Published: 15-Jan-2015

Climate Control - Air Conditioning

Description and Operation

COMPONENT LOCATION - Vehicles without an Internal Heat Exchanger (IHX)

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Item Description
1 Refrigerant pressure sensor
2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection
COMPONENT LOCATION - Vehicles with an Internal Heat Exchanger (IHX)

Item Description
1 Refrigerant pressure sensor
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2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection

OVERVIEW

A choice of Air Conditioning (A/C) systems are available with features to enhance the performance for second and third-row
seat passengers.
The system is available in two forms, with an optional rear air conditioning unit.

Manual air conditioning system.

Two-zone auto system, with separate LCD display controls for driver and front passenger.
Vehicles with 5+2 seating, an optional auxiliary air conditioning unit for third row passengers is available, with controls
for temperature and fan speed.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

The rear air conditioning has a child lock function which disables the rear fan speed control switches. This is feature is
accessed from the Touch Screen.

The A/C system transfers heat from the passenger compartment to the outside atmosphere to provide the climate control
assembly with dehumidified cool air.

The A/C system is a sealed closed-loop system, filled with refrigerant as the heat transfer medium. Refrigerant oil is added to
the refrigerant to lubricate the internal components of the A/C compressor:

R1234yf refrigerant is used in USA and Canada (NAS market); systems with an Internal Heat Exchanger (IHX)
installed.
R134a refrigerant is used in the ROW markets; systems without an Internal Heat Exchanger (IHX).

For additional information, refer to: Specifications (412-01 Climate Control, Specifications).

The compressor is a variable displacement unit, where the displacement (flow of refrigerant) is controlled to match the
thermal load of the evaporator. The type of compressor fitted will depend on engine variant, see below.

The operation of the A/C system is controlled by the Automatic Temperature Control Module (ATCM).
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

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DESCRIPTION

The air conditioning system includes the following features:

B-pillar mounted mid-level vents for row 2 passengers

Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row 3 passengers
A mist sensor on the windscreen, used to detect conditions likely to cause misting
An air quality sensor for detection of pollutant levels. When levels exceed set limits the system switches to
re-circulation mode
Timed climate control to pre-heat the cabin. This function can be activated remotely using the InControl Remote App
ECO mode enables the system to adopt a more economical operating mode.

Air Conditioning Layout with Optional Auxiliary Rear Air Conditioning Unit
 Item Description
1 B-pillar mounted mid-level vents for row two passengers
2 Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row three passengers
3 Optional auxiliary air conditioning unit
The optional auxiliary air conditioning unit is discussed in another section.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

Air Conditioning Compressor

2.0 GTDi Petrol

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Item Description
1 Pulley with electro-magnetic clutch
2 Refrigerant inlet port
3 Pressure relief valve
4 Electronic control valve connector
5 Refrigerant outlet port
6 Electro-magnetic clutch connector.
TD4 2.2L Diesel
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Item Description
1 Pulley with electro-magnetic clutch
2 Electro-magnetic clutch connector
3 Refrigerant outlet port
4 Refrigerant inlet port
5 Electronic control valve connector
6 Pressure relief valve.
Compressor

The Air Conditioning (A/C) compressor is driven by the engine primary drive belt. The compressor circulates refrigerant
around the A/C system by compressing low-pressure, low-temperature vapor from the evaporator and discharging the
resultant high-pressure, high-temperature vapor to the condensor.

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.

Both compressors are variable displacement units. Displacement is controlled by an integral electronic control valve operated
by the Automatic Temperature Control Module (ATCM). The control valve measures the input and output pressures of the
refrigerant entering and leaving the compressor and controls the angle of the internal swash plate accordingly. The ATCM
influences the control to match the thermal load of the evaporator and other factors.
Compressor clutch engagement is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Condensor

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Item Description
1 Condensor
2 Receiver/drier.
The condensor transfers heat from the refrigerant to the surrounding air to cool the refrigerant and therefore convert the
high-pressure vapor from the compressor into a liquid. The condensor is installed immediately in front of the radiator.

The condensor is classified as a sub-cooling condensor and consists of a fin and tube heat-exchanger core installed between 2
end tanks. Divisions in the end tanks separate the heat exchanger into a 4 pass upper (condensor) section and a 2 pass lower
(sub-cooler) section.

The right end tank provides the connections to the high-pressure line from the A/C compressor and the liquid line to the
evaporator.

Receiver/Drier

The receiver/drier is integral with the condensor left end-tank and removes solid impurities and moisture from the refrigerant.
It also acts as a reservoir for liquid refrigerant to accommodate changes of heat load at the evaporator.
Refrigerant entering the receiver drier passes through a filter and a desiccant pack, then collects in the base of the unit before
flowing through the outlet pipe back to the condensor.

Refrigerant Pressure Sensor

The refrigerant pressure sensor provides the Automatic Temperature Control Module (ATCM) with a pressure input from the
high-pressure side of the refrigerant system. The refrigerant pressure sensor is hardwired to the ATCM, which uses the signal
to control operation of the A/C compressor through the A/C compressor clutch relay in the Battery Junction Box (BJB).
Additionally, the ATCM is able to increase the amount of re-circulated air, if it is required. The ATCM broadcasts the refrigerant
high-pressure value over the medium-speed Controller Area Network (CAN) comfort bus to the Engine Control Module (ECM)
via the Gateway Module (GWM). The ECM calculates the additional load on the engine when the A/C compressor is working.

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For example, this signal is used as an input, for the idle speed control.

The refrigerant pressure sensor is located in the refrigerant line between the condensor and the Thermostatic Expansion Valve
(TXV).

Thermostatic Expansion Valve

Item Description
1 Metering valve
2 Housing
3 Diaphragm
4 Temperature sensor
5 Outlet passage from evaporator
6 Inlet passage to evaporator.
The Thermostatic Expansion Valve (TXV) meters the flow of refrigerant into the evaporator to match the refrigerant flow with
the heat-load of the air passing through the evaporator.

The TXV is a block type valve located behind the climate control assembly, and attached to the inlet and outlet ports of the
evaporator. The TXV consists of an aluminum housing containing inlet and outlet passages. A ball and spring metering valve is
installed in the inlet passage and a temperature sensor is installed in the outlet passage. The temperature sensor consists of a
temperature sensitive tube connected to a diaphragm. The bottom end of the temperature sensitive tube acts on the ball of
the metering valve. Pressure on top of the diaphragm is controlled by the evaporator outlet-temperature conducted through
the temperature sensitive tube. The bottom of the diaphragm senses evaporator outlet pressure.

Liquid refrigerant flows through the metering valve into the evaporator. The restriction across the metering valve reduces the
pressure and temperature of the refrigerant. The restriction also changes the liquid stream of refrigerant into a fine spray, to
improve the evaporation process. As the refrigerant passes through the evaporator, it absorbs heat from the air flowing
through the evaporator. The increase in temperature causes the refrigerant to vaporize and increase in pressure.
The temperature and pressure of the refrigerant leaving the evaporator acts on the diaphragm and temperature sensitive
tube, which regulate the metering valve opening and so controls the volume of refrigerant flowing through the evaporator.
The warmer the air flowing through the evaporator, the more heat available to evaporate refrigerant and thus the greater
volume of refrigerant allowed through the metering valve.

Evaporator

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Item Description
1 Heater core
2 Evaporator.
The evaporator is installed in the climate control assembly, between the blower and the heater core, to absorb heat from the
exterior or re-circulated air. Low pressure, low temperature refrigerant changes from liquid to vapor in the evaporator,
absorbing large quantities of heat as it changes state.

Most of the moisture in the air passing through the evaporator condenses into water, which drains out of the vehicle by
passing through a drain tube to the underside of the vehicle.

Refrigerant Lines

To maintain similar flow velocities around the A/C system the diameter of the refrigerant lines varies to suit the two
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.
Nylon lined, low permeability rubber hoses are used in the low pressure line into the A/C compressor, and in the high pressure
line from the condensor. The remainder of the refrigerant lines are manufactured from aluminum.

Low and high pressure charging connections are incorporated into the refrigerant lines for system servicing.

Internal Heat Exchanger

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Item Description
1 High pressure line
2 Low pressure line
3 Internal Heat Exchanger (IHX)
The Internal Heat Exchanger (IHX) is incorporated within the air conditioning pipes.

The IHX is part of the vehicle's air conditioning system and helps to increase its cooling capacity. The IHX combines a section
of the system's pipework before and after the evaporator into one pipe. It uses the cold vapour exiting the evaporator to cool
the hot liquid before it enters the expansion device, resulting in increased cooling. It also uses the heat to increase the
temperature of the low temperature gas before it enters the compressor. The amount of energy used by the air conditioning
system can be reduced by taking advantage of this increased cooling.

This gives the following benefits:

Helps reduce tailpipe CO2 emissions, due to less engine load

Improved fuel economy, due to reduced compressor power requirements
R1234yf - Increases the system capacity to increase cooling.

OPERATION

Principles of Operation

To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the regimes the refrigerant changes state, during this process the maximum heat
absorption or dissipation occurs.

The low pressure/temperature regime is from the TXV, then through the evaporator to the compressor. The refrigerant
decreases in pressure and temperature at the TXV then changes state from a liquid to a vapour in the evaporator to absorb
heat.

The high pressure/temperature regime is from the compressor, through the condensor and receiver drier assembly to the
thermostatic expansion valve. The refrigerant increases in pressure and temperature as it passes through the compressor;
then releases heat and changes state from a vapour to a liquid in the condenser.
The operation of the A/C system is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

NOTE: NOTE: Due to a drop in performance of the R1234yf system when compared to the R134a system an Internal
Heat Exchanger is installed

Input/Output Diagram

System without an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condensor
 7 Receiver/drier
8 A/C compressor
9 Low pressure servicing connection
10 Blower
System with an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condenser
7 Receiver/Drier
8 A/C compressor
9 IHX
10 Low pressure servicing connection
11 Blower

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Published: 15-Nov-2013
Climate Control System - General Information - Air Conditioning (A/C) Compressor
Commissioning
General Procedures

Activation

CAUTION: Failure to follow this instruction may result in damage to the component.

1. Set the ignition to the on position, make sure the air conditioning
(A/C) is in the off position.

2. Start the engine and allow to run for a minimum of 5 minutes.

3. Set the heater controls to 22°C, with the fan speed set to 75%.

4. Switch on the A/C system.

5. Open all air vents in the dashboard.

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6. Run the A/C system for a minimum of 5 minutes, while the engine
is still at idle speed.

7. Once this is achieved the compressor is stabilized, with the oil

being distributed evenly throughout the system.
Published: 14-Oct-2014
Climate Control - Control Components
Description and Operation

COMPONENT LOCATION

Component Location - Sheet 1 of 2

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Item Description
 1 Left temperature blend motor
2 Left distribution motor
3 Blower
4 Pollution sensor (dual zone climate control system only)
5 Right distribution motor
6 Right temperature blend motor
7 Air intake stepper motor
8 Evaporator temperature sensor
9 Automatic Temperature Control Module (ATCM)
10 In-vehicle temperature sensor
11 Sunload sensor
12 Blower control module
13 Refrigerant pressure sensor
Component Location - Sheet 2 of 2

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Item Description
1 Humidity sensor
2 Ambient air temperature sensor
3 Engine Coolant Temperature (ECT) sensor (TD4)
4 ECT sensor 1 (GTDI)
5 ECT sensor 2 (GTDI)
6 Air conditioning compressor (TD4)
7 Air conditioning compressor (GTDI)
OVERVIEW

The climate control system incorporates the heating, ventilation and A/C systems. There are 2 main types of climate control
system available:

a single zone manual system

a dual zone automatic system

The climate control functions for the single zone manual system is controlled by the Manual Temperature Control Module
(MTCM). The MTCM is mounted in the center console and contains both the system electronic software and user controls.

The climate control functions for the dual zone automatic system is controlled by the Automatic Temperature Control Module
(ATCM). The ATCM is mounted in the center console and contains both the system electronic software and user controls.

The MTCM or ATCM (vehicle specification dependant) works in conjunction with a number of other vehicle control modules,
including the ECM (engine control module), which controls a number of climate control sub-systems on receipt of requests
from the MTCM or ATCM.

The single zone manual system features manual control for air temperature, air distribution and air source, although a small
amount of automatic control does exist in the MTCM software. In response to system inputs, the MTCM controls the operation
of 3 motors mounted on the heater assembly. The motors then adjust the position of the air temperature, air distribution and
air source flaps accordingly.

The dual zone automatic system features automatic control of air temperature, air distribution and blower speed. The ATCM is
also able to control individual temperature requests for both the driver and passenger side of the cabin.

NOTE: The ATCM can only maintain a maximum temperature difference between the 2 sides of the cabin of up to

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approximately 3ºC (4ºF). This is due to the movement and mix of air within the cabin.

The dual zone automatic system features two additional sensors; an in-vehicle temperature sensor and a sunload sensor. The
In-vehicle temperature sensor provides a temperature feedback to enable the ATCM software to maintain a constant cabin
temperature. The sunload sensor provides a reading of solar loading on the vehicle occupants and enables the ATCM to adjust
the output from the climate control system accordingly.

Higher specification versions of the dual zone climate control system are also available. These systems feature 2 more
additional sensors; a pollution sensor and a humidity sensor.

The pollution sensor detects pollutants entering the cabin, allowing the ATCM to react by changing the position of the air
intake flap. The humidity sensor calculates the probability of misting on the windshield. The ATCM monitors the signal from
the humidity sensor and adjusts blower speed, air distribution and A/C compressor displacement accordingly.

Stop/Start System

To support the Stop/Start system, a number of features are integrated into the logic and operation of the climate control
system within a Stop/Start cycle to:

maintain occupant comfort

prevent windshield misting
conserve battery power.

This has been achieved by the ATCM monitoring and varying when necessary, various climate control functions within a
Stop/Start cycle. For additional information, refer to:

For additional information, refer to: Starting System (303-06A Starting System - INGENIUM I4 2.0L Diesel, Description and
Operation).

To maintain the passenger compartment temperature when the engine is shutdown in a Stop/Start cycle, an auxiliary electric
coolant-pump has also been integrated into the cooling system to maintain the coolant flow through the cabin’s heater core.
The pump is directly hardwired to the ECM. On vehicles fitted with a FFBH (Fuel Fired Booster Heater), the FFBH coolant pump
is utilized and activated via the FFBH.

For additional information, refer to: Fuel Fired Booster Heater (412-02 Auxiliary Climate Control, Description and Operation).

DESCRIPTION

Manual Temperature Control Module (MTCM)

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The MTCM is mounted in the instrument panel and is integral with the control panel. The MTCM works in conjunction with the
ECM to control all aspects of heating, ventilation, and A/C. An electrical connector on the rear of the MTCM provides hardwired
and Medium Speed (MS) CAN comfort bus connections to allow interaction with A/C system components and other vehicle
control modules.

Automatic Temperature Control Module (ATCM)

The ATCM is mounted in the instrument panel and is integral with the control panel. The ATCM works in conjunction with the
ECM to control all aspects of heating, ventilation, and A/C. An electrical connector on the rear of the ATCM provides
hardwired, MS CAN comfort bus connections and Local Interconnect Network (LIN) bus message to allow interaction with A/C
system components and other vehicle control modules.

In addition to the A/C system, the MTCM or ATCM (whichever installed) controls operation of:

The seat heaters

The rear window heater
The windshield heater
The exterior mirror heaters
The climate seat switches.

MTCM or ATCM (whichever installed) logic and operation of climate control system, within a Stop/Start cycle to:

maintain occupant comfort

prevent windshield misting
conserve battery power.

This has been achieved by the manual / automatic temperature control module monitoring and varying, as necessary various
climate control functions within a Stop/Start cycle.

In some circumstances the manual / automatic temperature control module has the capability to inhibit an engine shutdown
or initiate an engine restart within a Stop/Start cycle. This is achieved by the manual / automatic temperature control module
communicating with the CJB on the medium speed CAN Comfort and Body bus, by the help of the GWM. The various override
functions the manual / automatic temperature control module has in a Stop/Start cycle are discussed below:

Coolant temperature

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The manual / automatic temperature control module will inhibit an engine shutdown or initiate an engine restart within a
Stop/Start cycle if the coolant temperature falls below the calculated threshold to support the cabin temperature set by the
vehicle occupants.

Windshield demisting

The variant of climate control fitted to the vehicle influences the software changes that have been made. For example, the
single zone manual system does not have a humidity sensor, as used on a duel zone automatic system to initiate a windshield
demist. Therefore, a calculation for demisting the windshield is made using the signals from the rain sensor and ambient
temperature sensor. Using the probability that windshield misting will occur if it is raining and the ambient temperature is
cool, the manual / automatic temperature control module will presume a windshield demist is required and start the engine
when in a Stop/Start cycle.

Evaporator temperature the main cause of windshield misting is also monitored and the high-line climate control system will
periodically cool the evaporator as necessary to reduce misting during a Stop/Start cycle. The system operates the windshield
demist shutter and if the evaporator is wet the shutter will remain closed for a few seconds after an engine restart until the
vapor is dissipated.

If the driver selects either ‘programmed defrost’ or the ‘windshield heater’ it is assumed that a quick demist of the windshield
is required. Therefore, the manual / automatic temperature control module via the CJB will either: inhibit an engine shutdown
or initiate an engine restart.

Blower speed (dual zone automatic system only)

During an engine shutdown the ATCM monitors passenger compartment temperature and maintains the blower speed at a
level that will conserve, for as long as possible the heat in the core of the passenger compartment heater. If the driver selects
a higher fan speed and the heat cannot be maintained in the heater core, the engine will restart.

Heated rear window and heated seats

If the heated rear window or heated/climate seats are active or activated during an engine shutdown event the power output
of the relevant system will be interrupted until the engine is restarted. The tell-tale light in the relevant switch will illuminate
to indicate the system is active even though the system is receiving no power. This feature is used to conserve battery power.

Fuel Fired Booster Heater

The FFBH (Fuel Fired Booster Heater) and Stop/Start system will not operate simultaneously, due to low ambient
temperatures being a factor in the function of both systems.

A/C Compressor Pressure Control Valve

All vehicle variants are fitted with a variable displacement A/C compressor. Displacement is controlled by an integral electronic
control valve operated by the ATCM. The control valve measures the input and output pressures of the refrigerant entering
and leaving the compressor and controls the angle of the internal swash plate accordingly. The ATCM influences the control to
match the thermal load of the evaporator and other factors. Compressor clutch engagement is controlled by the ATCM.
For additional information, refer to: Air Conditioning (412-01 Climate Control, Description and Operation).

Refrigerant Pressure Sensor

The refrigerant pressure sensor provides the manual / automatic temperature control module with a pressure input from the
high pressure side of the refrigerant system. The pressure sensor is located in the refrigerant line between the condenser and
the thermostatic expansion valve.

The manual / automatic temperature control module supplies a 5 V reference feed to the pressure sensor and receives a
return signal voltage, between 0 V and 5 V, related to system pressure. The manual / automatic temperature control module
uses the signal from the sensor to protect the refrigerant system from extremes of pressure.

If the pressure within the refrigerant system exceeds the minimum or maximum pressure limits, the manual / automatic
temperature control module will de-energize the A/C compressor clutch relay in the BJB.

The manual / automatic temperature control module constantly sends a refrigerant system pressure signal on the medium

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speed CAN Comfort bus. The signal is converted to HS CAN Powertrain bus message via the GWM, which is received for
example by the ECM.

If the pressure within the refrigerant system rises above its maximum pressure limit, the manual / automatic temperature
control module will increase the amount of re-circulated air entering the cabin. This helps lower the pressure within the
refrigerant system and thus helps to avoid having to disable the A/C compressor.

Evaporator Temperature Sensor

The evaporator temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The sensor is mounted on the left
side of the heater casing, and measures the temperature of cooled air once it has traveled over the evaporator. The sensor
receives a 5 V reference feed from the manual / automatic temperature control module by monitoring the returned voltage,
the manual / automatic temperature control module can calculate the resistance of the sensor and hence evaporator
temperature.

In-Vehicle Temperature Sensor (dual zone automatic system only)

The in-vehicle temperature sensor comprises a NTC thermistor and a motor. The sensor is mounted behind a grill on the
driver’s side of the instrument panel, adjacent the steering column.

The motor is provided an electrical feed from the ATCM and draws cabin air in through the grill and over the thermistor. The
thermistor receives a 5V reference feed from the ATCM. By monitoring the returned voltage, the ATCM can calculate air
temperature within the passenger compartment.

Humidity Sensor (dual zone automatic system only)

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The humidity sensor is located on the windscreen and comprises 3 individual elements:

A humidity sensor
An air temperature sensor
A windshield glass temperature sensor.

NOTE: NOTE: The cabin humidity sensor is an optional fit only.

The readings from these 3 sensors combine to reduce the risk of misting on the windshield.

The humidity sensor element is contained behind a nylon mesh cover. The sensor comprises an element made up of film
capacitors on different substrates. The dielectric is a polymer which absorbs or releases water proportional to the humidity of
the air being drawn through the sensor. This causes a change in the capacitance of the sensor.

Humidity within the passenger compartment is controlled by raising or lowering the temperature of the evaporator. An
increase in evaporator temperature increases the moisture content of the air in the vehicle. Lowering the evaporator
temperature reduces the moisture content of the air in the passenger compartment.

The capacitance of the sensor, together with both temperature values, is provided as LIN bus messages to the ATCM. The
ATCM uses these signals to calculate the dew point of the air at the windshield. When the temperature of the windshield glass
reaches or falls below this value, misting is likely to occur. In this instance, the ATCM will:

raise the temperature of the air leaving the heater assembly

adjust the position of the windshield distribution (defrost) stepper motor
adjust the position of the air intake stepper motor
the power windshield heater elements.

