the vehicle.
4Refitting is the reverse of removal.
Centre trim panel
5Carefully pull outward to detach the centre
trim panel from the instrument panel (see
illustration).
6Refitting is the reverse of removal.
Glove box
7Detach the passenger side knee bolster as
described in Steps 2 and 3.8Remove the glove box door hinge bolts
(see illustration).
9Open the glove box door, then detach it
from the vehicle.
10Detach the heater duct and the relay
mounting panel from the bottom of the glove
box.
11Detach the remaining screws securing the
upper edge of the glove box (see illustration).
12Disconnect the lamp from the glove box
and remove the assembly from the vehicle.
13Refitting is the reverse of removal.
27 Steering column cover-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could cause
Bodywork and fittings 11•13
11
3261 Jaguar XJ6 26.2 Remove the retaining screws along the outer edge of the
knee bolster, then remove it from the vehicle
26.5 Grasp the centre trim panel with both hands, then unsnap
the retaining clips (arrowed) from the dashboard assembly
26.8 With the passenger side knee bolster removed, unscrew the
glove box door hinge bolts26.11 Remove the screws along the top edge (arrowed), pull the
glove box out and remove the lamp assembly

12•26 Wiring diagrams
3261 Jaguar XJ6
Typical 1988 heater and air conditioning system

Wiring diagrams 12•27
12
3261 Jaguar XJ6
Typical 1989 to 1992 heater and air conditioning system