Ambient Air Temperature Sensor

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The AAT sensor is a NTC thermistor, and is mounted in the left door mirror. The sensor receives a 5V reference feed from the
ECM. By monitoring the returned voltage, the ECM can calculate the resistance of the sensor and hence ambient air
temperature. The ECM transmits an ambient air temperature value over the HS CAN Powertrain bus. This value is relayed to
the manual / automatic temperature control module by the GWM over the HS CAN Powertrain bus.

Sunload Sensor (dual zone automatic system only)

The sunload sensor is mounted in the center of the instrument panel upper surface. The sensor contains a photoelectric cell,
which provides the CJB with an input of light intensity equating to the solar heating effect on the cabin.

The solar heating value is transmitted via a hardwired connection ATCM. The ATCM compensates for the solar heating effect
by adjusting blower speed, air output temperature and air distribution to maintain the required cabin temperature.

Pollution Sensor (dual zone automatic system only)

The pollution sensor allows the ATCM to monitor intake air for the level of carbon monoxide (CO) and oxides of nitrogen
(NOx). The sensor is mounted on the passenger side of the heater casing.

The pollution sensor is provided an ignition controlled feed from the ATCM and provides one of the following 4 signals to the
ATCM, based on ambient air quality:

Static or reduced pollution levels

Small increase in pollution levels
Medium increase in pollution levels
Rapid or large increase in pollution levels.

Based on the signal from the pollution sensor, the ATCM is able to control the intake air source to reduce the amount of

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contaminants entering the cabin. This function is fully automatic, but can be overridden by manual selection of the air intake
source using the fresh/re-circulated air switch on the control panel.

OPERATION

Intake Air Control - Single Zone Manual System

The intake air source is controlled manually by pressing the fresh/recirculated air switch located on the MTCM. When pressed,
the MTCM will illuminate the switch tell-tale Light Emitting Diode (LED) and close the air intake door. A second press of the
switch will cause the MTCM to extinguish the switch LED and open the air intake door, allowing fresh air to enter the cabin.

NOTE: The MTCM will reduce the amount of fresh air entering the cabin to reduce the ram effect caused by forward
motion of the vehicle.

When recirculated air is selected, the MTCM will return the air intake door to the open position after a period of 3 minutes.
This helps prevent misting within the cabin. The 3 minute time period for recirculated air can be overridden by pressing and
holding the fresh/recirculated air switch until the switch LED flashes 3 times. The air intake door will now remain closed until
the next drive cycle.

The MTCM controls the position of the air intake door via a hardwired connection to the air intake door motor. A Hall effect
sensor located within the motor informs the MTCM that movement of the motor is taking place.

Intake Air Control - Dual Zone Automatic System

The intake air source is controlled automatically unless overridden by pressing the fresh/recirculated air switch located on
ATCM. Under automatic control, the ATCM determines the required position of the air intake door using its 'comfort' algorithm
based on inputs from the ambient air temperature sensor, the In-vehicle temperature sensor and the pollution sensor.

NOTE: NOTE: The ATCM will reduce the amount of fresh air entering the cabin to reduce the ram effect caused by
forward motion of the vehicle.

When the vehicle first enters power mode 6 (ignition on), the 'AUTO' tell-tale LED on the fresh/recirculated air switch will be
illuminated and the air intake source will be automatically controlled by the ATCM. A single press of the fresh/recirculated air
switch will extinguish the 'AUTO' tell-tale LED and illuminate the 'MAN' tell-tale LED. The ATCM will now close the air intake
door and provide only recirculated air into the cabin for a period of 3 minutes. After this period, the ATCM will return the air
intake door to automatic control. This helps prevent misting within the cabin.

A second press of the fresh/recirculated air switch will extinguish both the 'AUTO' and 'MAN' tell-tale LED's. The ATCM will now
control the intake air source according to ambient air temperature and requested cabin temperature. The air intake door will
be opened to allow fresh air into the cabin, but a small amount of recirculated air will also be present. The amount of
recirculated air is determined by the ATCM using its 'comfort' algorithm based on inputs from the ambient air temperature
sensor and the in-vehicle temperature sensor.

A third press of the fresh/recirculated air switch returns the air intake source to automatic control and will illuminate the
'AUTO' tell-tale LED.
The 3 minute time period for recirculated air can be overridden by pressing and holding the fresh/recirculated air switch until
the switch LED's flash 3 times. The air intake door will now remain closed until the next drive cycle.

The ATCM controls the position of the air intake door via a hardwired connection to the air intake door motor to the air intake
door motor. A Hall effect sensor located within the motor informs the ATCM that movement of the motor is taking place.

Air Temperature Control - Single Zone Manual System

Cabin temperature selection is made by turning the left rotary controller to the required position. Turning the controller
counter clockwise will lower the temperature of the air exiting the heater assembly; turning the controller clockwise will raise
the temperature of the air exiting the heater assembly.

Maximum heating and cooling is represented on the control panel by a red and blue dot respectively. When either maximum
heating or cooling is selected, the 'comfort' algorithm in the MTCM will adopt a suitable strategy for air source, air distribution
and blower speed to maintain maximum heating or cooling within the cabin.

The MTCM adjusts the temperature of the air exiting the heater assembly by moving the position of the temperature blend
door. The temperature blend door directs a proportion of cooled air from the evaporator through the heater core to produce
the required temperature output. The MTCM adjusts the position of the temperature blend door by providing LIN bus
messages to the blend door motor. A Hall effect sensor located within the motor informs the MTCM that movement of the
motor is taking place.

Temperature Control - Dual Zone Automatic System

Dual zone systems feature 2 rotary heating controllers, which allow individual climate control for the left and right sides of the
cabin. Temperature selection can be made by turning the controller to the required temperature marked on the control panel.
Turning either controller past the 16°C (61°F) mark will initiate the maximum cooling strategy; turning either controller past
the 28°C (82°F) mark will initiate the maximum heating strategy.

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NOTE: Maximum cooling or heating can only be achieved if both rotary controllers are set to the same position.

The ATCM is able to maintain constant temperatures in both sides of the cabin by monitoring the feedback from the in-vehicle
temperature sensor. Unless any manual overrides have been selected, the ATCM will automatically control the intake air
source, air distribution into the cabin and blower speed to maintain the required temperatures.

Dual zone systems feature 2 temperature blend doors, allowing individual temperature output for the left and right sides of
the cabin.

NOTE: The driver's side temperature setting has priority over the passenger's side temperature setting.

The temperature blend doors are mounted on the left side of the heater assembly and direct a proportion of cooled air from
the evaporator through the heater core to provide the required temperature outputs. The ATCM controls the position of the
temperature blend doors by providing LIN bus messages to the blend door motors. Hall effect sensors located within the
motors inform the ATCM that movement of the motors is taking place.

Blower Control - Single Zone Manual System

Blower speed is set by turning the right rotary controller to the required position. Turning the controller fully counter clockwise
will turn the blower off.

Operation of the blower is controlled by the MTCM via the blower control module. The MTCM provides a Pulse Width
Modulation (PWM) signal to the blower control module based on the selected blower speed. The blower control module
interprets the PWM signal as a blower speed and controls the voltage to the blower accordingly.

Blower Control - Dual Zone Automatic System

Blower speed is controlled automatically by the ATCM unless a manual override has been requested. Manual overrides to
blower speed can be made by turning the central rotary controller to the required position. The rotary controller allows the
manual selection of blower speeds. Turning the controller fully counter clockwise will turn the blower off. When a manual
override has been made, the 'AUTO' LED will extinguish.

The blower can be returned to automatic control by pressing the 'AUTO' switch. Under automatic control, the ATCM varies the
speed of the blower in line with its 'comfort' algorithm to maintain the required cabin temperature. The ATCM will also vary
the blower speed to compensate for the ram effect on intake air produced by forward movement of the vehicle.

Operation of the blower is controlled by the ATCM via the blower control module. The ATCM provides a PWM signal to the
blower control module based on the required blower speed. The blower control module interprets the PWM signal as a blower
speed and controls the voltage to the Blower accordingly.

Air Distribution Control - Single Zone Manual System

Air distribution into the cabin can be adjusted by turning the central rotary controller to the required position. The MTCM
adjusts the position of the air distribution door to the required position via a hardwired connection to the air distribution door
motor. A Hall effect sensor located within the motor informs the MTCM that movement of the motor is taking place.
Air Distribution Control - Dual Zone Automatic System

Air distribution into the cabin is controlled automatically by the ATCM unless any manual overrides have been requested.
Manual overrides can be made by pressing the air distribution switch on the ATCM. If a manual override has been requested,
the 'AUTO' LED will extinguish.

Air distribution can be returned to automatic control by pressing the 'AUTO' switch. This will illuminate the 'AUTO' LED and
allow the ATCM to control air distribution in line with its 'comfort' algorithm.

Air distribution is controlled by 2 air distribution doors. The ATCM controls the position of the air distribution doors by
providing LIN bus messages to the door motors. Hall effect sensors located within the motors inform the ATCM that
movement of the motors is taking place.

Air Conditioning (A/C) On/Off - Single Zone Manual System

Pressing the A/C On/Off switch on the MTCM will switch off the A/C system. When selected, the MTCM will transmit a message
over the HS CAN powertrain bus to the ECM requesting the A/C compressor is disabled. The ECM disables the compressor by
de-energizing the A/C compressor control relay. The tell-tale LED in the switch will illuminate to alert the vehicle occupants
that the A/C system is switched off.

When A/C system is switched off, temperature control is still available but no cooling of intake air will take place. The
minimum output air temperature from the system will be ambient air temperature plus any heat pick up in the air intake path.

A/C can be switched back on by pressing the A/C On/Off switch a second time. This will also extinguish the 'A/C' LED.

A/C On/Off - Dual Zone Automatic System

Pressing the A/C On/Off switch on the ATCM will switch off the A/C system. When selected, the ATCM will transmit a message
over the HS CAN powertrain bus to the ECM requesting the A/C compressor is disabled. The ECM disables the compressor by

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de-energizing the A/C compressor control relay. The tell-tale LED in the switch will illuminate to alert the vehicle occupants
that the A/C system is switched off.

When A/C system is switched off, temperature control is still available but no cooling of intake air will take place. The
minimum output air temperature from the system will be ambient air temperature plus any heat pick up in the air intake path.

A second press of the will extinguish the 'A/C' LED and illuminate the 'OFF' LED. When in 'OFF' mode the ATCM sets the blower
speed to 0. Air distribution into the cabin will remain as previously selected. All LED's on the control panel will be
extinguished, although night time illumination will remain active.

NOTE: When in 'OFF' mode, the heated seat, heated windshield and heated rear window functions will still be available.

A third press of the A/C On/Off switch returns the system to normal (A/C) operation and extinguishes the 'OFF' LED. The
system can be returned to automatic operation at any time by pressing the 'AUTO' switch.

Programmed Defrost (dual zone automatic system only)

The function is selected by pressing the 'MAX' momentary switch on the ATCM. When selected, the ATCM provides maximum
windshield defrosting/demisting by configuring the system as follows:

'AUTO' mode off

Intake air set to fresh air
Air distribution set to windshield
Blower motor speed set to maximum
Heated windshield on
Rear window heater on.

When programmed defrost is selected, the set temperature will remain unchanged. Programmed defrost can be cancelled by
any of the following methods:

Pressing any air distribution momentary switch

Pressing the 'AUTO' switch
Pressing the 'MAX' momentary switch a second time.

NOTE: NOTE: Blower motor speed can be adjusted without terminating programmed defrost.

Heated Windshield (Where Fitted)

Heated windshield operation is only enabled when the engine is running. The manual / automatic temperature control module
controls operation of the heated windshield using a relay in the Battery Junction Box (BJB). When a request is made for
heated windshield operation, the manual / automatic temperature control module broadcasts a message to the GWM on the
MS CAN comfort bus, the GWM then relays this message on to the CJB using the MS CAN body bus. On receipt of the
message, the CJB energizes the relay by providing a ground path for the relay coil. This allows a battery feed to flow across
the relay to power the left and right heater elements.

There are 2 modes of heated windshield operation; manual and automatic.

Manual operation is activated by pressing the heated windshield switch. When the switch is pressed, the status LED in the
switch illuminates and the windshield heater elements are energized. Manual operation is discontinued when the heated
windshield switch is pressed a second time, between 2 and 5 minutes have elapsed (dependent on ambient air temperature),
or the engine stops. If manual operation is discontinued by the engine stopping, the previous heating phase is resumed if the
engine is re-started within 30 seconds.

There are 2 variants of automatic operation; automatic operation at the start of a journey and automatic operation during a
journey.

Automatic operation at the start of a journey is initiated for between 2 and 5 minutes have elapsed (dependent on ambient air
temperature). The warmer the ambient air temperature, the shorter the time. In this instance, the switch LED is illuminated
and the heater elements are energized. In addition to shorter operating times in temperate winter conditions, there are
condition qualifiers to prevent subsequent operations once the cabin, engine or screen is warm, or there is a significant
sunload. Automatic operation is discontinued if the heated windshield switch is pressed or the engine stops.

NOTE: This feature can be selected on and off on the Settings page of the Climate menu in the touch screen.

Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been traveling for a set period of time above a threshold speed. In this instance, no feedback is given to inform the driver that
the heated windshield is operational (the switch LED is not illuminated) and the duration of operation is variable depending
upon the ambient air temperature, vehicle speed and the amount of time the vehicle has been travelling.

Heated Rear Window

Heated rear window operation is only enabled when the engine is running. The manual / automatic temperature control
module controls operation of the heated rear window using a relay in the CJB. When a request is made for heated rear window
operation, the manual / automatic temperature control module broadcasts a message to the Gateway Module (GWM) on the
MS CAN comfort bus, the GWM then relays this message on to the CJB using the MS CAN body bus. On receipt of this

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message, the CJB energizes the relay by providing a ground path for the relay coil. This allows a battery feed to flow across
the relay to power the heater element.

There are 2 modes of heated rear window operation; manual and automatic.

Manual operation is activated by pressing the heated rear window switch. When the switch is pressed, the status Light
Emitting Diode (LED) in the switch illuminates and the rear window heater element is energized. Manual operation is
discontinued when the heated rear window switch is pressed a second time, between 5 and 21 minutes have elapsed
(dependent on ambient air temperature), or the engine stops. If manual operation is discontinued by the engine stopping, the
previous heating phase is resumed if the engine is re-started within 30 seconds.

There are 2 variants of automatic operation; automatic operation at the start of a journey and automatic operation during a
journey.

Automatic operation at the start of a journey is initiated for between 5 and 21 minutes (dependent on ambient air
temperature). The warmer the ambient air temperature, the shorter the time. In this instance, the switch LED is illuminated
and the heater element is energized. In addition to shorter operating times in temperate winter conditions, there are condition
qualifiers to prevent subsequent operations once the cabin or engine is warm, or there is a significant sunload. Automatic
operation is discontinued if the heated rear window switch is pressed or the engine stops

NOTE: This feature can be selected on and off on the Settings page of the Climate menu in the touch screen.

Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been traveling for a set period of time above a threshold speed. In this instance, no feedback is given to inform the driver that
the heated rear window is operational (the switch LED is not illuminated) and the duration of operation is variable depending
upon the ambient air temperature, vehicle speed and the amount of time the vehicle has been travelling.

Door Mirror Heaters

The operation of the door mirror heaters are activated by pressing of the rear window heater switch, which is located on
manual / automatic temperature control module. The door mirror heaters will then remain active for the rest of the ignition
cycle, based upon ambient air temperature and PWM (Pulse Width Modulation) percentage level. If the ambient air
temperature is less than 8°C (46°F) the door mirror heaters work on 50%, between 8°C and 16°C they work on 33% and
over 16°C they go to 0% when does not rain and 25% when rains. The ambient air temperature value is provided by the ECM
on the HS CAN Powertrain bus. On receipt of this temperature value, the manual / automatic temperature control module
calculate the required PWM percentage.

The CJB requests door mirror heating by transmitting a medium speed CAN Body bus message to both the drivers and
passenger door modules. The door modules provide feed and ground paths to the respective door mirror heating elements.
When ambient and engine coolant temperature rises above the values stated earlier, the CJB transmits a CAN bus message to
the door modules cancelling the heating request.

Seat Heaters

The operation of the seat heaters is controlled by the manual / automatic temperature control module on receipt of a heating
request from either of the seat heater momentary switches located on the control panel. The switches are mounted in the
manual / automatic temperature control module. A single press of a seat heater switch will implement high level heating and
illuminate a tell-tale LED. A second press of the switch will implement mid-level heating and illuminate 2 tell-tale LED's. A
third press of the switch will implement low level heating and illuminate 3 tell-tale LED's. A fourth press of the switch will turn
the seat heater off.

Seat heating requests are transmitted from the manual / automatic temperature control module to the seat heater control
modules on the LIN bus. Two seat heater control modules are fitted, one under each front seat. The seat heater control
modules provide an electrical supply to the seat heater elements and a temperature sensor located in the seat cushion.

The seat heater control module provides a 5 V reference feed to the seat heater temperature sensor. The seat heater
temperature sensor is an NTC thermistor. By monitoring the returned voltage, the control module can calculate the
temperature of the seat. If the temperature rises above the target temperature, the control module will disable operation of
the heater elements.

Climate seats are controlled via the manual / automatic temperature control module and the touch screen display.
For additional information, refer to: Seats (501-10 Seating, Description and Operation).

Published: 15-Jan-2015
Climate Control - Air Conditioning
Description and Operation

COMPONENT LOCATION - Vehicles without an Internal Heat Exchanger (IHX)

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Item Description
 1 Refrigerant pressure sensor
2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection

COMPONENT LOCATION - Vehicles with an Internal Heat Exchanger (IHX)

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Item Description
1 Refrigerant pressure sensor
2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
 5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection

OVERVIEW

A choice of Air Conditioning (A/C) systems are available with features to enhance the performance for second and third-row
seat passengers.

The system is available in two forms, with an optional rear air conditioning unit.

Manual air conditioning system.

Two-zone auto system, with separate LCD display controls for driver and front passenger.
Vehicles with 5+2 seating, an optional auxiliary air conditioning unit for third row passengers is available, with controls
for temperature and fan speed.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

The rear air conditioning has a child lock function which disables the rear fan speed control switches. This is feature is
accessed from the Touch Screen.

The A/C system transfers heat from the passenger compartment to the outside atmosphere to provide the climate control
assembly with dehumidified cool air.

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The A/C system is a sealed closed-loop system, filled with refrigerant as the heat transfer medium. Refrigerant oil is added to
the refrigerant to lubricate the internal components of the A/C compressor:

R1234yf refrigerant is used in USA and Canada (NAS market); systems with an Internal Heat Exchanger (IHX)
installed.
R134a refrigerant is used in the ROW markets; systems without an Internal Heat Exchanger (IHX).

For additional information, refer to: Specifications (412-01 Climate Control, Specifications).

The compressor is a variable displacement unit, where the displacement (flow of refrigerant) is controlled to match the
thermal load of the evaporator. The type of compressor fitted will depend on engine variant, see below.

The operation of the A/C system is controlled by the Automatic Temperature Control Module (ATCM).
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

DESCRIPTION

The air conditioning system includes the following features:

B-pillar mounted mid-level vents for row 2 passengers

Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row 3 passengers
A mist sensor on the windscreen, used to detect conditions likely to cause misting
An air quality sensor for detection of pollutant levels. When levels exceed set limits the system switches to
re-circulation mode
Timed climate control to pre-heat the cabin. This function can be activated remotely using the InControl Remote App
ECO mode enables the system to adopt a more economical operating mode.

Air Conditioning Layout with Optional Auxiliary Rear Air Conditioning Unit
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Item Description
1 B-pillar mounted mid-level vents for row two passengers
2 Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row three passengers
3 Optional auxiliary air conditioning unit
The optional auxiliary air conditioning unit is discussed in another section.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

Air Conditioning Compressor

2.0 GTDi Petrol

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Item Description
1 Pulley with electro-magnetic clutch
2 Refrigerant inlet port
3 Pressure relief valve
4 Electronic control valve connector
5 Refrigerant outlet port
6 Electro-magnetic clutch connector.
TD4 2.2L Diesel
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Item Description
1 Pulley with electro-magnetic clutch
2 Electro-magnetic clutch connector
3 Refrigerant outlet port
4 Refrigerant inlet port
5 Electronic control valve connector
6 Pressure relief valve.
Compressor

The Air Conditioning (A/C) compressor is driven by the engine primary drive belt. The compressor circulates refrigerant
around the A/C system by compressing low-pressure, low-temperature vapor from the evaporator and discharging the
resultant high-pressure, high-temperature vapor to the condensor.

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.

Both compressors are variable displacement units. Displacement is controlled by an integral electronic control valve operated
by the Automatic Temperature Control Module (ATCM). The control valve measures the input and output pressures of the
refrigerant entering and leaving the compressor and controls the angle of the internal swash plate accordingly. The ATCM
influences the control to match the thermal load of the evaporator and other factors.
Compressor clutch engagement is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Condensor

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Item Description
1 Condensor
2 Receiver/drier.
The condensor transfers heat from the refrigerant to the surrounding air to cool the refrigerant and therefore convert the
high-pressure vapor from the compressor into a liquid. The condensor is installed immediately in front of the radiator.

The condensor is classified as a sub-cooling condensor and consists of a fin and tube heat-exchanger core installed between 2
end tanks. Divisions in the end tanks separate the heat exchanger into a 4 pass upper (condensor) section and a 2 pass lower
(sub-cooler) section.

The right end tank provides the connections to the high-pressure line from the A/C compressor and the liquid line to the
evaporator.

Receiver/Drier

The receiver/drier is integral with the condensor left end-tank and removes solid impurities and moisture from the refrigerant.
It also acts as a reservoir for liquid refrigerant to accommodate changes of heat load at the evaporator.
Refrigerant entering the receiver drier passes through a filter and a desiccant pack, then collects in the base of the unit before
flowing through the outlet pipe back to the condensor.

Refrigerant Pressure Sensor

The refrigerant pressure sensor provides the Automatic Temperature Control Module (ATCM) with a pressure input from the
high-pressure side of the refrigerant system. The refrigerant pressure sensor is hardwired to the ATCM, which uses the signal
to control operation of the A/C compressor through the A/C compressor clutch relay in the Battery Junction Box (BJB).
Additionally, the ATCM is able to increase the amount of re-circulated air, if it is required. The ATCM broadcasts the refrigerant
high-pressure value over the medium-speed Controller Area Network (CAN) comfort bus to the Engine Control Module (ECM)
via the Gateway Module (GWM). The ECM calculates the additional load on the engine when the A/C compressor is working.

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For example, this signal is used as an input, for the idle speed control.

The refrigerant pressure sensor is located in the refrigerant line between the condensor and the Thermostatic Expansion Valve
(TXV).

Thermostatic Expansion Valve

Item Description
1 Metering valve
2 Housing
3 Diaphragm
4 Temperature sensor
5 Outlet passage from evaporator
6 Inlet passage to evaporator.
The Thermostatic Expansion Valve (TXV) meters the flow of refrigerant into the evaporator to match the refrigerant flow with
the heat-load of the air passing through the evaporator.

The TXV is a block type valve located behind the climate control assembly, and attached to the inlet and outlet ports of the
evaporator. The TXV consists of an aluminum housing containing inlet and outlet passages. A ball and spring metering valve is
installed in the inlet passage and a temperature sensor is installed in the outlet passage. The temperature sensor consists of a
temperature sensitive tube connected to a diaphragm. The bottom end of the temperature sensitive tube acts on the ball of
the metering valve. Pressure on top of the diaphragm is controlled by the evaporator outlet-temperature conducted through
the temperature sensitive tube. The bottom of the diaphragm senses evaporator outlet pressure.

Liquid refrigerant flows through the metering valve into the evaporator. The restriction across the metering valve reduces the
pressure and temperature of the refrigerant. The restriction also changes the liquid stream of refrigerant into a fine spray, to
improve the evaporation process. As the refrigerant passes through the evaporator, it absorbs heat from the air flowing
through the evaporator. The increase in temperature causes the refrigerant to vaporize and increase in pressure.
The temperature and pressure of the refrigerant leaving the evaporator acts on the diaphragm and temperature sensitive
tube, which regulate the metering valve opening and so controls the volume of refrigerant flowing through the evaporator.
The warmer the air flowing through the evaporator, the more heat available to evaporate refrigerant and thus the greater
volume of refrigerant allowed through the metering valve.

Evaporator

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Item Description
1 Heater core
2 Evaporator.
The evaporator is installed in the climate control assembly, between the blower and the heater core, to absorb heat from the
exterior or re-circulated air. Low pressure, low temperature refrigerant changes from liquid to vapor in the evaporator,
absorbing large quantities of heat as it changes state.

Most of the moisture in the air passing through the evaporator condenses into water, which drains out of the vehicle by
passing through a drain tube to the underside of the vehicle.

Refrigerant Lines

To maintain similar flow velocities around the A/C system the diameter of the refrigerant lines varies to suit the two
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.
Nylon lined, low permeability rubber hoses are used in the low pressure line into the A/C compressor, and in the high pressure
line from the condensor. The remainder of the refrigerant lines are manufactured from aluminum.

Low and high pressure charging connections are incorporated into the refrigerant lines for system servicing.

Internal Heat Exchanger

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Item Description
1 High pressure line
2 Low pressure line
3 Internal Heat Exchanger (IHX)
The Internal Heat Exchanger (IHX) is incorporated within the air conditioning pipes.

The IHX is part of the vehicle's air conditioning system and helps to increase its cooling capacity. The IHX combines a section
of the system's pipework before and after the evaporator into one pipe. It uses the cold vapour exiting the evaporator to cool
the hot liquid before it enters the expansion device, resulting in increased cooling. It also uses the heat to increase the
temperature of the low temperature gas before it enters the compressor. The amount of energy used by the air conditioning
system can be reduced by taking advantage of this increased cooling.

This gives the following benefits:

Helps reduce tailpipe CO2 emissions, due to less engine load

Improved fuel economy, due to reduced compressor power requirements
R1234yf - Increases the system capacity to increase cooling.

OPERATION

Principles of Operation

To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the regimes the refrigerant changes state, during this process the maximum heat
absorption or dissipation occurs.

The low pressure/temperature regime is from the TXV, then through the evaporator to the compressor. The refrigerant
decreases in pressure and temperature at the TXV then changes state from a liquid to a vapour in the evaporator to absorb
heat.

The high pressure/temperature regime is from the compressor, through the condensor and receiver drier assembly to the
thermostatic expansion valve. The refrigerant increases in pressure and temperature as it passes through the compressor;
then releases heat and changes state from a vapour to a liquid in the condenser.
The operation of the A/C system is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

NOTE: NOTE: Due to a drop in performance of the R1234yf system when compared to the R134a system an Internal
Heat Exchanger is installed

Input/Output Diagram

System without an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condensor
 7 Receiver/drier
8 A/C compressor
9 Low pressure servicing connection
10 Blower
System with an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
 1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condenser
7 Receiver/Drier
8 A/C compressor
9 IHX
10 Low pressure servicing connection
11 Blower

Published: 21-Jul-2015
Starting System - INGENIUM I4 2.0L Diesel - Starting System
Description and Operation

COMPONENT LOCATION - SHEET 1 OF 3 - VEHICLES WITHOUT AUTO STOP/START SYSTEM

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Item Description
1 Stop/Start switch
2 Engine Control Module (ECM)
3 Starter motor
COMPONENT LOCATION - SHEET 2 OF 3 - VEHICLES WITH AUTO STOP/START SYSTEM - MANUAL TRANSMISSION

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Item Description
1 Stop/Start switch
2 Engine Control Module (ECM)
3 Starter motor
4 Auto Stop/Start switch
COMPONENT LOCATION - SHEET 3 OF 3 - VEHICLES WITH AUTO STOP/START SYSTEM - AUTOMATIC TRANSMISSION
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Item Description
1 Stop/Start switch
2 Engine Control Module (ECM)
3 Starter motor
4 Auto Stop/Start switch

OVERVIEW

The starting system is equipped with a starter motor incorporating a single solenoid, in a system with or without auto
stop/start system.

Both types of starting system are passive systems controlled by the Engine Control Module (ECM). The ECM initiates starting
system operation when a valid smart key is in the vehicle and the engine stop/start switch is pressed.

The ECM controls operation of the starter motor using a starter relay in the Engine Junction Box (EJB), on vehicles with and
without stop/start system.

On vehicles with auto stop/start system the ECM interacts with other vehicle systems to determine when stop/start operation
is required. An auto stop/start warning indicator provides a visual indication when the engine is stopped in a stop/start cycle.
The stop/start function is automatically activated each time an ignition cycle occurs. However, if required the driver can
deactivate the system using an auto stop/start switch.
Vehicles with auto stop/start system incorporate a brake vacuum sensor to enable the ECM to monitor the pressure in the
brake booster during stop/start operation.

To accommodate the increased electrical loads, vehicles are fitted with two batteries if equipped with the auto stop/start
system.

COMPONENT DESCRIPTION

STARTER MOTOR

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Item Description
A Starter motor solenoid - vehicles with manual transmission
B Starter motor solenoid - vehicles with automatic transmission
1 Solenoid electrical connection
2 Starter motor electrical connection
3 Breather pipe
4 Starter motor
5 Pinion gear
6 Starter motor solenoid
The starter motor is attached to the cylinder block, at the joint between the transmission and the engine. The pinion gear of
the starter motor protrudes through an aperture in the transmission housing, adjacent to the ring gear on the drive plate. The
starter motor incorporates a snorkel breather pipe to assist with ventilation and sealing, during water submergence.

The starter motor has the motor located directly behind the pinion gear. The motor is geared directly to the pinion gear and is
a pre-engaged type comprising a series wound motor and an over-running clutch.

The starter solenoid is connected to a power feed from the starter relay in the EJB, which is controlled by the ECM. When the
starter solenoid is energized it engages the pinion gear with the ring gear and simultaneously closes a switch to supply the
motor with power from the starter fuse on the battery positive terminal.

Auto Stop/Start Starter Motor Strategy

Engine restart without starter motor intervention

When the ECM detects engine restart parameters resulting from a driver action or system request, the ECM activates the fuel
injection and ignition systems to allow the engine to continue to operate. This is available at a variable engine speed threshold
which depends on engine type.
Engine restart with starter motor intervention

If the ECM cannot restart the engine without intervention, the restarting of the engine is controlled via the starter motor. The
starter motor has the capability of engaging with the transmission ring gear whilst still rotating.

If an engine restart is initiated, the ECM activates the starter motor via the starter relay at the earliest opportunity to rotate
the engine, then on the first available compression the ECM operates the fuel injection and ignition systems to restart the
engine in less than 0.36 sec.

STOP/START SWITCH

The stop/start switch is located in the Instrument Panel (IP) and is hardwired to the Central Junction Box (CJB). When the

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switch is pressed two signal lines from the CJB are connected to ground.

AUTO STOP/START WARNING INDICATOR

The auto stop/start warning indicator is located in the Instrument Cluster (IC). The warning indicator comes on when the
engine stops during a stop/start cycle, then goes off when the engine restarts. The warning indicator is controlled in the IC by
a Medium Speed Controller Area Network (MS-CAN) comfort bus message from the ECM.

AUTO STOP/START SWITCH

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The auto stop/start switch is located in the front floor console. An amber Light Emitting Diode (LED) in the auto stop/start
switch remains illuminated while the auto stop/start system is active. The auto stop/start switch sends a signal to the CJB
using the MS-CAN comfort bus, to inform the ECM assembly when on or off.

BRAKE VACUUM SWITCH

To ensure the brake system is never compromised, a brake vacuum switch is installed on auto stop/start vehicles to monitor
vacuum reserves in the brake booster. The brake vacuum switch is mounted in the vacuum pipe and hardwired to the ECM. If
the brake vacuum decreases below a set threshold while stop/start is enabled, the ECM either:

Restarts the engine to replenish the vacuum reserves

Inhibits the engine shutting down if vacuum reserves are not sufficient.

An example of vacuum reserves depleting, is by the driver repeatedly pressing the brake pedal while the engine is shut down
during an auto stop/start stop. This action will initiate an engine restart when vacuum reserves decrease below the set
threshold.

If a fault develops with the brake vacuum sensor a Diagnostic Trouble Code (DTC) will be logged in the ECM.

NEUTRAL GEAR SENSOR

A permanent magnet, linear contactless displacement sensor is located on the exterior of the transmission casing and
hardwired to the ECM. The sensors function is to detect that neutral gear has been selected within a calibrated window.

SYSTEM OPERATION

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VEHICLES WITHOUT AUTO STOP/START SYSTEM

Engine cranking is requested when the stop/start switch is pressed and the driver has depressed the brake pedal. When
engine cranking is requested, the ECM checks that a valid key code has been received and the transmission is in Park (P) or
Neutral (N) before granting the crank request.

Once engine cranking has been granted, the ECM energizes the starter relay located in the right EJB. The closing of the starter
relay contacts causes battery voltage to be applied to the starter solenoid in the starter motor. The solenoid is energized and
the pinion gear is pushed to engage with the drive plate ring gear. Simultaneously, the starter solenoid contacts close,
causing current to flow into the motor brushes and armature. The armature rotational force is transferred to the drive plate
ring gear through the pinion gear, rotates the drive plate and starts the engine.

When the engine reaches self-sustaining operating speed, the ECM de-energizes the starter relay to disconnect power from
the starter motor and disengage the pinion gear from the drive plate ring gear.

VEHICLES WITH AUTO STOP/START SYSTEM

Engine cranking is requested when the stop/start switch is pressed and the driver has depressed the brake pedal. When
engine cranking is requested, the ECM checks that a valid key code has been received and the transmission is in Park (P) or
Neutral (N) before granting the crank request.

Once engine cranking has been granted, the ECM energizes the starter relay located in the right EJB. The closing of the starter
relay contacts causes battery voltage to be applied to the motor solenoid, which energizes and causes current to flow into the
motor brushes and armature. The armature rotational force is transferred to the drive plate ring gear through the pinion gear,
rotates the drive plate and starts the engine.

When the engine reaches self-sustaining operating speed, the ECM then de-energizes the starter relay to disconnect power
from the starter motor and disengage the pinion gear from the drive plate ring gear.

Auto Stop/Start System

The auto stop/start system automatically shuts down the engine in appropriate conditions, resulting in zero tailpipe emissions
and saving fuel that would otherwise be used idling the engine when stationary. When the driver is ready to move off, the
engine instantly restarts. Sophisticated controls ensure that the stop/start system does not compromise the needs of either
the driver or the vehicle.

By default the stop/start system is enabled at the start of each ignition cycle. The auto stop/start system can be
enabled/disabled using the auto stop/start switch in the front floor console. The LED in the auto stop/start switch is
extinguished when the stop/start system is disabled.

Software within the ECM controls the operation of the stop/start system. In addition to its own dedicated components the auto
stop/start system encompasses many other vehicle systems. Complex technology interconnects these systems and ensures all
the necessary conditions are satisfied by monitoring, among others:

Brake hydraulic system pressure

Transmission Control Switch (TCS) position
Road speed
The state of vital vehicle systems
 Environmental conditions.

If all necessary conditions are satisfied the stop/start system will automatically stop the engine if:

The vehicle stops from a speed greater than 4 km/h (2.5 mph)
Sufficient pressure is applied to the brake pedal to ensure the vehicle is stationary and the transmission is in Drive (D)
or Sport (S), or the vehicle is stationary and Park (P) or Neutral (N) selected on the TCS.

The driver will be notified that the engine is shut down by the auto stop/start warning indicator being illuminated in the IC.
Other warnings normally associated with an engine shut down, for example the ignition and low oil pressure indicators, are
suppressed so will not illuminate during an engine shut down in a stop/start cycle.

To restart the engine, the driver simply releases the brake pedal or presses the accelerator pedal. The ECM then operates the
starter motor and starts the engine.

If system conditions are not approved by the ECM the auto stop/start system will not behave as expected, examples of this
are:

System inhibit: the engine will continue running even though the vehicle is stationary with the brake pedal pressed
and the TCS in Drive (D) or Sport (S), or the vehicle is stationary and the TCS is in Park (P) or Neutral (N)
System override: the engine has been stopped by the stop/start system but conditions have since changed, this will
activate an early automatic engine restart.

These interventions are to ensure the auto stop/start system does not impact on:

Vehicle and occupant safety

Driver requirements
Occupant comfort
Vehicle on-road and off-road capabilities.

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Although the main control logic for stop/start operation resides in the ECM, the CJB has software to communicate engine shut
down inhibits to the ECM. In some instances, depending on the reason for the system intervention the driver will be notified,
via the message center, of the reason for the intervention.

Stop Inhibitors

The following conditions will prevent the auto stop/start system from stopping the engine:

Driver effected stop inhibitors

Driver switches off the auto stop/start system

A steering wheel paddle switch has been used to select a gear
Brake pedal not fully pressed
Accelerator pedal depressed
Hood is open
Driver door is open
Driver seatbelt is not fastened
Climate control system used above calibrated threshold
Windshield demist is operating
Trailer electrical connection detected

Vehicle system effected stop inhibitors

Brake booster vacuum below threshold

Battery cold cranking capability below threshold
Battery state of charge is low
Catalytic converter outside either pre or post calibration range
Engine coolant temperature below threshold
Engine oil temperature below threshold.

Environmental effected stop inhibitors

Ambient air temperature above 40 °C (104 °F)

Ambient air temperature below 0 °C (32 °F).

Start Initiators

When the engine has shut down within an auto stop/start cycle the following conditions will initiate an early restart within the
same auto stop/start cycle:

Driver effected start initiators

Driver switches off the auto stop/start system

The accelerator pedal is pressed
A steering wheel paddle switch is operated to select a gear
Reverse (R) is selected on the TCS
Vehicle speed above calibrated threshold 3 km/h (2 mph) (a restart will only occur if the transmission is in neutral and
the driver is present, for example, the driver seatbelt remains fastened and the driver door remains latched)
Brake booster vacuum below threshold (driver operating brake pedal)
 A higher climate control blower speed is selected
Windshield demist is activated.

Vehicle system effected start initiators

Battery cranking capability is near its lower threshold

Battery state of charge is near its lower threshold
Windshield demist activates
The passenger compartment temperature decreases below or increases above the selected thresholds.

Environmental effected start initiators

Ambient air temperature rises above 40 °C (104 °F)

Ambient air temperature falls below 0 °C (32 °F).

The maximum engine stop duration is 270 seconds, after this duration the vehicle will restart.

Start Inhibitors

When the engine has shut down within a stop/start cycle certain conditions will prevent an automatic restart:

Driver effected start inhibitors

Hood has been opened

Driver seatbelt is disengaged (this is an automatic start inhibitor therefore the engine can be restarted by depressing
the clutch pedal)
Driver door is unlatched (this is an automatic start inhibitor therefore the engine can be restarted by depressing the
clutch pedal).

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Vehicle system inhibitor

There is a system fault.

INPUT/OUTPUT DIAGRAM

INPUT/OUTPUT DIAGRAM - SHEET 1 OF 2 - STARTING SYSTEM WITHOUT AUTO STOP/START SYSTEM

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A = Hardwired; AO = Medium Speed Controller Area Network (MS-CAN) body systems bus.
Item Description
1 Engine Control Module (ECM)
2 Stop/start switch
3 Central Junction Box (CJB)
4 Keyless Vehicle Module (KVM)
5 Engine Junction Box (EJB)
6 Starter motor
7 Ground
8 Power supply
9 Crankshaft Position (CKP) sensor

INPUT/OUTPUT DIAGRAM - SHEET 2 OF 2 - STARTING SYSTEM WITH AUTO STOP/START SYSTEM

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A = Hardwired; AN = High Speed Controller Area Network (HS-CAN) powertrain systems bus; AO = Medium Speed Controller
Area Network (MS-CAN) body systems bus; O = Local Interconnect Network (LIN) bus.
Item Description
1 Engine Control Module (ECM)
2 Keyless Vehicle Module (KVM)
3 Central Junction Box (CJB)
4 Gateway Module (GWM)
5 Transmission control switch control module (equipped on vehicles with automatic transmissions only)
 6 Instrument Cluster (IC)
7 Voltage Quality Module (VQM)
8 Starter relay
9 Starter motor
10 Ground
11 Power supply
12 Brake vacuum switch
13 Accelerator Pedal Position (APP) sensor
14 Ambient Air Temperature (AAT) sensor
15 Crankshaft Position (CKP) sensor
16 Neutral gear sensor
17 Clutch pedal position sensor
18 Brake pedal switch
19 Engine Coolant Temperature (ECT) sensor
20 Auto Stop/start switch
21 Hood switch
22 Stop/start switch

Published: 14-Dec-2015

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Auxiliary Climate Control - Fuel Fired Booster Heater
Description and Operation

COMPONENT LOCATION - Fuel Fired Booster Heater without Remote Control

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Item Description
1 Automatic Temperature Control Module (ATCM)
2 Ambient Air Temperature (AAT) sensor
3 Fuel Fired Booster Heater - fuel pump.
4 Fuel Fired Booster Heater - coolant pump
5 Fuel Fired Booster Heater (FFBH)

COMPONENT LOCATION - Fuel Fired Booster Heater with Remote Control

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Item Description
1 Automatic Temperature Control Module (ATCM)
2 Ambient Air Temperature (AAT) sensor
3 Fuel Fired Booster Heater - fuel pump.
4 Fuel Fired Booster Heater - receiver
5 Fuel Fired Booster Heater - antenna amplifier
6 Fuel Fired Booster Heater - coolant pump
7 Fuel Fired Booster Heater (FFBH)

OVERVIEW

The Fuel Fired Booster Heater (FFBH) is rated at 5 W and compensates for the relatively low-coolant temperatures inherent in
the engine. The unit is located behind the right front fender splash shield and heats engine coolant upstream of the heater
core.

Operation of the FFBH is controlled by the Automatic Temperature Control Module (ATCM) via a Local Interconnect Network
(LIN) bus connection. The operation of the FFBH is influenced by:

Ambient air temperature.

Engine coolant temperature.
The FFBH will operate in supplementary mode if the ambient air temperature is lower than 5°C (41°F) and stop if ambient
temperature reaches 8°C (46°F), or will provide a level of heating to the cabin or engine if the ambient is below 15°C upon a
user request by either the:

FFBH remote control,

timed climate,
or TS (Touch Screen).

Operation of the FFBH may also be inhibited if the fuel level drops below a predetermined level.

DESCRIPTION

Automatic Temperature Control Module

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The Automatic Temperature Control Module (ATCM) is mounted in the center console and is integral with the control panel.
The module works in conjunction with the Engine Control Module (ECM) to control all aspects of heating, ventilation, and Air
Conditioning (A/C).

For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Fuel Fired Booster Heater - Fuel Pump

Item Description
1 Fuel line connector
 2 Non return valve
3 Solenoid coil
4 Plunger
5 Filter insert
6 Fuel line connector
7 O-ring seal
8 Spring
9 Piston
10 Bush
The Fuel Fired Booster Heater (FFBH), fuel pump is mounted adjacent to the fuel tank and regulates the fuel supply to the
FFBH. The pump is a self-priming, solenoid operated plunger pump, controlled by a Pulse Width Modulation (PWM) signal from
the control module in the FFBH. When the pump is de-energized, it provides a positive shut-off of the fuel supply.

The solenoid coil of the fuel pump is installed around a housing which contains a plunger and piston. The piston locates in a
bush, and a spring is installed on the piston between the bush and the plunger. A filter insert and a fuel line connector are
installed in the inlet end of the housing. A non-return valve and a fuel-line connector are installed in the fuel outlet end of the
housing.

While the solenoid coil is de-energized, the spring holds the piston and plunger in the closed position at the inlet end of the
housing. An O-ring seal on the plunger provides a fuel tight seal between the plunger and the filter insert, preventing any flow
through the pump. When the solenoid coil is energized, the piston and plunger move towards the outlet end of the housing,
until the plunger contacts the bush; fuel is then drawn in through the inlet connection and filter. The initial movement of the
piston also closes transverse drillings in the bush and isolates the pumping chamber at the outlet end of the housing.
Subsequent movement of the piston then forces fuel from the pumping chamber through the non-return valve and into the

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line to the fuel fired booster heater. When the solenoid de-energizes, the spring moves the piston and plunger back towards
the closed position. As the piston and plunger move towards the closed position, fuel flows past the plunger and through the
annular gaps and transverse holes in the bush to replenish the pumping chamber.

Fuel Fired Booster Heater

The Fuel Fired Booster Heater (FFBH) is installed in the coolant supply line to the climate control assembly and is located
behind the front-right fender. One electrical connector connects the FFBH to the vehicle wiring.

The FFBH comprises the following:

Combustion air fan

Burner housing
Heat exchanger
Air inlet hose and muffler
Exhaust pipe and muffler
Control module.

Sectioned View of Typical Fuel Fired Booster Heater

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Item Description
1 Combustion air fan
2 Coolant inlet
3 Coolant outlet
4 Burner insert
5 Heat exchanger
6 Overheat temperature sensor
7 Exhaust
8 Fuel inlet
9 Evaporator
10 Air inlet
Combustion Air Fan

The combustion air fan regulates the flow of air into the FFBH to support combustion of the fuel supplied by the FFBH fuel
pump. It is also used to purge and cool the FFBH.

Burner Housing

The burner housing contains the burner insert and also incorporates connections for the exhaust pipe, the coolant inlet from
the auxiliary coolant pump and the coolant outlet to the vehicle heater.

The burner insert incorporates the fuel combustion chamber, an evaporator and a glow pin and flame sensor. Fuel from the
FFBH fuel pump is supplied to a metal mesh, where it evaporates and enters the combustion chamber to mix with air from the
combustion air fan. The glow pin and flame sensor provides the ignition source for the fuel-air mixture and, once combustion
is established, monitors the flame.

Heat Exchanger

The heat exchanger transfers heat generated by combustion to the coolant. Two sensors are installed in the heat exchanger
casing to provide the control module with inputs of engine coolant temperature. The control module uses the temperature
inputs to control system operation.

Air Inlet Hose and Muffler

A canister type muffler is included in the air inlet supply line. The muffler reduces the noise caused by induction roar and acts
as a water separator to protect the FFBH in the event of water ingress.
Exhaust Pipe and Muffler

The exhaust pipe and muffler directs exhaust combustion gases to atmosphere below the front right wheel arch. Exhaust
vapor may be visible when the FFBH is running, depending on atmospheric conditions.

Control Module

The control module controls and monitors operation of the FFBH system. An internal flow of air from the combustion air-fan
ventilates the control module to prevent it from overheating.

The control module is powered by a permanent feed from the Battery Junction Box (BJB) through the Quiescent Current
Control Module (QCCM). The control module communicates with the Automatic Temperature Control Module (ATCM) over the
Local Interconnect Network (LIN) bus.

Auxiliary Coolant Pump

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The auxiliary coolant pump is mounted on the bulkhead panel in the engine compartment and is used to assist coolant flow
through the FFBH and the heater core.

The auxiliary coolant pump runs continuously while the FFBH is active. When the FFBH is inactive, coolant flow is reliant on
the engine coolant pump. Operation of the auxiliary coolant pump is controlled by a power-feed direct from the control module
within the FFBH.

Stop/Start System

During a Stop/Start cycle when the engine is shutdown and consequently the engine-driven coolant pump is stationary, the
desired set cabin temperature cannot be maintained for a prolonged period, especially in cold ambient temperatures. To
counteract this, the FFBH auxiliary electric coolant-pump (when fitted), controlled by the ECM, is used to maintain the coolant
flow through the cabin’s heater core. This supporting circulation prolongs the set temperature setting in the cabin and
accordingly prevents an early engine restart.

Ambient Air Temperature Sensor

The Ambient Air Temperature (AAT) sensor is a Negative Temperature Coefficient (NTC) thermistor, and is mounted in the
passenger door mirror. The sensor is connected to the ECM, which broadcasts an ambient air temperature value over the HS
CAN Powertrain bus. This value is received by the Central Junction Box (CJB) over the HS CAN Powertrain bus, and this value
is transmitted into the ATCM over the MS CAN Comfort bus, via the GWM.

Remote Control Components

The remote control system comprises of the following components:

FFBH
 FFBH remote control
FFBH receiver
Antenna and antenna amplifier
Antenna harness to connect receiver co-axial cable to existing DAB antenna in side window.

Fuel Fired Booster Heater - Remote Control

Item Description
1 On button
2 Off button
3 LED operation indicator

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4 Antenna
The remote control allows the driver to remotely activate the FFBH without entering the vehicle. The remote control has a
range of at least 100m (328ft) in free space, although this distance may be decreased depending on the location of obstacles
such as buildings. The remote control is powered by a 3.3volt CR1/3N replaceable battery which can be accessed by removing
a cover from the rear of the remote control. The battery life in the remote control is approximately 300 FFBH cycles. One cycle
is defined as a remote control button press followed by 30 minute burn time with flashing LED feedback.

The remote control has a green LED to indicate the FFBH is active. When the 'ON' button is pressed on the remote control for
more than 2 seconds, the LED will illuminate for 2 seconds. After the 2 second period has passed, the LED will illuminate for
50ms every 2 seconds for up to the 30 minute on time of the FFBH. The LED will only stop flashing if the 'OFF' button is
pressed or the 30 minute on timer has elapsed.

Remote Control LED Indicator Functionality

The LED illuminates in different ways to alert the driver to the various states of the FFBH remote control system as follows:

Illuminates green for 2 seconds when the ON button has been pressed to show that the receiver unit has successfully
received the remote control on request. The FFBH may now start operating providing that fuel level, battery voltage
and coolant temperature variables are within limits
Flashes green for 50 ms every 2 seconds to indicate that the FFBH may be active.
Illuminates red for 2 seconds when the OFF button has been pressed to show that the receiver unit has successfully
received the remote control off request. The FFBH should then stop operating.
Flashes green or red for 2 seconds when pressing the ON or OFF buttons to indicate that the signal was not received
by the FFBH receiver.
Illuminates orange before changing to green or red to show that remote control battery voltage is low.
Flashes orange for 5 seconds to show that signal was not received by the FFBH and that the remote control battery
requires replacement.

Remote Control Pairing

Each remote control must be 'paired' to the receiver to enable communications. Each remote control has a unique
identification number which is stored by the receiver. The receiver can store up 3 remote control identification numbers. If a
fourth remote control is paired to the receiver, the receiver will replace the first paired remote control number with that for
the fourth remote control in the receiver memory. Subsequently, the first paired remote control will no longer be paired and
will not be recognized by the receiver.

The following procedure details the pairing process:

Remove fuse F7 from the RJB

Wait for a minimum of 5 seconds
Replace fuse to position F7 in the RJB
Within 5 seconds of replacing the fuse (and restoring the receiver power supply), press and hold the remote control
OFF button
Confirmation of successful pairing is displayed by the remote control LED illuminating in a red color for 2 seconds.
 NOTE: NOTE: The pairing process relies on the FFBH receiver having the power supply removed and then the power
supply re-instated. The fuse method is the easiest method but it can also be achieved by battery disconnection or removal of
the harness connector from the receiver unit.

Fuel Fired Booster Heater - Receiver

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The receiver is located in the left side of the luggage compartment. The receiver is mounted on an integral bracket which in
turn is attached to the audio system bracket which locates the gold plated TV antenna.

The receiver is connected to the antenna on the left side window with a co-axial cable. RF signals from the remote control are
received by the antenna and passed via the antenna matching unit and co-axial cable to the receiver. The receiver processes
the signals and transmits appropriate messages to the FFBH on a dedicated bus.

Antenna and Antenna Amplifier

The FFBH antenna is located in the rear left side window and uses the same antenna elements as used by the gold plated TV
antenna system.

The antenna amplifier, a flying lead from this unit connects directly to a stud on the glass antenna. The receiver unit connects
to the amplifier via a co-axial cable.

The glass mounted antenna receives RF transmitted signals from the remote control and transmits them, via the amplifier and
co-axial cable, to the FFBH receiver.

OPERATION

If a heating request is received and the ambient air temperature is less than or equal to 5°C (41°F), the Automatic
Temperature Control Module (ATCM) transmits a 'supplemental heat' message to the Fuel Fired Booster Heater (FFBH) control
module on the LIN bus. The control module responds by returning a 'supplemental heat' status message back to the ATCM.
The control module will now initiate the FFBH start sequence.
If the heating request is removed, or ambient air temperature rises to 8°C (46°F), the ATCM transmits a 'heater off' message
to the FFBH control module on the LIN bus. Again, the control module responds by returning a 'heater off' status message
back to the ATCM. The control module will now de-activate the FFBH.

If maximum heating is requested, ECM becomes the overriding factor. In this instance, the ATCM will change the LIN bus
message from 'heater off' to 'supplemental heat' when engine coolant temperature measured by the FFBH is below or equal to
70°C (158°F). If the engine coolant temperature measured by the FFBH rises to 78°C (172°F) the ATCM returns the message
to 'heater off'.

The control module will not start the FFBH, or will discontinue operation, if any of the following occur:

The control module is in the error lockout mode (see Diagnostics below)
The engine is not running, or stops running for approximately 4 seconds. The time delay is included for stall detection
• 'fuel A cut-off' message is received from the CJB over the MS CAN Body and Comfort bus via the GWM.
For additional information, refer to: Electronic Engine Controls (303-14A Electronic Engine Controls - INGENIUM I4
2.0L Diesel, Description and Operation).
• A low fuel level message is received from the CJB over the MS CAN Comfort and Body bus via the GWM (see table
below).
For additional information, refer to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - INGENIUM I4 2.0L Diesel,
Description and Operation).
• If the supply voltage is above/below the required threshold.

The control module will control FFBH operation based on the following levels of fuel in the tank.

Fuel Level, liters (UK Gallons) Description

7.5 (1.54) Start
4.5 (0.88) Stop

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10.5 (2.2) Restart
Start Sequence

At the beginning of a start sequence, the FFBH control module:

energizes the glow pin and flame sensor to pre heat the combustion chamber,
starts the combustion air fan at slow speed,
and energizes the auxiliary coolant pump.

After approximately 30 seconds, the control module energizes the auxiliary fuel pump at the starting sequence speed. The fuel
delivered by the auxiliary fuel pump evaporates in the combustion chamber, mixes with air from the combustion air fan and is
ignited by the glow pin and flame sensor. The control module then progressively increases the speed of the auxiliary fuel
pump and the combustion air fan. Once combustion is established the control module switches the glow pin and flame sensor
to the flame sensing function to monitor combustion. From the beginning of the start sequence to stable combustion at full
load takes approximately 150 seconds.

Full and Part Load Combustion

While the FFBH is running, the control module cycles the heater between full load combustion, part load combustion (available
for vehicles with Diesel engine) and a control idle phase of operation, depending on the temperature of the coolant in the
FFBH heat exchanger.

The heat output level at part load combustion is 2.5kW. This rises to 5kW at full load combustion. The control module
transmits the amount of fuel used by the FFBH to the Instrument Cluster (IC), and the FFBH coolant temperature to the
ATCM.

Switching Point Temperatures

NOTE: NOTE: Vehicles with Diesel engine.

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Switching Point Item Number Switching Point Description Temperature, ºC (ºF)
1 Full load to part load 79ºC (174ºF)
2 Part load to control idle 90ºC (194ºF)
3 Control idle to part load 74ºC (165ºF)
4 Part load to full load 69ºC (156ºF)
After the start sequence, the control module maintains full load combustion until the coolant temperature reaches switching
point temperature 1. At this temperature, the control module decreases the speed of the auxiliary fuel pump and the
combustion air fan to half speed, to produce part load combustion. The control module maintains part load combustion while
the coolant temperature remains between switching point temperatures 2 and 4. At part load combustion the temperature of
the coolant will increase or decrease depending on the amount of heat required to heat the vehicle interior. If the coolant
temperature decreases to switching point temperature 4, the control module increases the speed of the auxiliary fuel pump
and the combustion air fan to full speed, to return to full load combustion. If the coolant temperature increases to switching
point temperature 2, the control module enters a control idle phase of operation.

On entering the control idle phase, the control module immediately switches the auxiliary fuel pump off, to stop combustion,
and starts a timer for the combustion air fan. After a 2 minute cool down period, the control module switches the combustion
air fan off and then remains in the control idle phase while the coolant temperature remains above switching point
temperature 3. If the coolant temperature decreases to switching point temperature 3, the control module initiates a start to
part load combustion. A start to part load combustion takes approximately 90 seconds.

In order to limit the build-up of carbon deposits on the glow pin and flame sensor, the control module also enters the control
idle phase if continuous combustion time exceeds 72 minutes (at part load, full load or a combination of both). After the cool
down period, if the coolant is still in the temperature range that requires additional heat, the control module restarts the fuel
fired booster heater.

Shutdown

To stop the FFBH, the control module de-energizes the auxiliary fuel pump to stop combustion, but continues operation of the
combustion air fan and the auxiliary coolant pump for a time, to cool down the FFBH. The cool down time is 100 seconds if the
FFBH was operating at part load combustion and 175 seconds if the FFBH was operating at full load combustion.

Diagnostics

The control module monitors the fuel fired booster heater system for faults. The Diagnostic Trouble Codes (DTC) are stored in
a volatile memory in the control module, which can be interrogated by the Land Rover approved diagnostic system via the MS
CAN Comfort bus.

The control module also incorporates an error lockout mode of operation that inhibits operation to prevent serious faults from
causing further damage to the system. In the error lockout mode, the control module immediately stops the FFBH fuel pump,
and stops the combustion air fan and auxiliary coolant pump after a cool down time of approximately 2 minutes. Error lockout
occurs for:
 Start failure and flameout: If a start sequence fails to establish combustion, or a flameout occurs after combustion is
established, the control module immediately initiates another start sequence. The start failure or flameout is also
recorded by an event timer in the control module. The event timer is increased by one after each start failure,
flameout, and FFBH component failure, and will set back to zero if a subsequent start is successful. If the event timer
increases to six (over any number of drive cycles), the control module enters the error lockout mode.
Heat exchanger casing overheat: To protect the system from excessive temperatures, the control module enters the
error lockout mode if the heat exchanger coolant temperature exceeds 125°C (257°F).

The error lockout mode can be cleared using the Land Rover approved diagnostic system, or by disconnecting the battery
power supply for a minimum of 10 seconds.

Remote Operation

The remote system includes the addition of a FFBH receiver, FFBH antenna and a remote control for operation of the system.
The FFBH unit remains as previously fitted. The IC message center displays FFBH messages when required.

The 868.3MHz RF signals transmitted by the remote control are received by the TV/FFBH antenna located in the rear left side
window. The signals received by the antenna are detected by the FFBH receiver. A 'handshake' signal is sent back from the
receiver to the remote control to confirm a valid on or off request and activate the remote control Light Emitting Diode (LED)
accordingly. The receiver processes the signal it received and transmits the appropriate signals via a dedicated bus to the
FFBH control module.

NOTE: NOTE: The ‘handshake’ signal only confirms remote control-receiver communications were successful, and not
that the FFBH has turned on.

When the FFBH is activated by the remote control, the FFBH control module will allow the FFBH to operate for 30 minutes or
until an off request is received from the remote control or CJB. During the 30 minute period, the FFBH may operate in either

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full load combustion, part load combustion or a controlled idle phase of operation, depending on the temperature of the
coolant in the heat exchanger.

Pre-burn Thresholds

The FFBH unit will only activate remotely if the following threshold conditions are met:

Pre-burn battery voltage check: ≥11.5V (voltage at FFBH terminals)

Pre-burn coolant temperature check: ≤15°C (internal FFBH measurement)
Pre-burn fuel level check: ≥7.5 liters (value stored in FFBH at ignition off)

The fuel level value stored within the FFBH unit is only updated when the engine is running. When starting the FFBH via
remote control with the engine off, the fuel level value used in the FFBH calculations will be that stored at the last key off
event. It is therefore possible for the FFBH to fail to operate remotely if the engine was stopped with a low fuel level; if the
fuel tank is subsequently refueled, the FFBH stored fuel level will still read low if the engine has not been started since
refueling.

If the FFBH does not activate due to low battery voltage or low fuel level, the FFBH control module transmits a message on
the LIN bus to the IC message center, which will display one of the following messages at ignition on:

AUXILIARY HEATER UNAVAILABLE LOW FUEL

AUXILIARY HEATER UNAVAILABLE LOW BATTERY

If both low fuel and low battery voltage messages are valid, the instrument cluster message center will alternate between the
two messages.

Remote Control ‘Park Heat’ to ATCM ‘Supplementary Heat’ Transitions

NOTE: NOTE: The FFBH can still be activated by the ATCM as previously described.

If the FFBH has been operated remotely (‘park heat’) and the vehicle is started whilst the FFBH is still active, it will transition
into the ATCM-controlled ‘supplementary heat’ mode if the ATCM requests it.

Should the ATCM then send a message to the FFBH to turn off, the FFBH will remain active if 30 minutes has not yet elapsed
from the original remote control ‘park heat’ request. Once the remainder of 30 minutes has elapsed, the FFBH will turn off.

Switching Point Temperatures

NOTE: NOTE: Vehicles with Diesel engine.

When remotely started the FFBH uses a different set of switching point temperatures to the normal ‘supplemental heat’ mode.
This is because the remote start feature can start the FFBH with the engine off – thus different thresholds are required to
optimize the heating of the engine coolant.

Switching Point Temperatures

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Switching Point Item Number Switching Point Description Temperature, ºC (ºF)
1 Full load to part load 79ºC (174ºF)
2 Part load to control idle 90ºC (194ºF)
3 Control idle to part load 74ºC (165ºF)
4 Part load to full load 69ºC (156ºF)

Published: 17-Nov-2014
Seating - Seats
Description and Operation

COMPONENT LOCATION - MANUAL FRONT SEAT ADJUSTMENT

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Item Description
1 Seat forward/rearward adjustment lever
2 Seat height adjustment lever
3 Seat backrest recline adjustment knob

COMPONENT LOCATION - ELECTRIC FRONT SEAT ADJUSTMENT

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Item Description
1 Seat backrest recline motor
2 Seat switchpack
3 Seat module
4 Seat cushion tilt motor
5 Seat forward/rearward motor
6 Seat height motor
COMPONENT LOCATION - SECOND ROW SEATS

NOTES:

North American Specification (NAS) head restraints shown

Illustration shows several variants of the seat depending on vehicle specification.

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Item Description
 1 Right seat backrest upper release lever (if fitted)
2 Left Seat backrest upper release lever (if fitted)
3 Seat backrest lower release lever (2 off) (if fitted)
4 Left seat backrest release motor (if fitted)
5 Left seat backrest release return spring (if fitted)
6 Right seat backrest release return spring (if fitted)
7 Right seat backrest release motor (if fitted)
8 Left seat slide release bar (if fitted)
9 Right seat slide release bar (if fitted)

COMPONENT LOCATION - THIRD ROW SEATS

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Item Description
1 Right head restraint latch release cable
2 Left head restraint latch release cable
3 Release strap
4 Latch release assembly
5 Left seat backrest latch release cable
 6 Right seat backrest latch release cable
7 Latch release assembly

COMPONENT LOCATION - HEATED SEATS

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Item Description
1 Left seat heater switch - Automatic Temperature Control Module (ATCM)
2 Right seat heater switch - ATCM
3 Right seat backrest heater element
4 Left seat backrest heater element
5 Left seat cushion heater element
6 Right seat cushion heater element
7 Left rear seat heater switch
8 Right rear seat heater switch
9 Right rear seat backrest heater element
10 Left rear seat cushion heater element
11 Left rear seat backrest heater element
12 Right rear seat cushion heater element

COMPONENT LOCATION - CLIMATE SEATS

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Item Description
1 Seat backrest climate assembly
2 Right seat cushion climate assembly
3 Seat climate switch - ATCM
4 Left seat climate switch - Automatic Temperature Control module (ATCM)
5 Front seat climate control module (1 per seat)

COMPONENT LOCATION - SEAT LUMBAR

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Item Description
1 Right seat lumbar assembly
2 Left seat lumbar assembly
3 Front seat switchpack - lumbar control switch

OVERVIEW

Front Seats

Dependent on vehicle specification, various options are available for the front seats with regard to temperature control and
electrical adjustment. Seats are heated or heated and cooled (climate), with the following adjustment options:

Manual six-way adjustment

Electric six-way adjustment
Electric eight-way adjustment

Six-way adjustments consist of seat slide, seat height and backrest recline. Eight-way adjustments consist of seat slide, seat
height, backrest recline and two-way lumbar adjustment.

The driver and passenger seats on vehicles with electric seats have a 3-channel memory for easy recall of stored position
settings for the seat and door mirrors. The controls for memory operation are in the related front door trim panel. Lumbar
settings are not included in the memory function.
The driver has an easy entry/exit feature which automatically lowers the driver's seat when the ignition is off (power mode 0)
and the driver's door is opened. When the driver's door is closed and the ignition is on (power mode 6) the seat will return to
its previous set position. The feature can enabled or disabled using the Instrument Cluster (IC) menu.

Operation of the temperature settings for heated and climate seats is controlled from the Climate / Front Climate / Front
Seats menu of the Touch Screen (TS).

Second Row Seats

Dependent on vehicle specification the following options are available for the second row rear seats:

Heated seats
Climate seats
Recline function
Manual fold or power fold.

Operation of the temperature settings for heated second row seats is controlled by switches at the rear of the floor console
and/or the Climate / Rear Climate / Rear Seats menu of the TS.

ISOFIX fastening points are attached to the second row seat frame to provide secure fastening for compatible child seats in
the rear seats.

The second row seats has a 60/40 split which allows for the seating of three persons, or the whole seat or partial seat can be
lowered for additional luggage compartment capacity.

Third Row Seats

Two third row seats can be fitted. These seats can be folded flat to optimize the luggage compartment space or raised to
increase the seating capacity to seven persons.

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The third row seats are manually operated.

DESCRIPTION

The vehicle seats are each based around a number of fabricated steel pressings. The components are welded, rivetted and
bolted together to form the seat frame structure which is secured to the vehicle floorpan. The seat frame varies in design
according to specification and if manual or electrical adjustment.

The seat frame is fitted with a fabricated sprung framework in the seat base and backrest. The sprung framework supports
the eat foam and increases occupant comfort.

The seat frame provides location for the seat foam for the cushion and backrest. The seat foam is covered with a tailored seat
cover.

The front seats are each mounted on rails which allow the seat position to be adjusted forwards or rearwards. The rails are
secured to the floor pan with brackets.

The second row and third row (if fitted) seats are also secured to the floorpan. Depending on specification, the second row
seats can have a slide and recline feature. If third row seats are fitted, the second row seats fold and slide to allow easy
access to the third row seats.

The third row seats are fixed in their position. The seat frame design allows the seat to be folded flat to increase the capacity
of the luggage compartment area.

Front Seat Adjustment - Manual Seats

 Item Description
1 Forward and rearward adjustment
2 Height adjustment

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3 Backrest angle adjustment
The manual front seats have three adjustments available.

A lever at the front of the seat releases a latch on the seat rails allowing the seat position to be adjusted in a forward or
rearward direction.

A lever on the side of seat allows the seat height to be adjusted. The lever releases a catch and the seat height is spring
assisted in the raise position. The occupants weight against the spring provides controlled lowering the seat to the required
position.

A rotary knob on the side of the seat provides for adjustment of the seat backrest position.

Front Seat Adjustment - Electric Seats

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Item Description
1 Lumbar adjustment
2 Seat backrest recline adjustment
3 Seat cushion height adjustment
4 Seat forward and rearward adjustment
5 Seat cushion tilt adjustment
The electric seats can be operated when the smart key has been recognised by the vehicle and vehicle is in accessory power
mode 4.

Each seat has four electric motors; seat backrest recline motor, seat forward/rearward motor, seat height motor and a seat
cushion tilt motor.

The seat backrest recline motor is located on the left side of the backrest frame. The motor is secured to the frame with two
screws.

The backrest recline motor rotates a worm drive shaft. The worm drive shaft acts on a gear attached to the seat cushion
frame to raise or lower the backrest.

Operation of the backrest angle adjustment switch changes the polarity of the power supply and ground to the seat backrest
recline motor dependent on which direction the switch is operated.

Power is supplied to the switch from a fuse in the Central Junction Box. Power is supplied direct from the primary battery
regardless of power mode state.

On vehicles without memory seats, the switches are connected directly to the applicable seat motor.

On vehicles with memory seats, the seat switchpack is connected the driver or passenger seat module with a Local
Interconnect Network (LIN) bus connection. switch operation is sensed by the module which operates the required seat motor
accordingly.

Seat Modules - Vehicles with Memory Seats Only

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Item Description
1 Seat module
On vehicles with seat memory, a seat module is located on the underside of the seat cushion frame on both the driver's and
passenger's seats. The module is located towards the front of the seat cushion, behind a plastic trim.

The driver and passenger seat modules are connected by hardwired connections to the seat adjustment motors. The seat
switchpacks are connected to the seat module with a Local Interconnect Network (LIN) bus. The seat module contains a
non-volatile Erasable Programmable Read Only Memory (EPROM). The seat module monitors the seat positions and stores
information provided by Hall sensors within the seat adjustment motors. All seat memory values and current seat adjustment
motor positions are stored in the EPROM.

If power is lost to the seat module, when power is restored the current seat adjustment motor positions are recalled from the
EPROM and adopted as the current positions. This allows the relative memory positions to be retained without any need to
re-calibrate the seat module.

Each seat module can be 'flashed' for service updates or interrogated using Land Rover approved diagnostic equipment.

Up to 3 different seat positions can be stored in the seat module. Seat positions are stored in memory by pressing the
memory switch (M), and then 1, 2, or 3 memory store switches within 5 seconds. The memory switches are located on the
door trim panel. The seat memory switchpack memory switches allow the driver to control the memory storage and recall
operations for the driver's seat and door mirror glass positions. The passenger seat memory switchpack stores only the seat
positions and does not control the exterior door mirror glass position. The driver's seat memory switchpack is connected to
the driver's door module by two hardwired connections for door mirror glass position recall.
The switchpack switches are non-latching, momentary action switches. The seat lumbar adjustment is not stored by the
EPROM and therefore cannot be recalled via a memory switch position selection.

The seat module provides the following selectable functions:

Seat memory recall

Powerfold door mirrors memory recall (driver's seat module only)
Seat adjustment via seat switchpack.

Second Row Seat Recline Adjustment

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The second row seat has a manual recline feature.

A lever at the side of the seat cushion releases a catch when pulled and allows the seat to be reclined backwards. The lever
also releases the seat from the reclined position.

Second Row Seat Folded Position - Fixed Seat (5 seat vehicle)

Item Description
1 Seat cushion raise strap
2 Lower head restraint
3 Backrest release and fold
The rear seat can be folded flat to increase the luggage compartment area.

A strap at the rear of the seat cushion releases the seat cushion and allows it to be folded to a vertical position.

The head restraints are lowered using a button to release the head restraint which can pushed to its fully lowered position.

Each seat has a release catch that releases the seat backrest. When the catch is operated, the seat backrest can be folded to
a horizontal position.

Second Row Seat Folded Position

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The 60/40 split rear seat can be fully or partially folded. Partial folding allows large loads to be carried in the luggage
compartment while retaining seating for passengers.

A lever at the side of the seat cushion is lifted to release the seat backrest. The backrest is then lowered into a horizontal
position.

Item Description
1 Second row seats backrest release strap or electric backrest release switches
2 Backrest to folded position
The second row seat can also be folded by the third row seat passengers or from the luggage compartment.

A strap on the rear of each second row seat backrest is pulled to release the locking mechanism. The seat can them be
lowered to the horizontal position.

On vehicles with electric seat backrest release fitted, the applicable switch in the right side of the luggage compartment can
be operated to release the locking mechanism. The seat backrest can then be lowered to the horizontal position.

Second Row Seat Access Position - Sliding Seat (7 seat vehicle)

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Item Description
1 Backrest release lever
2 Seat slide release lever
On vehicles with third row seats, the second row seats have an access position to allow easy entry and exit for the third row
seat passengers.

A lever on the outside upper edge of the seat backrest is pulled to release the backrest to a tilted position. A lever at the front
of the seat cushion is pulled to slide the second row seat forwards.

When normal seating is required, the second row seat is moved to its fixed position along with the seat backrest.

Third Row Seats

Third Row Seat Fold

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Third Row Seat Raise

Item Description
1 Release strap
2 Head restraint raised position
Each of the third row seats can be folded individually. A strap operated locking mechanism locks the seat back rest and the
head restraint in the vertical position.

To fold the seat, pull the strap to release the head restraint and fold the head restraint flat onto the seat backrest.

Pull the strap a second time and fold the seat backrest flat. The strap releases the locking mechanisms for both the head
restraint and the seat backrest.

To raise the seat, pull the strap from inside the luggage compartment and raise the seat back rest to the vertical position.
Raise the head restraint to the vertical position.

Make sure both the head restraint and the seat backrest are securely locked by their locking mechanisms.

Memory Seat Switchpack - Where Fitted

 Item Description
1 Memory store switch
2 Memory preset switches 1 - 3
The seat memory switchpack is located in the driver's and passenger's front door trim, adjacent to the interior door handle.

The seat memory switchpack is connected to the applicable seat switchpack. A Local Interconnect Network (LIN) bus connects
the seat switchpack to the applicable seat control module. The selected memory position switch operation is passed from the
seat switchpack on the LIN bus to the seat control module which operates the seats motors to the correct positions associated
with that memory preset position.

On the driver's seat, the memory function will also store the exterior mirror positions associated with the selected memory
preset switch 1 - 3.

To store a memory position, move the seat to the required positions (and the exterior mirror for the driver's seat), and press
the 'M' switch on the memory switchpack. Then press a memory preset switch 1 - 3 to store the position against the selected

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memory switch preset number.

Heated Front Seats (if fitted)

Seat heater elements are in installed in the seat cushion and backrest. The seat heaters comprise a resistive element which is
located within a pad. The pad is located between the foam of the cushion or backrest and the outer trim.

Each element is fitted with a thermostat which maintains the element at a temperature set by the user. The elements are
controlled by a seat heater switch for each seat. The switches are located in the Automatic Temperature Control Module
(ATCM) which is located in the instrument panel. Each switch has three levels of heat setting; low, medium and high, which
can be selected by sequential presses of the switch. Light Emitting Diodes (LEDs) on each switch indicate the selected heat
setting requested.

Heated 2nd Row Seats (if fitted)

Seat heater elements are in installed in the seat cushion and backrest. The seat heaters comprise a resistive element which is
located within a pad. The pad is located between the foam of the cushion or backrest and the outer trim.

Each element is fitted with a thermostat which maintains the element at a temperature set by the user. The elements are
controlled by a seat heater switch for each switch located in the rear of the floor console. The switches are connected via a
Local Interconnect Network (LIN) bus to the Automatic Temperature Control Module (ATCM) located in the instrument panel.
Each switch has three levels of heat setting; low, medium and high, which can be selected by sequential presses of the switch.
Light Emitting Diodes (LEDs) on each switch indicate the selected heat setting requested.

Climate Front Seats

Climate front seats are controlled by a front seat climate control module (SCCM). The front SCCM is located on the underside
of the seat cushion, behind a plastic trim on the forward edge of the seat frame of each front seat.

The climate seat backrest and cushion contain climate assemblies. The climate assemblies are thermal electric devices which
operate on the Peltier principle, which heat up or cool down depending on the voltage provided by the SCCM. Each climate
assembly in the seat cushion and backrest each contain a blower, which blows air over the thermal electric devices to
distribute the heated or cooled air through liners in the related cushion or backrest. The blower is also controlled by the
SCCM.

Seat climate heating and cooling for the front seats is selected on switches for each seat on the ATCM. Pressing the switch
selects the climate menu in the touch screen (TS). The menu allows the user to select seat heating or cooling and allows a
number of levels of heating and cooling to be selected.

Front Seat Lumbar Adjustment (if fitted)

Lumbar adjustment is provided by a lumbar assembly which comprises of an inflatable air cell, a solenoid valve and an air
pump, installed in each front seat backrest. The lumbar assembly consists of an inflatable cushion with a single two-way air
cell. A solenoid valve controls the air pump for the inflation or deflation of the lumbar cushion.

Seat lumbar is controlled using a two-way switch which is integral with the seat switchpack. Pressing the forward section of
the switch inflates the lumbar assembly. Pressing the rearward section of the switch deflates the lumbar assembly.
OPERATION

Front Seat Adjustment - Non-Memory Seats

The driver and passenger seat switchpacks each receive a permanent fused primary battery power supply from the Central
Junction Box (CJB). This feed is always live regardless of ignition power mode status.

Each switch provides a ground and power supply to the respective seat motor. When a particular function is required to
operate in the opposite direction, the polarity to the motor is reversed via the respective switches.

A separate power supply is used for the lumbar assembly power supply. Power for the lumbar assembly is from the primary
battery via a fuse and seat relay in the Rear Junction Box (RJB).

In the event that a motor reaches the end of its functions travel, an internal thermal cut-out switch will trip to temporarily
remove voltage from the motor.

Front Seat Adjustment - Memory Seats

On memory front seats, the driver or passenger seat module receives two permanent power supplies; one from the Central
Junction Box (CJB) and one from the Rear Junction Box (RJB). The power supply from the CJB is used to operate the
adjustment motors. The power supply from the RJB is used to operate the driver or passenger seat module.

A fused power supply is connected from the RJB via a seat relay to the seat switchpack and the seat module. Operation of a
seat motor switch is converted to a Local interconnect Network (LIN) bus message within the switchpack, which is passed to
the seat module. The seat module processes the LIN bus signal and operates the applicable seat motor as required. The seat
lumbar assembly is operated with a power supply direct from the seat switchpack.

The driver and passenger seat modules are connected to the medium speed Controller Area Network (CAN) body systems bus.

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This allows the driver seat module to monitor the position of the door mirrors, using signals from the door modules and CJB
respectively, when storing and recalling memory settings. The medium speed Controller Area Network (CAN) body systems
bus connection also allows both the driver seat module and the driver door module to transmit memory information to enable
confirmation chimes and message display in the Instrument Cluster (IC).

Stall Detection

A seat adjustment motor is deemed to have stalled if there is no change in the input from the feedback sensor of the motor
for 200 ms. If a stall condition is detected then the drive to that motor is cancelled for the remainder of the memory recall
operation or until the switch is re-selected (manual movement). The motor may be activated again, to move past the stall
position, by pressing the appropriate switch for more than 2 seconds. If sensor feedback is detected, then the motor will
continue to be driven until the switch is released. If sensor feedback is not detected, then the motor is only driven for 0.5
second and then stops until the switch is released and pressed again, when a further 0.5 second of activation is permitted.
This is known as inch mode, which allows seat adjustment to be maintained if sensor feedback is lost.

Initialization

When a replacement driver or passenger seat module is fitted, it must be calibrated using Land Rover approved diagnostic
equipment so that the seat module can learn the positions of the seat adjustment motors.

Battery Monitor

If the primary battery voltage drops below 10.5 V, the driver seat module ignores all requests for a memory recall until the
battery voltage has reached 11.5 V. This conserves as much battery power in the primary battery as possible to enable engine
cranking.

Front Driver's Seat Memory

The seat memory switchpack has three hardwired connections to the driver door module. One wire provides a reference
voltage to the memory switches, the second provides a ground and the third controls the memory LED status. Operation of
the any of the memory switches is passed through resistors of varying resistance within the switchpack to the driver door
module. The switch operation is detected by the driver door module and converted into a medium speed CAN body systems
bus signal which is sent to the driver seat module to recall or store the memory positions.

Memory settings are stored in the driver seat module by pressing the memory switch and then, within 5 seconds, one of the
memory switches 1-3. When the memory switch is pressed the Light emitting Diode (LED) in the switch illuminates. After the
memory switch 1-3 is pressed, the LED goes off and a chime sounds to confirm that the settings have been memorized. If the
ignition is on (power mode 6), the message center will display a confirmation message. Any previously stored settings on the
selected memory switch will be over-written.

Memory settings are recalled by pressing the applicable memory switch 1-3. If the ignition is on (power mode 6), the message
center will display a confirmation message.

Front Seat Heating

The front seat heater switches are integral to the Automatic Temperature Control Module (ATCM).
Operation of a seat heater switch is converted to Local Interconnect Network (LIN) bus signal by the Automatic Temperature
Control Module (ATCM). The LIN bus signal is passed to the seat heater control module which is integral with the seat cushion
heater element. The seat heater control module processes the LIN bus signal and outputs the required voltage to the seat
heater elements to maintain the requested temperature.

Three levels of heating are selectable by sequential operation of the switch to select low, medium or high heat settings. The
ATCM detects the switch operation and transmits the appropriate LIN bus signal to the seat heater control module.

Rear Seat Heating

The rear seat heater switches are located in the rear of the floor console.

Operation of a seat heater switch transmits a LIN bus signal from the switch to the ATCM which passes the LIN bus signal to
the rear seat heater control module which is integral with the rear seat cushion heater element. The seat heater control
module processes the LIN bus signal and outputs the required voltage to the seat heater elements to maintain the requested
temperature.

Three levels of heating are selectable by sequential operation of the switch to select low, medium or high heat settings. The
ATCM detects the switch operation and transmits the appropriate LIN bus signal to the rear seat heater control module.

Front Seat Climate

The front seat climate switches are integral to the Automatic Temperature Control Module (ATCM). Operation of a climate seat
switch is detected by the ATCM which send a medium speed CAN comfort systems bus message to the Touch Screen to
display the climate menu. Selections on the menu screen are passed back to the ATCM on the medium speed CAN comfort
systems bus. The ATCM processes the CAN signals and outputs a LIN bus message to the applicable front seat climate control
module. The front seat climate control module processes the LIN bus signals and operates the seat cushion and backrest
climate assemblies as required to heat or cool the seat.

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The seat climate control module uses the signals from temperature sensors in the backrest and the cushion climate
assemblies to regulate the seat at the selected temperature. If full seat heating/cooling is selected, both the backrest and the
cushion climate assemblies are activated. If partial seat heating/cooling is selected, only the backrest climate assembly is
activated.

Climate seat operation will only operate when the engine is running (power mode 6). The power supply to the front seat
climate control modules is controlled by an extended ignition relay in the Central Junction Box (CJB). The thermal electrical
device and the blower in the climate assemblies have a high power demand which is controlled by the CJB to preserve primary
battery power.

Front Seat Lumbar (if fitted)

The lumbar switch is a two-way switch located in the seat switchpack.

A separate power supply is used for the lumbar assembly power supply. Power for the lumbar assembly is from the primary
battery via a fuse and seat relay in the Rear Junction Box (RJB). The relay is controlled by the CJB. The CJB will de-energize
the seat relay to preserve primary battery power if required.

The two-way lumbar switch controls both the lumbar air pump and the solenoid valve. When the switch is moved to the inflate
position, power is supplied through the seat relay contacts to the air pump motor. The air pump motor will operate for as long
as the switch is held in the 'inflate' position, or until the maximum pressure is achieved. When the switch is moved to the
'deflate' position, power is supplied to the solenoid valve which operates to open the valve to deflate the lumbar assembly air
cell.

Second Row Seat Electric Backrest Release (if fitted)

Power is supplied to each seat backrest release motor via a relay the Quiescent Current Control Module (QCCM). The QCCM
can remove power from non-essential systems if primary battery voltage becomes low.

The switch for each seat backrest release motor provides a ground path for the motor. When the ground is completed for
more than 0.5 seconds and the operating criteria have been met, the motor operates, pulling the release cable. When the
switch is released, the ground path is removed and the seat backrest return spring returns the cable and motor to its initial
position.

Each seat backrest release motor is connected on a LIN bus to the Central Junction Box (CJB).

The LIN bus provides control by the CJB for the backrest release motor to make sure that the operating conditions are correct
before releasing the backrest latch.

The following conditions must be met:

The backrest release switch must operated for ore than 0.5 seconds
Vehicle speed must be less than 5 km/h (3 mph)
Tailgate must be open
Ignition must be in powers modes 0, 4, 6 or 7.
Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.

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Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

pressure connections.
 All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of

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refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

8. Following the A/C Charging Trolley manufacturer's instructions,

evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles
 1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

4. Disconnect the A/C Charging Trolley high and low pressure

connections.

Vehicles without auxiliary climate control

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5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm
 Activation

1. Authoring Template

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Published: 15-Jan-2015
Climate Control - Air Distribution and Filtering
Description and Operation

Authoring Template

COMPONENT LOCATION

NOTE: Right Hand Drive (RHD) illustration shown, Left Hand Drive (LHD) illustration similar

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Item Description
1 Driver and passenger face vents
2 Driver and passenger instrument panel center vents
3 Left and right side window vents
4 Driver and passenger face ducts
5 Windshield vents
6 Driver and passenger footwell ducts
7 Filter
 8 Left and right rear footwell ducts
9 Left and right rear footwell vents

OVERVIEW

The air distribution and filtering system controls the distribution and quality of air supplied into the front and rear of the
passenger compartment. The system consists of:

• Air ducts and vents

• and filter.

DESCRIPTION

Air Ducts

The air ducts distribute air from the climate control assembly to the various ducts and vents in the instrument panel and to
the rear of the vehicle.

The face level, side window and windshield ducts form part of the instrument panel assembly.

Each front footwell duct is a snap fit into the side of the heater assembly.

The rear cabin ducts are also a snap fit into the heater assembly. Each rear footwell duct runs underneath the carpet and is
secured to the floor of the vehicle.

Air Vents - Adjustable and Fixed

The adjustable air vents allow the vehicle occupants to control the flow and direction of air from the air ducts. The instrument

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panel contains 4 adjustable vents; 1 mounted on either end of the instrument panel and 2 mounted centrally.

The instrument panel contains 4 fixed air vents; 1 mounted in either 'A' pillar trim and 2 mounted along the top edge, below
the windshield.

Filter

The filter is located behind the passenger side of the instrument panel and is housed within the climate control assembly. The
filter removes odors and fine particles, including pollen, from the air entering the climate control assembly.

OPERATION

For additional information, refer to: Control Components (412-01, Description and Operation).
Published: 30-Apr-2015
Climate Control System - General Information -
Climate Control

NOTE: ROW Vehicles.

Item Specification
Heating, ventilation and air conditioning (A/C)
Dual zone automatic system fitted controlled by ATC module.
unit
Visteon VS16 internally controlled variable capacity air conditioning (A/C)
Compressor
compressor
A/C refrigerant R134a

Climate Control

NOTE: NAS Vehicles.

Item Specification
Heating, ventilation and air conditioning (A/C)
Dual zone automatic system fitted controlled by ATC module.
unit
Visteon VS16 internally controlled variable capacity air conditioning (A/C)
Compressor
compressor
A/C refrigerant HFO-R1234yf

Climate Control

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NOTE: EU Vehicles.

Item Specification
Heating, ventilation and air conditioning (A/C)
Dual zone automatic system fitted controlled by ATC module.
unit
Visteon VS16 internally controlled variable capacity air conditioning (A/C)
Compressor
compressor
A/C refrigerant HFO-R1234yf

Lubricants, Fluids, Sealers and Adhesives

CAUTION: HFO-1234yf systems use the refrigerant oil (Sanden SPA2) and is not compatible with any other refrigerant
oils.

NOTE: The refrigerant oil (Sanden SPA2) is compatible with R134a systems.

Item Specification
A/C compressor oil type Sanden SPA2
System oil quantity Total system oil quantity = 150g. New compressor supplied with 150g.

General Specification
Item Description
A/C compressor Visteon VS16
Sensor locations:
Ambient temperature sensor LH door mirror
Mounted behind a grill on the drivers side of the instrument panel, adjacent the steering
Cabin temperature sensor
column.
Cabin humidity sensor (optional
Located within the interior mirror and comprises 3 individual elements
fit)
Evaporative temperature sensor Mounted on the LH side of the heater casing
High pressure sensor Located between the condenser and the thermostatic expansion valve
Pollution sensor RH side of the heater casing.
Solar sensor Center of dash top

Capacities
Item Capacity
Total system capacity 650 grams ± 10 grams

Refrigerant oil adding capacities for replacment parts

NOTE: Rotate the A/C compressor shaft at least 6 to 8 turns when draining the refrigerant oil.

Item Specification
1. Drain old A/C compressor. With drain plug removed and ports uncapped, rotate shaft to remove A/C
compressor oil and measure the amount of oil captured. 2. Drain new A/C compressor into a clean vessel. With
A/C drain plug removed and ports uncapped, rotate shaft to remove oil. Then add back a quantity of the new oil that
compressor is identical to the quantity of oil removed from the old A/C compressor. However, if this quantity is less than
30ml, then make it up to 30ml.
A/C
Add 30 ml.
condenser
A/C lines,
if the A/C
Add 10 ml per A/C line.
has been
operational

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Published: 17-Jul-2015
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 section in the
workshop manual. REFER to: (412-01 Climate Control)

Air Distribution and Filtering (Description and Operation),

Air Distribution and Filtering (Description and Operation),
Heating and Ventilation (Description and Operation),
Heating and Ventilation (Description and Operation),
Heating and Ventilation (Description and Operation),
Air Conditioning (Description and Operation),
Air Conditioning (Description and Operation),
Air Conditioning (Description and Operation).

Inspection and Verification

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.

NOTES:

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If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation
of a new module/component.

When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.

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
Hoses
Coolant pump
Control flap(s)
Duct(s)
Vent(s)
Cabin air filter
Fuses
Drive belt
Wiring harnesses and connectors
Air conditioning compressor
Automatic temperature control module
Air conditioning compressor clutch
Refrigerant pressure sensor
Thermostatic expansion valve
Blower
Evaporator
Electric cooling fan
Receiver drier
Air conditioning condenser
Refrigerant pipes
Primary drive belt
Fuel fired booster heater
Fuel fired booster heater fuel pump
Fuel fired booster heater fuel pipes

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
Air Conditioning System Performance Check

NOTES:

Normal pressures for a correctly charged and working system are 1.0 bar to 2.0 bar (low pressure system) and 11.0 bar
to 15.0 bar (high pressure system).

Normal temperature (measured at the center air vent) for a correctly charged and working system is approximately 2°C
to 7°C when the ambient temperature is 20°C.

When a failure symptom has been reproduced, refer to the symptom chart. After completing a repair, the air conditioning
performance check should be repeated to confirm that the repair is successful.

1. Close the valves on the air conditioning station

2. Connect the air conditioning station to the vehicle charging ports

3. Check that the gauges register pressure

4. Open all doors and the tailgate

5. Start the engine

6. Set the temperature to the lowest setting (all zones)

7. Set the blower speed to maximum

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8. Set the recirculate switch to on

9. Set the air conditioning to on and check that the air conditioning compressor clutch engages and that the gauges
register a change in pressure

10. Insert a temperature probe into the centre air vent

11. Raise engine speed to 1500rpm and maintain this speed for 5 minutes

12. Check the pressure gauge readings

13. Check the temperature reading

Symptom Chart

Symptom Possible Causes Action

No refrigerant in air conditioning
system (no pressure registered Refrigerant leak GO to Pinpoint Test A.
on gauges)

Air conditioning
Refer to the electrical circuit diagrams and check the air
compressor clutch
conditioning compressor clutch circuit for short circuit to
circuit short circuit
ground, short circuit to power, open circuit, high
to ground, short
Air conditioning compressor circuit to power, resistance. Repair the wiring harness or install a new air
clutch not engaging open circuit, high conditioning compressor clutch as necessary
resistance GO to Pinpoint Test B.
Refrigerant
undercharged

Climate control
system fault
Using the manufacturer approved diagnostic system,
Air conditioning
check the automatic temperature control module for
compressor clutch
related DTCs and refer to the relevant DTC index
circuit short circuit
Air conditioning inoperative (no Refer to the electrical circuit diagrams and check the air
to ground, short
change in pressure when setting conditioning compressor clutch circuit for short circuit to
circuit to power,
the air conditioning to on) ground, short circuit to power, open circuit, high
open circuit, high
resistance. Repair the wiring harness or install a new air
resistance
conditioning compressor clutch as necessary
Air conditioning
GO to Pinpoint Test C.
compressor internal
failure

Electric cooling fan Check the operation of the electric cooling fan
inoperative Check the air conditioning condenser for external
Air conditioning obstructions
Air conditioning operates briefly
condenser airflow Using the manufacturer approved equipment, recover
and then switches off
obstructed the refrigerant. Evacuate and recharge the air
Refrigerant conditioning system with the correct quantity of
overcharged refrigerant and oil

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Refrigerant
contaminated
High and low pressure system
Air conditioning GO to Pinpoint Test D.
pressures unstable
compressor internal
failure

Excessive volume
Using the manufacturer approved equipment, recover
High and low pressure system of oil in the
the refrigerant. Evacuate and recharge the air
pressures normal and refrigerant or
conditioning system with the correct quantity of
insufficient cooling refrigerant
refrigerant and oil
contaminated

Electric cooling fan

inoperative
Air conditioning
condenser airflow
obstructed
Thermostatic
High and low pressure system
expansion valve GO to Pinpoint Test E.
pressures too high
internal failure
Refrigerant
overcharged
Air conditioning
compressor internal
failure

Refrigerant
High and low pressure system undercharged
GO to Pinpoint Test B.
pressures too low Low pressure pipe
damaged/restricted

Low pressure system pressure

too low and high pressure Low pressure liquid
Check the low pressure liquid pipe for damage and
system pressure too high and pipe restricted
restrictions. Install a new pipe as necessary
frost present on the low Receiver drier
Install a new receiver drier as necessary
pressure liquid pipe to the restricted
condensor

Air conditioning
compressor pulley
bearing
Air conditioning
compressor pulley
foul condition
 Air conditioning
compressor clutch
operation
excessively noisy
Air conditioning
Noise from air conditioning compressor internal
failure GO to Pinpoint Test F.
system
Thermostatic
expansion valve
internal failure
Refrigerant
undercharged
Refrigerant
overcharged
Air conditioning
pipe(s) fouling
body
Air conditioning
system blower fault

Remove the evaporator filter

REFER to: Pollen Filter (412-01, Removal and
Installation).
Check the type of filter fitted. The correct filter is a
Incorrect type of
particle filter NOT a carbon filter. If a carbon filter is
evaporator filter
fitted, replace the filter with a new particle filter. Clean
fitted
Air conditioning evaporator odor the evaporator unit and filter housing before refitting the
Water infiltration to

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filter
the evaporator
Check the filter is dry and has not been subject to any
filter
water damage. If the filter is wet or damaged, replace
the interior filter with a new particle filter. Clean the
evaporator unit and filter housing before refitting the
filter

Perform an air conditioning system performance check

(see above) to ascertain if the system is still pressurized.
If there is pressure in the system, either a sniffer-tool or
a UV light may be used to look for system leaks. If there
is no pressure available, use a UV light to check for leaks
Check the security of the fixings that fasten the air
Loose pipes or
conditioning pipes to the thermostatic expansion valve. If
Air conditioning evaporator components
the screws are loose, install new O-rings and refasten
leakage Evaporator internal
screws
failure
Check for leaks around the refrigerant pressure sensor.
If leaks are detected install new O-rings and reinstall the
refrigerant pressure sensor
Remove the glove box and interior filter. Check for leaks
from the evaporator core. If leaks are detected install a
new evaporator as required

Blower motor
Check the blower motor power and ground circuits for
circuit connections
circuit faults and rectify as required
insecure
Check the operation of the blower control module and
Air conditioning blower defective Blower control
rectify as required
module fault
Check that nothing is blocking or obstructing the blower
Blower wheel is
wheel and rectify as required
blocked or jammed

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: Automatic Temperature Control Module (ATCM) (100-00 General Information,
Description and Operation).

Pinpoint Tests

PINPOINT TEST A : LEAK TESTS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: LEAK TEST 1
 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. Using the manufacturer approved equipment,
evacuate and recharge the air conditioning system with the correct quantity of refrigerant and oil
No
Using the manufacturer approved equipment, evacuate and recharge the air conditioning system with the
correct quantity of refrigerant and oil
PINPOINT TEST B : LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO LOW TESTS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
B1: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO LOW TEST 1
1 Stop the engine
2 Using the manufacturer approved refrigerant leak detector, check for a refrigerant leak
Was a refrigerant leak detected?
Yes
Using the manufacturer approved equipment, recover the refrigerant. Repair the leak as necessary.

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Evacuate and recharge the air conditioning system with the correct quantity of refrigerant and oil
No
GO to B2 .
B2: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO LOW TEST 2
1 Using the manufacturer approved equipment, recover the refrigerant
2 Compare the weight of recovered refrigerant to that specified for the vehicle
Was the weight of the recovered refrigerant less than specified for the air conditioning system?
Yes
Using the manufacturer approved equipment, evacuate and recharge the air conditioning system with the
correct quantity of refrigerant and oil
No
Check the low pressure pipes for external damage and restrictions. Repair as necessary
PINPOINT TEST C : COMPRESSOR MECHANICAL TESTS

TEST CONDITIONS DETAILS/RESULTS/ACTIONS

C1: COMPRESSOR MECHANICAL TEST 1
1 Remove the primary drive belt
2 Rotate the air conditioning compressor shaft by hand and check for smooth rotation
Does the air conditioning compressor shaft rotate smoothly?
Yes
Tests inconclusive
No
Install a new air conditioning compressor
PINPOINT TEST D : LOW AND HIGH PRESSURE SYSTEM PRESSURES UNSTABLE TESTS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
D1: LOW AND HIGH PRESSURE SYSTEM PRESSURES UNSTABLE TEST 1
1 Start the engine
2 Set the air conditioning to on
3 Check the pressure gauge readings
4 Set the air conditioning to off
5 Check the pressure gauge readings
Do the pressure gauge readings equalise immediately when the air conditioning is set to off?
Yes
Air conditioning compressor internal failure. Install a new air conditioning compressor
No
Air or moisture present in the air conditioning system. Using the manufacturer approved equipment,
recover the refrigerant. Install a new receiver drier. Evacuate and recharge the air conditioning system
with the correct quantity of refrigerant and oil
PINPOINT TEST E : LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO HIGH TESTS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
E1: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO HIGH TEST 1
1 Start the engine
2 Set the air conditioning to on
3 Check the operation of the electric cooling fan
Is the electric cooling fan operating?
Yes
GO to E2 .
No
Check for foreign objects jamming the electric cooling fan. Refer to the electrical circuit diagrams and
check the electric cooling fan circuit for short circuit to ground, short circuit to power, open circuit, high
resistance
E2: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO HIGH TEST 2
1 Stop the engine
2 Check the air conditioning condenser for external obstructions
Are any external obstructions present?
Yes
Repair as necessary
No
GO to E3 .
E3: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO HIGH TEST 3
1 Start the engine
2 Set the air conditioning to on
3 Check the pressure gauge readings
4 Set the air conditioning to off

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5 Check the pressure gauge readings
Do the pressure gauge readings equalise immediately when the air conditioning is set to off?
Yes
Air conditioning compressor internal failure. Install a new air conditioning compressor
No
GO to E4 .
E4: LOW AND HIGH PRESSURE SYSTEM PRESSURES TOO HIGH TEST 4
1 Stop the engine
2 Using the manufacturer approved equipment, recover the refrigerant
3 Compare the weight of recovered refrigerant to that specified for the vehicle
Was the weight of the recovered refrigerant greater than specified for the air conditioning system?
Yes
Using the manufacturer approved equipment, evacuate and recharge the air conditioning system with the
correct quantity of refrigerant and oil
No
Thermostatic expansion valve internal failure. Install a new thermostatic expansion valve
PINPOINT TEST F : AIR CONDITIONING SYSTEM NOISE TESTS

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
F1: AIR CONDITIONING SYSTEM NOISE TEST 1
1 Reproduce the reported air conditioning system noise
Is the noise present only when setting the air conditioning system to on?
Yes
GO to F3 .
No
GO to F2 .
F2: AIR CONDITIONING SYSTEM NOISE TEST 2
1 Reproduce the reported air conditioning system noise
Is the noise present only when the air conditioning system to operating?
Yes
GO to F4 .
No
GO to F7 .
F3: AIR CONDITIONING SYSTEM NOISE TEST 3
1 Set the air conditioning on and off repeatedly and check the noise made by the air conditioning
compressor clutch
Is the noise made by the air conditioning compressor clutch excessively loud (compare to another similar
vehicle for reference)?
Yes
Refer to the relevant section of the workshop manual and install a new air conditioning compressor
No
No further action
F4: AIR CONDITIONING SYSTEM NOISE TEST 4
1 Check the installation of the air conditioning pipes:
 Check that all brackets are present and secure

Check for foul conditions

Is the noise caused by a problem with the air conditioning pipe installation?
Yes
Rectify as necessary. Re-test the system
No
GO to F5 .
F5: AIR CONDITIONING SYSTEM NOISE TEST 5
1 Set the air conditioning to on and check assess the duration of the noise
Does the noise occur for a short period immediately after setting the air conditioning to on?
Yes
Refer to the relevant section of the workshop manual and install a new thermostatic expansion valve.
Re-test the system
No
GO to F6 .
F6: AIR CONDITIONING SYSTEM NOISE TEST 6
1 Using the manufacturer approved equipment, recover the refrigerant
Was the weight of the recovered refrigerant different than specified for the air conditioning system?
Yes
Using the manufacturer approved equipment, evacuate and recharge the air conditioning system with the
correct quantity of refrigerant and oil
No
GO to Pinpoint Test C.
F7: AIR CONDITIONING SYSTEM NOISE TEST 7
1 Assess the source of the noise

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Is the noise caused by the air conditioning compressor (bearing, contact between rotating and fixed
components)?
Yes
Refer to the relevant section of the workshop manual and install a new air conditioning compressor
No
GO to F8 .
F8: AIR CONDITIONING SYSTEM NOISE TEST 8
1 Assess the source of the noise
Is the noise caused by the air conditioning blower?
Yes
Check that nothing is blocking or obstructing the blower wheel. Rectify as required
No
No further action
Published: 26-Jun-2015
Climate Control - Heating and Ventilation
Description and Operation

COMPONENT LOCATION

NOTE: Right Hand Drive (RHD) shown; Left Hand Drive (LHD) similar.

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Item Description
 1 Blower control module
2 Climate control assembly
3 Body air outlets
4 Automatic Temperature Control Module (ATCM)

OVERVIEW

Two levels of heating and ventilation are available.

Standard specification vehicles are fitted with a dual zone automatic system, which can provide different temperature
settings for the left and right sides of the passenger compartment.
- The dual zone system may also be fitted with a pollution sensor to control the quality of air in the passenger
compartment.
The higher specification also offers a face option for rear passengers through the rear face vents fitted in B-pillar.

The climate control assembly for both systems is installed on the vehicle center line between the instrument panel and the
engine bulkhead as part of the cockpit assembly.

The Automatic Temperature Control Module (ATCM) controls operation of the blower via the blower control module, which is
mounted on the bulkhead side of the climate control assembly casing.

For additional information, refer to: (412-01 Climate Control)

Air Distribution and Filtering (Description and Operation),

Air Conditioning (Description and Operation),
Control Components (Description and Operation).

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DESCRIPTION

Automatic Temperature Control Module (ATCM)

Air distribution and temperature is controlled by the Automatic Temperature Control Module (ATCM), which is integral with the
control panel. In response to commands from the control panel, the ATCM controls operation of 5 stepper motors mounted on
the climate control assembly casing.

For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Climate Control Assembly

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Item Description
1 Blower
2 Air Conditioning (A/C) evaporator
3 Blower control module
4 Coolant heat exchanger
5 Electric booster heater
The climate control assembly controls the temperature of the air supplied to the air distribution ducts, as directed by the
ATCM. The climate control assembly is mounted on the vehicle center line and comprises the following components:

Blower.
Coolant heat exchanger.
Interior filter.
For additional information, refer to: Air Distribution and Filtering (412-01 Climate Control, Description and Operation).
A/C evaporator.
For additional information, refer to: Air Conditioning (412-01 Climate Control, Description and Operation).
Air intake stepper motor.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).
Two distribution motors,
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).
Two temperature blend motors.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).
 Electric booster heater (if fitted).
For additional information, refer to: Electric Booster Heater (412-02 Auxiliary Climate Control, Description and
Operation).

Blower

The blower comprises an open hub centrifugal-fan powered by an electric motor. Operation of the blower is controlled by the
ATCM in conjunction with the blower control module. The ATCM provides a Pulse Width Modulation (PWM) signal to the blower
control module based on the required blower speed. The blower control module interprets the PWM signal as a blower speed
and controls the voltage to the blower accordingly.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Coolant heat exchanger

The coolant heat exchanger provides the heat source to warm the air being supplied into the passenger compartment. The
heater core is an aluminum, two pass fin-and-tube heat-exchanger installed across the width of the climate control assembly.
Two aluminum tubes attached to the coolant heat exchanger extend through the engine bulkhead and connect to the engine
cooling system. When the engine is running, engine coolant is constantly circulated through the coolant heat exchanger by the
coolant pump.

For additional information, refer to: Engine Cooling (303-03A Engine Cooling - INGENIUM I4 2.0L Diesel, Description and
Operation).

Ventilation Outlets

The ventilation outlets allow the free-flow of air through the passenger compartment. The outlets are installed in the left and
right rear quarter panels, behind the tail lamps.

Each ventilation outlet comprises a grille covered by a soft rubber flap, and is effectively a non-return valve. The flaps open

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and close automatically depending on the differential between passenger compartment and outside air pressures.

OPERATION

Operation of the heating and ventilation system is controlled by the Automatic Temperature Control Module (ATCM).
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Published: 15-Jan-2015
Climate Control - Air Distribution and Filtering
Description and Operation

Authoring Template

COMPONENT LOCATION

NOTE: Right Hand Drive (RHD) illustration shown, Left Hand Drive (LHD) illustration similar
 cardiagn.com
Item Description
1 Driver and passenger face vents
2 Driver and passenger instrument panel center vents
3 Left and right side window vents
4 Driver and passenger face ducts
5 Windshield vents
6 Driver and passenger footwell ducts
7 Filter
8 Left and right rear footwell ducts
9 Left and right rear footwell vents

OVERVIEW

The air distribution and filtering system controls the distribution and quality of air supplied into the front and rear of the
passenger compartment. The system consists of:

• Air ducts and vents

• and filter.

DESCRIPTION
Air Ducts

The air ducts distribute air from the climate control assembly to the various ducts and vents in the instrument panel and to
the rear of the vehicle.

The face level, side window and windshield ducts form part of the instrument panel assembly.

Each front footwell duct is a snap fit into the side of the heater assembly.

The rear cabin ducts are also a snap fit into the heater assembly. Each rear footwell duct runs underneath the carpet and is
secured to the floor of the vehicle.

Air Vents - Adjustable and Fixed

The adjustable air vents allow the vehicle occupants to control the flow and direction of air from the air ducts. The instrument
panel contains 4 adjustable vents; 1 mounted on either end of the instrument panel and 2 mounted centrally.

The instrument panel contains 4 fixed air vents; 1 mounted in either 'A' pillar trim and 2 mounted along the top edge, below
the windshield.

Filter

The filter is located behind the passenger side of the instrument panel and is housed within the climate control assembly. The
filter removes odors and fine particles, including pollen, from the air entering the climate control assembly.

OPERATION

For additional information, refer to: Control Components (412-01, Description and Operation).

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Published: 15-Jan-2015
Climate Control - Air Conditioning
Description and Operation

COMPONENT LOCATION - Vehicles without an Internal Heat Exchanger (IHX)

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Item Description
1 Refrigerant pressure sensor
2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection

COMPONENT LOCATION - Vehicles with an Internal Heat Exchanger (IHX)

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Item Description
1 Refrigerant pressure sensor
2 Thermostatic eXpansion Valve (TXV)
3 Evaporator
4 Receiver/Drier
5 Condensor
6 Air Conditioning (A/C) compressor
7 Low pressure line
8 High pressure line
9 Low pressure servicing connection
10 High pressure servicing connection

OVERVIEW

A choice of Air Conditioning (A/C) systems are available with features to enhance the performance for second and third-row
seat passengers.

The system is available in two forms, with an optional rear air conditioning unit.

Manual air conditioning system.

 Two-zone auto system, with separate LCD display controls for driver and front passenger.
Vehicles with 5+2 seating, an optional auxiliary air conditioning unit for third row passengers is available, with controls
for temperature and fan speed.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

The rear air conditioning has a child lock function which disables the rear fan speed control switches. This is feature is
accessed from the Touch Screen.

The A/C system transfers heat from the passenger compartment to the outside atmosphere to provide the climate control
assembly with dehumidified cool air.

The A/C system is a sealed closed-loop system, filled with refrigerant as the heat transfer medium. Refrigerant oil is added to
the refrigerant to lubricate the internal components of the A/C compressor:

R1234yf refrigerant is used in USA and Canada (NAS market); systems with an Internal Heat Exchanger (IHX)
installed.
R134a refrigerant is used in the ROW markets; systems without an Internal Heat Exchanger (IHX).

For additional information, refer to: Specifications (412-01 Climate Control, Specifications).

The compressor is a variable displacement unit, where the displacement (flow of refrigerant) is controlled to match the
thermal load of the evaporator. The type of compressor fitted will depend on engine variant, see below.

The operation of the A/C system is controlled by the Automatic Temperature Control Module (ATCM).
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

DESCRIPTION

The air conditioning system includes the following features:

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B-pillar mounted mid-level vents for row 2 passengers
Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row 3 passengers
A mist sensor on the windscreen, used to detect conditions likely to cause misting
An air quality sensor for detection of pollutant levels. When levels exceed set limits the system switches to
re-circulation mode
Timed climate control to pre-heat the cabin. This function can be activated remotely using the InControl Remote App
ECO mode enables the system to adopt a more economical operating mode.

Air Conditioning Layout with Optional Auxiliary Rear Air Conditioning Unit

Item Description
1 B-pillar mounted mid-level vents for row two passengers
 2 Face-level vents mounted in the C-pillar on vehicles with 5+2 seating, for row three passengers
3 Optional auxiliary air conditioning unit
The optional auxiliary air conditioning unit is discussed in another section.
For additional information, refer to: Auxiliary Climate Control (412-02, Description and Operation).

Air Conditioning Compressor

2.0 GTDi Petrol

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Item Description
1 Pulley with electro-magnetic clutch
2 Refrigerant inlet port
3 Pressure relief valve
4 Electronic control valve connector
5 Refrigerant outlet port
6 Electro-magnetic clutch connector.
TD4 2.2L Diesel
 cardiagn.com
Item Description
1 Pulley with electro-magnetic clutch
2 Electro-magnetic clutch connector
3 Refrigerant outlet port
4 Refrigerant inlet port
5 Electronic control valve connector
6 Pressure relief valve.
Compressor

The Air Conditioning (A/C) compressor is driven by the engine primary drive belt. The compressor circulates refrigerant
around the A/C system by compressing low-pressure, low-temperature vapor from the evaporator and discharging the
resultant high-pressure, high-temperature vapor to the condensor.

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.

Both compressors are variable displacement units. Displacement is controlled by an integral electronic control valve operated
by the Automatic Temperature Control Module (ATCM). The control valve measures the input and output pressures of the
refrigerant entering and leaving the compressor and controls the angle of the internal swash plate accordingly. The ATCM
influences the control to match the thermal load of the evaporator and other factors.
Compressor clutch engagement is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

Condensor

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Item Description
1 Condensor
2 Receiver/drier.
The condensor transfers heat from the refrigerant to the surrounding air to cool the refrigerant and therefore convert the
high-pressure vapor from the compressor into a liquid. The condensor is installed immediately in front of the radiator.

The condensor is classified as a sub-cooling condensor and consists of a fin and tube heat-exchanger core installed between 2
end tanks. Divisions in the end tanks separate the heat exchanger into a 4 pass upper (condensor) section and a 2 pass lower
(sub-cooler) section.

The right end tank provides the connections to the high-pressure line from the A/C compressor and the liquid line to the
evaporator.

Receiver/Drier

The receiver/drier is integral with the condensor left end-tank and removes solid impurities and moisture from the refrigerant.
It also acts as a reservoir for liquid refrigerant to accommodate changes of heat load at the evaporator.
Refrigerant entering the receiver drier passes through a filter and a desiccant pack, then collects in the base of the unit before
flowing through the outlet pipe back to the condensor.

Refrigerant Pressure Sensor

The refrigerant pressure sensor provides the Automatic Temperature Control Module (ATCM) with a pressure input from the
high-pressure side of the refrigerant system. The refrigerant pressure sensor is hardwired to the ATCM, which uses the signal
to control operation of the A/C compressor through the A/C compressor clutch relay in the Battery Junction Box (BJB).
Additionally, the ATCM is able to increase the amount of re-circulated air, if it is required. The ATCM broadcasts the refrigerant
high-pressure value over the medium-speed Controller Area Network (CAN) comfort bus to the Engine Control Module (ECM)
via the Gateway Module (GWM). The ECM calculates the additional load on the engine when the A/C compressor is working.

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For example, this signal is used as an input, for the idle speed control.

The refrigerant pressure sensor is located in the refrigerant line between the condensor and the Thermostatic Expansion Valve
(TXV).

Thermostatic Expansion Valve

Item Description
1 Metering valve
2 Housing
3 Diaphragm
4 Temperature sensor
5 Outlet passage from evaporator
6 Inlet passage to evaporator.
The Thermostatic Expansion Valve (TXV) meters the flow of refrigerant into the evaporator to match the refrigerant flow with
the heat-load of the air passing through the evaporator.

The TXV is a block type valve located behind the climate control assembly, and attached to the inlet and outlet ports of the
evaporator. The TXV consists of an aluminum housing containing inlet and outlet passages. A ball and spring metering valve is
installed in the inlet passage and a temperature sensor is installed in the outlet passage. The temperature sensor consists of a
temperature sensitive tube connected to a diaphragm. The bottom end of the temperature sensitive tube acts on the ball of
the metering valve. Pressure on top of the diaphragm is controlled by the evaporator outlet-temperature conducted through
the temperature sensitive tube. The bottom of the diaphragm senses evaporator outlet pressure.

Liquid refrigerant flows through the metering valve into the evaporator. The restriction across the metering valve reduces the
pressure and temperature of the refrigerant. The restriction also changes the liquid stream of refrigerant into a fine spray, to
improve the evaporation process. As the refrigerant passes through the evaporator, it absorbs heat from the air flowing
through the evaporator. The increase in temperature causes the refrigerant to vaporize and increase in pressure.
The temperature and pressure of the refrigerant leaving the evaporator acts on the diaphragm and temperature sensitive
tube, which regulate the metering valve opening and so controls the volume of refrigerant flowing through the evaporator.
The warmer the air flowing through the evaporator, the more heat available to evaporate refrigerant and thus the greater
volume of refrigerant allowed through the metering valve.

Evaporator

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Item Description
1 Heater core
2 Evaporator.
The evaporator is installed in the climate control assembly, between the blower and the heater core, to absorb heat from the
exterior or re-circulated air. Low pressure, low temperature refrigerant changes from liquid to vapor in the evaporator,
absorbing large quantities of heat as it changes state.

Most of the moisture in the air passing through the evaporator condenses into water, which drains out of the vehicle by
passing through a drain tube to the underside of the vehicle.

Refrigerant Lines

To maintain similar flow velocities around the A/C system the diameter of the refrigerant lines varies to suit the two
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.
Nylon lined, low permeability rubber hoses are used in the low pressure line into the A/C compressor, and in the high pressure
line from the condensor. The remainder of the refrigerant lines are manufactured from aluminum.

Low and high pressure charging connections are incorporated into the refrigerant lines for system servicing.

Internal Heat Exchanger

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Item Description
1 High pressure line
2 Low pressure line
3 Internal Heat Exchanger (IHX)
The Internal Heat Exchanger (IHX) is incorporated within the air conditioning pipes.

The IHX is part of the vehicle's air conditioning system and helps to increase its cooling capacity. The IHX combines a section
of the system's pipework before and after the evaporator into one pipe. It uses the cold vapour exiting the evaporator to cool
the hot liquid before it enters the expansion device, resulting in increased cooling. It also uses the heat to increase the
temperature of the low temperature gas before it enters the compressor. The amount of energy used by the air conditioning
system can be reduced by taking advantage of this increased cooling.

This gives the following benefits:

Helps reduce tailpipe CO2 emissions, due to less engine load

Improved fuel economy, due to reduced compressor power requirements
R1234yf - Increases the system capacity to increase cooling.

OPERATION

Principles of Operation

To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the regimes the refrigerant changes state, during this process the maximum heat
absorption or dissipation occurs.

The low pressure/temperature regime is from the TXV, then through the evaporator to the compressor. The refrigerant
decreases in pressure and temperature at the TXV then changes state from a liquid to a vapour in the evaporator to absorb
heat.

The high pressure/temperature regime is from the compressor, through the condensor and receiver drier assembly to the
thermostatic expansion valve. The refrigerant increases in pressure and temperature as it passes through the compressor;
then releases heat and changes state from a vapour to a liquid in the condenser.
The operation of the A/C system is controlled by the ATCM.
For additional information, refer to: Control Components (412-01 Climate Control, Description and Operation).

NOTE: NOTE: Due to a drop in performance of the R1234yf system when compared to the R134a system an Internal
Heat Exchanger is installed

Input/Output Diagram

System without an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condensor
 7 Receiver/drier
8 A/C compressor
9 Low pressure servicing connection
10 Blower
System with an Internal Heat Exchanger (IHX)

NOTE: NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow

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Item Description
 1 Evaporator
2 TXV
3 High pressure servicing connection
4 Refrigerant pressure sensor
5 Electric cooling fan
6 Condenser
7 Receiver/Drier
8 A/C compressor
9 IHX
10 Low pressure servicing connection
11 Blower

Published: 21-Jul-2015
Engine Cooling - INGENIUM I4 2.0L Diesel - Engine Cooling
Description and Operation

COMPONENT LOCATION

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Item Description
1 Expansion tank
2 Coolant pump
3 Oil cooler
4 Fuel cooler
5 Heater hoses
6 Exhaust Gas Recirculation (EGR)
7 Exhaust Gas Recirculation (EGR) cooler
8 Charger air cooler
9 Transmission fluid cooler
10 Cooling fan
11 Thermostat
12 Coolant pump - electronic

OVERVIEW

The engine cooling system maintains the engine within an optimum temperature range under changing ambient and engine
operating conditions. The system is a pressurized expansion tank system with continuous bleeds to separate air from the
engine coolant and prevent the formation of air locks.
The engine cooling system also provides:

Heating for:
- The passenger compartment.
For additional information, refer to: Heating and Ventilation (412-01, Description and Operation).
Cooling for:
- The engine.
For additional information, refer to: Engine (303-01B, Description and Operation).
- The engine oil cooler.
For additional information, refer to: Engine (303-01B, Description and Operation).
- The automatic transmission fluid (ATF) cooler.
For additional information, refer to: Transmission Cooling (307-02, Description and Operation).
- The exhaust gas recirculation (EGR).

The primary components of the engine cooling system are the:

Coolant pump - variable

Radiator
Electric cooling fan
Coolant expansion tank
Electric thermostat
ATF Cooler
Engine oil cooler
Connecting hoses and pipes.
Cylinder block heater

In cold climate markets, an optional block heater is available as a dealer fit accessory. The block heater is located in the
cylinder block and is connected to a power supply via an external plug.

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DESCRIPTION

Coolant Pump - Variable

Item Description
1 Impeller
2 Shroud
3 Coolant pump housing
4 Pulley
5 Solenoid
The coolant pump is located at the front of the cylinder block. A pulley is attached to the pump flange.

The pulley is driven by the primary drive belt at engine speed.

For additional information, refer to: Accessory Drive (303-05 Accessory Drive - INGENIUM I4 2.0L Diesel, Description and
Operation).

The coolant pump is controlled to give the minimum flow to support all cooling requests from the engine components. The
coolant pump has a shroud inside that slides over the impeller to prevent engine coolant from being pumped into the engine.
The coolant pump generates internal pressure, used to move the shroud.

Pressure is generated with every rotation of the coolant pump. This pressure is then diverted either to the shroud assembly or
leaked back to the engine coolant system, which is controlled by a solenoid valve. Therefore, the shroud will not move if there
is no rotation of the coolant pump.

The control of the solenoid is by a pulse width modulation (PWM) signal from the engine control module (ECM).
For additional information, refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - INGENIUM I4 2.0L Diesel,
Description and Operation).

Any request from 0 – 100% flow can be fulfilled at most engine speeds, contributing to the whole engine thermal
management strategy. The internal pressure within the coolant pump acts against a return spring in the housing. Without a
signal from the ECM the solenoid is open, therefore the shroud returns to its base position under spring force, resulting in full
flow from the coolant pump.

During engine cold start, the impeller is fully covered by the shroud, therefore no engine coolant is pumping into the cylinder
block. As components warm up, the flow request will increase in 5 stages. The coolant pump is controlled to give the
minimum flow to support all cooling requests from the engine components. Upon engine coolant temperature reaching 85
degrees centigrade, the shroud will move to its furthest position allowing maximum pumping, with temperature control
managed by the thermostat.

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The ECM receives input signals from the following components to calculate the level of cooling required:

Cylinder head metal temperature

Cylinder block metal temperature
EGR temperature
Ambient temperature
Engine coolant temperature
Selected drive mode

Control of engine coolant flow reduces engine load. The foremost objective in this respect is reducing fuel consumption under
all operating conditions, in addition to reducing emissions.

Radiator
 Item Description
1 Overflow pipe connection
2 Radiator
3 Lower hose connection
4 Charge air cooler fill connection
5 Upper hose connection
The radiator is a vertical flow type with an aluminum core and plastic end tanks in the upper and lower position of the
radiator. The radiator uses brazed aluminum tube technology to reduce weight. A low temperature zone is located at the left
side of the radiator and provides cooled engine coolant for the ATF cooler.

The radiator is located in the vehicle by locating spigots and supports integrated into the end tanks. The supports are installed
in rubber isolator bushes in the lower support bracket. The upper mounting of the end tanks is via a cross-strut attached to
the vehicle body.

A drain plug is integrated into the bottom left end tank. Coolant outlet and inlet connections are incorporated into the left and
right end tanks respectively. The right end tank also has a connection for coolant outlet to the ATF cooler and to the auxiliary
radiator.

There is a connection to the charge air cooler to allow filling and bleeding of that system. The charge air cooler has a stand
alone cooling circuit with its own radiator, pump and pipe work.
For additional information, refer to: Intake Air Distribution and Filtering (303-12B, Description and Operation).

Electric Cooling Fan

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Item Description
1 Fan shroud
2 Cooling fan motor
3 Electrical connection
4 Speed flaps
An electric, variable speed cooling fan is installed in a shroud attached to the rear of the radiator. The cooling fan is operated
by an electric cooling fan control module, integrated into the electric motor, under the control of the ECM via a PWM signal. An
electrical connector at the right side of the shroud provides the interface between the cooling fan harness and the vehicle
wiring.

The electric cooling fan control module is provided with:

A battery power supply from the engine junction box (EJB)..

 An ignition signal from the ECM relay in the EJB.
A PWM signal from the ECM.
A ground.

The ECM varies the PWM signal to the fan control module between 0 and 100% to operate the fan motor in one of four
modes:

Off
Minimum speed (750 rev/min).
Linear variable speed between minimum and maximum speeds.
Maximum speed (2820 rev/min).

Under hot operating conditions, the electric cooling fan may continue to operate for up to five minutes after the engine has
been switched off.

The system is protected against abnormal internal temperature by measuring its internal temperature at two points with
temperature sensors.

Sensor 1 : This sensor is used to calculate the temperature of active components near the micro controller. The fan
will stop immediately if the fan internal temperature reaches 135ºC (275ºF). At motor stop, after a delay of 120
seconds the diagnostic feedback will be sent. Normal operation will resume once the temperature is less than 120ºC
(248ºF).

Sensor 2 : This sensor is used to measure the temperature of the power stage of the PCBA (near the metal oxide
semi-conductor field effect transistors (MOSFETs)) to reduce the power if the temperature is too high (derating) and to
stop the motor in case of an over temperature condition.

The fan will derate if the powerstage internal temperature reaches 135ºC (275ºF) and stop motor function at 145ºC (293ºF).
At motor stop, after a delay of 120 seconds the diagnostic feedback will be sent. Normal fan operation will resume once the

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powerstage temperature falls to 135ºC (275ºF).

Coolant Expansion Tank

Item Description
1 Pipe connection – coolant expansion line from radiator
2 Pipe connection – coolant expansion line from engine thermostat housing
3 O-ring seal
4 Cap
5 Bolt and washer
6 Coolant expansion tank
 7 Location grommet
8 Coolant level sensor
9 Hose connection to coolant pump
The coolant expansion tank is located in the left side of the engine compartment. The tank is located by a grommet on its
underside and positively secured with a bolt and washer to a bracket on the vehicle body and a second bracket that locates in
a molded slot in the tank body.

The coolant expansion tank has three connections; one for radiator bleed, one for engine bleed and one for outlet to the
thermostat housing.

An engine coolant level sensor is located in the underside of the tank body. The sensor reacts to the influence of a magnetic
field. A float, with integral magnet, is located inside the tank, over the sensor tube. The sensor has contacts inside the tube,
which are normally open. When the fluid level reduces, the magnetic float moves down the tube. When the magnet reaches
the sensor contacts, the magnetic field closes the contacts. The sensor connects hardwired to the Central Junction Box (CJB)
which receives the signals from the sensor. Maximum and minimum marks are molded on the tank body.

The coolant expansion tank provides the following functions:

Service fill.
Coolant expansion during warm-up
Air separation during operation.
System pressurization by the filler cap.

Electric Thermostat

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Item Description
1 Thermostat housing
2 Heater element
3 Temperature sensor
The electric thermostat independently controls the engine coolant flow to the cylinder head and cylinder block, improving
engine warm-up times. The thermostat contains a wax expansion element. Inside the wax element is a heater element. When
energised the heating element heats the wax element, partially controlling the thermostat function, along with engine coolant
temperature control. Operation is therefore performed not only by the engine coolant temperature, but as specified by the
ECM, enabling a finer control of the opening and closing of the thermostat. Opening of the thermostat is at a temperature of
95ºC +/- 2ºC (203ºF +/- 4ºF).

The electrically heated thermostat is used to regulate the engine coolant temperature by the ECM. The increased wax
temperature provides higher engine coolant temperature during part load conditions and at low speed cycles. The increased
engine coolant temperature results in reduced friction in the engine, improved combustion in the cylinders, and reduced fuel
consumption and emissions. An electric thermostat heater element assembled within the wax element to regulate the engine
coolant temperature during high load conditions and speed points to protect the engine from thermal overload.

Operation of the electric thermostat is controlled by the ECM upon the following inputs:

Engine load
Engine speed
Vehicle speed
Engine coolant temperature
Intake air temperature

The electric thermostat has a battery feed from the EJB located in the right front of the engine compartment, a switched
power supply from the ECM relay, located in the left EJB a hardwired connection to the ECM and a ground connection. If the
ECM starts to regulate the system, the ECM supplies a ground path for the heater element in the electric thermostat. This
causes the element to expand and increase the opening dimension of the thermostat.

Automatic Transmission Fluid (ATF) Cooler

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Item Description
1 Coolant inlet
2 ATF cooler
3 Coolant outlet
The ATF cooler is secured to the left side of the transmission main casing with three bolts. The ATF cooler has three lugs
which locate in corresponding lugs on the transmission main casing and secured with a screw. The ATF cooler is an aluminum
housing comprising louvred fins and plates. The plates allow a cross-flow of ATF and engine coolant through the ATF cooler.

The plates are immersed in engine coolant from the 'cold' side of the radiator which provides cooling of the ATF. The ATF
cooler receives engine coolant from the low temperature zone at the end third of the radiator. The engine coolant flow
through this section of the radiator is restricted by the ATF cooler. Therefore the engine coolant has a slower flow rate across
the cooling tubes of this section of the radiator. This cools the engine coolant more than the main section of the radiator and
consequently provides increased cooling of the ATF. The engine coolant then passes from the ATF cooler into the radiator
bottom hose.

The ATF cooler has an integral thermostatic valve, which controls the ATF flow through the cooler. Flow is restricted to
improve ATF warm-up time. The thermostatic valve is closed at temperatures of 78°C (172°F) and below, starts to open at
temperatures of between 78 and 84°C (172 and 183°F) and is fully open at temperatures of 96°C (204°F) and higher.

For additional information, refer to: Transmission Cooling (307-02, Description and Operation).

Fuel Cooler
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Item Description
1 Coolant outlet
2 Fuel outlet
3 Fuel inlet
4 Coolant inlet
5 Mounting bracket
The fuel cooler is located on left side of the engine, under the engine cover, mounted on a bracket.

The coolant inlet and outlet pipes are connected to the corresponding pipes of the charge air cooler circuit. The electric coolant
pump circulates the coolant in this circuit.

For additional information, refer to: Intake Air Distribution and Filtering (303-12B, Description and Operation).

The fuel inlet connection is connected to the fuel rail and the outlet is connected to the fuel filter.

For additional information, refer to: Fuel Charging and Controls (303-04C, Description and Operation).

Engine Block Heater

Item Description
A 110 V Alternating Current (AC) version
B 240 V AC version
For vehicle markets subject to very cold climatic conditions, an engine block heater is installed in place of the cylinder block
drain plug on the left side of the engine block. The engine block heater is either a 110 V AC or 240 V AC electric heater
element (depending on the market), which can be connected to a domestic power supply via a connector in the left side grill
of the front bumper.

OPERATION

When the thermostat is fully open, the by-pass circuit is closed and allows maximum engine coolant flow through the radiator
system to provide maximum engine cooling. From the engine coolant outlet the majority of the engine coolant is passed
through the radiator and the ATF cooler to the coolant pump, with a proportion still passing through the turbocharger, heater
core and engine oil cooler.

When the thermostat is open the engine coolant flow from the radiator bottom hose passes through a venturi. This venturi
creates a depression which pulls engine coolant through the ATF cooler. The upper section of the radiator provides low
temperature cooling of the engine coolant for the ATF cooler.

The engine coolant expansion tank accommodates expansion of engine coolant due to temperature changes.

Electric Cooling Fan

The electric cooling fan is operated by a fan control module which is located at the rear of the cooling fan motor. The electric
cooling fan control module regulates the voltage, and subsequently the speed, of the cooling fan motor in response to a PWM
signal from the ECM. The ECM calculates the required fan speed from the engine temperature, Air Conditioning (A/C) system
pressure and ATF temperature. Under hot operating conditions, the fan may continue to operate for up to five minutes after
the engine has been switched off.

The speed of the cooling fan is also influenced by vehicle road speed. The ECM adjusts the speed of the cooling fan to
compensate for the ram effect of vehicle speed, using the High Speed (HS) Controller Area Network (CAN) powertrain bus to

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receive the speed signal from the Anti-lock Brake System (ABS) control module.

INPUT/OUTPUT DIAGRAM

A = Hardwired; AL = Pulse Width Modulation (PWM); AN = High Speed (HS) Controller Area Network (CAN) Powertrain Bus
Item Description
1 Engine Control Module (ECM)
2 Anti-lock Braking System (ABS) Control Module
3 Cooling fan motor
4 Electric thermostat
5 Coolant pump
 6 Coolant pump - Charge air cooler cooling circuit
7 Ground
8 Power supply
9 Electric thermostat - temperature sensor
10 Coolant pump
11 Engine Cooling Temperature (ECT) sensor

Published: 26-Jun-2015
Auxiliary Climate Control - Electric Booster Heater
Description and Operation

COMPONENT LOCATION

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Item Description
1 Climate control assembly
2 Electric booster heater

OVERVIEW

Due to the slower warm up times associated with some engines, an electric booster heater may be fitted to increase heater
performance. The electric booster heater does this by heating the air leaving the coolant heat exchanger assembly. The
electric booster heater comprises ceramic coated thermistor elements and a micro-controller. A request for electric booster
heater operation originates in the Automatic Temperature Control Module (ATCM). This request is in the form of a Pulse Width
Modulation (PWM) percentage and is transmitted to the electric booster heater micro-controller.

The amount of heating requested by the ATCM is based on:

Ambient air temperature.

Engine coolant temperature.
Heating request.

NOTE: There is also a minimum blower-motor speed required for the electric booster heater operation.

The electric booster heater is limited to 1.25kW. If electrical load management is in force, electric booster heater performance
will be reduced.
DESCRIPTION

Electric Booster Heater

The electric booster heater is installed in the climate control assembly, on the downstream side of the heater core. It consists
of ceramic coated Positive Temperature Coefficient (PTC) thermistor elements, rated at 1.25kW, and a micro-controller.
Electrical power for the booster heater is supplied via a 100A megafuse. The CJB provides the electric booster heater with
ignition feed also, by the ignition relay and a 5A fuse. Operation of the electric booster heater is controlled by the Automatic
Temperature Control Module (ATCM).

OPERATION

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General

The electric booster heater consists of a matrix, containing ceramic coated PTC elements, which is installed in the climate
control assembly. On vehicles without an electric booster heater, a baffle plate is installed in place of the booster heater.

Operation of the electric booster heater is activated by the ATCM using Pulse Width Modulation (PWM) signal. The ATCM uses
the following inputs from the Controller Area Network (CAN) bus, to control operation of the electric booster heater:

Climate control system selections from the ATCM and the Touch Screen (TS), through the Medium Speed (MS) CAN
Comfort and Body buses, via the GateWay Module (GWM).
Ambient air temperature and engine coolant temperature from the Engine Control Module (ECM) via the HS CAN
Powertrain bus.

The ATCM requests operation of the electric booster heater, provided the vehicle is not in transit mode and there are no
generator faults recorded, when the following conditions occur:

The engine is running.

The blower is on (any speed).
Heating is requested on the ATCM, or on the menu of the Touch Screen, and the desired vent temperature (calculated
by the ATCM), is not being achieved.
The ambient air temperature is less than 10°C (50°F).
The engine coolant temperature is less than 90°C (194°F).
Battery charge state is more than 10A.

The duration of the PWM pulses requested by the ATCM is proportional to the amount of heating required.

If the electrical load management is in force, the electric booster heater performance is reduced by the modification of the
PWM signal.

For additional information, refer to: Generator (414-02B Generator and Regulator - INGENIUM I4 2.0L Diesel, Description and
Operation).

The ATCM discontinues request of operation of the electric booster heater if the ambient temperature increases to 15°C
(59°F), or any of the other required conditions ceases to exist.

The ATCM monitors the control circuits of the electric booster heater and records a Diagnostic Trouble Code (DTC) if it detects
a short or open circuit.

Control Diagram
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NOTE: A = Hardwired, O = Local Interconnect Network (LIN) bus; AN = High Speed (HS) Controller Area Network (CAN)
Powertrain bus; AO = Medium Speed (MS) CAN Body bus; AP = MS CAN Comfort bus.
Item Description
1 Automatic Temperature Control Module (ATCM)
2 Engine Control Module (ECM)
3 Gateway Module (GWM)
4 Touch Screen (TS)
5 Generator
6 Ground
 7 Power supply
8 Electric booster heater
9 Engine Junction Box (EJB)
10 Battery
11 Ambient Air Temperature (AAT) sensor
12 Engine Coolant Temperature (ECT) sensor
13 Battery Monitoring System (BMS) control module

Published: 14-Oct-2014
Climate Control - Control Components
Description and Operation

COMPONENT LOCATION

Component Location - Sheet 1 of 2

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 cardiagn.com

Item Description
1 Left temperature blend motor
2 Left distribution motor
3 Blower
4 Pollution sensor (dual zone climate control system only)
5 Right distribution motor
6 Right temperature blend motor
7 Air intake stepper motor
 8 Evaporator temperature sensor
9 Automatic Temperature Control Module (ATCM)
10 In-vehicle temperature sensor
11 Sunload sensor
12 Blower control module
13 Refrigerant pressure sensor
Component Location - Sheet 2 of 2

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Item Description
 1 Humidity sensor
2 Ambient air temperature sensor
3 Engine Coolant Temperature (ECT) sensor (TD4)
4 ECT sensor 1 (GTDI)
5 ECT sensor 2 (GTDI)
6 Air conditioning compressor (TD4)
7 Air conditioning compressor (GTDI)

OVERVIEW

The climate control system incorporates the heating, ventilation and A/C systems. There are 2 main types of climate control
system available:

a single zone manual system

a dual zone automatic system

The climate control functions for the single zone manual system is controlled by the Manual Temperature Control Module
(MTCM). The MTCM is mounted in the center console and contains both the system electronic software and user controls.

The climate control functions for the dual zone automatic system is controlled by the Automatic Temperature Control Module
(ATCM). The ATCM is mounted in the center console and contains both the system electronic software and user controls.

The MTCM or ATCM (vehicle specification dependant) works in conjunction with a number of other vehicle control modules,
including the ECM (engine control module), which controls a number of climate control sub-systems on receipt of requests
from the MTCM or ATCM.

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The single zone manual system features manual control for air temperature, air distribution and air source, although a small
amount of automatic control does exist in the MTCM software. In response to system inputs, the MTCM controls the operation
of 3 motors mounted on the heater assembly. The motors then adjust the position of the air temperature, air distribution and
air source flaps accordingly.

The dual zone automatic system features automatic control of air temperature, air distribution and blower speed. The ATCM is
also able to control individual temperature requests for both the driver and passenger side of the cabin.

NOTE: The ATCM can only maintain a maximum temperature difference between the 2 sides of the cabin of up to
approximately 3ºC (4ºF). This is due to the movement and mix of air within the cabin.

The dual zone automatic system features two additional sensors; an in-vehicle temperature sensor and a sunload sensor. The
In-vehicle temperature sensor provides a temperature feedback to enable the ATCM software to maintain a constant cabin
temperature. The sunload sensor provides a reading of solar loading on the vehicle occupants and enables the ATCM to adjust
the output from the climate control system accordingly.

Higher specification versions of the dual zone climate control system are also available. These systems feature 2 more
additional sensors; a pollution sensor and a humidity sensor.

The pollution sensor detects pollutants entering the cabin, allowing the ATCM to react by changing the position of the air
intake flap. The humidity sensor calculates the probability of misting on the windshield. The ATCM monitors the signal from
the humidity sensor and adjusts blower speed, air distribution and A/C compressor displacement accordingly.

Stop/Start System

To support the Stop/Start system, a number of features are integrated into the logic and operation of the climate control
system within a Stop/Start cycle to:

maintain occupant comfort

prevent windshield misting
conserve battery power.

This has been achieved by the ATCM monitoring and varying when necessary, various climate control functions within a
Stop/Start cycle. For additional information, refer to:

For additional information, refer to: Starting System (303-06A Starting System - INGENIUM I4 2.0L Diesel, Description and
Operation).

To maintain the passenger compartment temperature when the engine is shutdown in a Stop/Start cycle, an auxiliary electric
coolant-pump has also been integrated into the cooling system to maintain the coolant flow through the cabin’s heater core.
The pump is directly hardwired to the ECM. On vehicles fitted with a FFBH (Fuel Fired Booster Heater), the FFBH coolant pump
is utilized and activated via the FFBH.

For additional information, refer to: Fuel Fired Booster Heater (412-02 Auxiliary Climate Control, Description and Operation).

DESCRIPTION
Manual Temperature Control Module (MTCM)

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The MTCM is mounted in the instrument panel and is integral with the control panel. The MTCM works in conjunction with the
ECM to control all aspects of heating, ventilation, and A/C. An electrical connector on the rear of the MTCM provides hardwired
and Medium Speed (MS) CAN comfort bus connections to allow interaction with A/C system components and other vehicle
control modules.

Automatic Temperature Control Module (ATCM)

The ATCM is mounted in the instrument panel and is integral with the control panel. The ATCM works in conjunction with the
ECM to control all aspects of heating, ventilation, and A/C. An electrical connector on the rear of the ATCM provides
hardwired, MS CAN comfort bus connections and Local Interconnect Network (LIN) bus message to allow interaction with A/C
system components and other vehicle control modules.

In addition to the A/C system, the MTCM or ATCM (whichever installed) controls operation of:

The seat heaters

The rear window heater
The windshield heater
The exterior mirror heaters
The climate seat switches.

MTCM or ATCM (whichever installed) logic and operation of climate control system, within a Stop/Start cycle to:

maintain occupant comfort

prevent windshield misting
conserve battery power.

This has been achieved by the manual / automatic temperature control module monitoring and varying, as necessary various
climate control functions within a Stop/Start cycle.

In some circumstances the manual / automatic temperature control module has the capability to inhibit an engine shutdown
or initiate an engine restart within a Stop/Start cycle. This is achieved by the manual / automatic temperature control module
communicating with the CJB on the medium speed CAN Comfort and Body bus, by the help of the GWM. The various override
functions the manual / automatic temperature control module has in a Stop/Start cycle are discussed below:

Coolant temperature

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The manual / automatic temperature control module will inhibit an engine shutdown or initiate an engine restart within a
Stop/Start cycle if the coolant temperature falls below the calculated threshold to support the cabin temperature set by the
vehicle occupants.

Windshield demisting

The variant of climate control fitted to the vehicle influences the software changes that have been made. For example, the
single zone manual system does not have a humidity sensor, as used on a duel zone automatic system to initiate a windshield
demist. Therefore, a calculation for demisting the windshield is made using the signals from the rain sensor and ambient
temperature sensor. Using the probability that windshield misting will occur if it is raining and the ambient temperature is
cool, the manual / automatic temperature control module will presume a windshield demist is required and start the engine
when in a Stop/Start cycle.

Evaporator temperature the main cause of windshield misting is also monitored and the high-line climate control system will
periodically cool the evaporator as necessary to reduce misting during a Stop/Start cycle. The system operates the windshield
demist shutter and if the evaporator is wet the shutter will remain closed for a few seconds after an engine restart until the
vapor is dissipated.

If the driver selects either ‘programmed defrost’ or the ‘windshield heater’ it is assumed that a quick demist of the windshield
is required. Therefore, the manual / automatic temperature control module via the CJB will either: inhibit an engine shutdown
or initiate an engine restart.

Blower speed (dual zone automatic system only)

During an engine shutdown the ATCM monitors passenger compartment temperature and maintains the blower speed at a
level that will conserve, for as long as possible the heat in the core of the passenger compartment heater. If the driver selects
a higher fan speed and the heat cannot be maintained in the heater core, the engine will restart.

Heated rear window and heated seats

If the heated rear window or heated/climate seats are active or activated during an engine shutdown event the power output
of the relevant system will be interrupted until the engine is restarted. The tell-tale light in the relevant switch will illuminate
to indicate the system is active even though the system is receiving no power. This feature is used to conserve battery power.

Fuel Fired Booster Heater

The FFBH (Fuel Fired Booster Heater) and Stop/Start system will not operate simultaneously, due to low ambient
temperatures being a factor in the function of both systems.

A/C Compressor Pressure Control Valve

All vehicle variants are fitted with a variable displacement A/C compressor. Displacement is controlled by an integral electronic
control valve operated by the ATCM. The control valve measures the input and output pressures of the refrigerant entering
and leaving the compressor and controls the angle of the internal swash plate accordingly. The ATCM influences the control to
match the thermal load of the evaporator and other factors. Compressor clutch engagement is controlled by the ATCM.
For additional information, refer to: Air Conditioning (412-01 Climate Control, Description and Operation).

Refrigerant Pressure Sensor

The refrigerant pressure sensor provides the manual / automatic temperature control module with a pressure input from the
high pressure side of the refrigerant system. The pressure sensor is located in the refrigerant line between the condenser and
the thermostatic expansion valve.

The manual / automatic temperature control module supplies a 5 V reference feed to the pressure sensor and receives a
return signal voltage, between 0 V and 5 V, related to system pressure. The manual / automatic temperature control module
uses the signal from the sensor to protect the refrigerant system from extremes of pressure.

If the pressure within the refrigerant system exceeds the minimum or maximum pressure limits, the manual / automatic
temperature control module will de-energize the A/C compressor clutch relay in the BJB.

The manual / automatic temperature control module constantly sends a refrigerant system pressure signal on the medium

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speed CAN Comfort bus. The signal is converted to HS CAN Powertrain bus message via the GWM, which is received for
example by the ECM.

If the pressure within the refrigerant system rises above its maximum pressure limit, the manual / automatic temperature
control module will increase the amount of re-circulated air entering the cabin. This helps lower the pressure within the
refrigerant system and thus helps to avoid having to disable the A/C compressor.

Evaporator Temperature Sensor

The evaporator temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The sensor is mounted on the left
side of the heater casing, and measures the temperature of cooled air once it has traveled over the evaporator. The sensor
receives a 5 V reference feed from the manual / automatic temperature control module by monitoring the returned voltage,
the manual / automatic temperature control module can calculate the resistance of the sensor and hence evaporator
temperature.

In-Vehicle Temperature Sensor (dual zone automatic system only)

The in-vehicle temperature sensor comprises a NTC thermistor and a motor. The sensor is mounted behind a grill on the
driver’s side of the instrument panel, adjacent the steering column.

The motor is provided an electrical feed from the ATCM and draws cabin air in through the grill and over the thermistor. The
thermistor receives a 5V reference feed from the ATCM. By monitoring the returned voltage, the ATCM can calculate air
temperature within the passenger compartment.

Humidity Sensor (dual zone automatic system only)

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The humidity sensor is located on the windscreen and comprises 3 individual elements:

A humidity sensor
An air temperature sensor
A windshield glass temperature sensor.

NOTE: NOTE: The cabin humidity sensor is an optional fit only.

The readings from these 3 sensors combine to reduce the risk of misting on the windshield.

The humidity sensor element is contained behind a nylon mesh cover. The sensor comprises an element made up of film
capacitors on different substrates. The dielectric is a polymer which absorbs or releases water proportional to the humidity of
the air being drawn through the sensor. This causes a change in the capacitance of the sensor.

Humidity within the passenger compartment is controlled by raising or lowering the temperature of the evaporator. An
increase in evaporator temperature increases the moisture content of the air in the vehicle. Lowering the evaporator
temperature reduces the moisture content of the air in the passenger compartment.

The capacitance of the sensor, together with both temperature values, is provided as LIN bus messages to the ATCM. The
ATCM uses these signals to calculate the dew point of the air at the windshield. When the temperature of the windshield glass
reaches or falls below this value, misting is likely to occur. In this instance, the ATCM will:

raise the temperature of the air leaving the heater assembly

adjust the position of the windshield distribution (defrost) stepper motor
adjust the position of the air intake stepper motor
the power windshield heater elements.

Ambient Air Temperature Sensor

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The AAT sensor is a NTC thermistor, and is mounted in the left door mirror. The sensor receives a 5V reference feed from the
ECM. By monitoring the returned voltage, the ECM can calculate the resistance of the sensor and hence ambient air
temperature. The ECM transmits an ambient air temperature value over the HS CAN Powertrain bus. This value is relayed to
the manual / automatic temperature control module by the GWM over the HS CAN Powertrain bus.

Sunload Sensor (dual zone automatic system only)

The sunload sensor is mounted in the center of the instrument panel upper surface. The sensor contains a photoelectric cell,
which provides the CJB with an input of light intensity equating to the solar heating effect on the cabin.

The solar heating value is transmitted via a hardwired connection ATCM. The ATCM compensates for the solar heating effect
by adjusting blower speed, air output temperature and air distribution to maintain the required cabin temperature.

Pollution Sensor (dual zone automatic system only)

The pollution sensor allows the ATCM to monitor intake air for the level of carbon monoxide (CO) and oxides of nitrogen
(NOx). The sensor is mounted on the passenger side of the heater casing.

The pollution sensor is provided an ignition controlled feed from the ATCM and provides one of the following 4 signals to the
ATCM, based on ambient air quality:

Static or reduced pollution levels

Small increase in pollution levels
Medium increase in pollution levels
Rapid or large increase in pollution levels.

Based on the signal from the pollution sensor, the ATCM is able to control the intake air source to reduce the amount of

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contaminants entering the cabin. This function is fully automatic, but can be overridden by manual selection of the air intake
source using the fresh/re-circulated air switch on the control panel.

OPERATION

Intake Air Control - Single Zone Manual System

The intake air source is controlled manually by pressing the fresh/recirculated air switch located on the MTCM. When pressed,
the MTCM will illuminate the switch tell-tale Light Emitting Diode (LED) and close the air intake door. A second press of the
switch will cause the MTCM to extinguish the switch LED and open the air intake door, allowing fresh air to enter the cabin.

NOTE: The MTCM will reduce the amount of fresh air entering the cabin to reduce the ram effect caused by forward
motion of the vehicle.

When recirculated air is selected, the MTCM will return the air intake door to the open position after a period of 3 minutes.
This helps prevent misting within the cabin. The 3 minute time period for recirculated air can be overridden by pressing and
holding the fresh/recirculated air switch until the switch LED flashes 3 times. The air intake door will now remain closed until
the next drive cycle.

The MTCM controls the position of the air intake door via a hardwired connection to the air intake door motor. A Hall effect
sensor located within the motor informs the MTCM that movement of the motor is taking place.

Intake Air Control - Dual Zone Automatic System

The intake air source is controlled automatically unless overridden by pressing the fresh/recirculated air switch located on
ATCM. Under automatic control, the ATCM determines the required position of the air intake door using its 'comfort' algorithm
based on inputs from the ambient air temperature sensor, the In-vehicle temperature sensor and the pollution sensor.

NOTE: NOTE: The ATCM will reduce the amount of fresh air entering the cabin to reduce the ram effect caused by
forward motion of the vehicle.

When the vehicle first enters power mode 6 (ignition on), the 'AUTO' tell-tale LED on the fresh/recirculated air switch will be
illuminated and the air intake source will be automatically controlled by the ATCM. A single press of the fresh/recirculated air
switch will extinguish the 'AUTO' tell-tale LED and illuminate the 'MAN' tell-tale LED. The ATCM will now close the air intake
door and provide only recirculated air into the cabin for a period of 3 minutes. After this period, the ATCM will return the air
intake door to automatic control. This helps prevent misting within the cabin.

A second press of the fresh/recirculated air switch will extinguish both the 'AUTO' and 'MAN' tell-tale LED's. The ATCM will now
control the intake air source according to ambient air temperature and requested cabin temperature. The air intake door will
be opened to allow fresh air into the cabin, but a small amount of recirculated air will also be present. The amount of
recirculated air is determined by the ATCM using its 'comfort' algorithm based on inputs from the ambient air temperature
sensor and the in-vehicle temperature sensor.

A third press of the fresh/recirculated air switch returns the air intake source to automatic control and will illuminate the
'AUTO' tell-tale LED.
The 3 minute time period for recirculated air can be overridden by pressing and holding the fresh/recirculated air switch until
the switch LED's flash 3 times. The air intake door will now remain closed until the next drive cycle.

The ATCM controls the position of the air intake door via a hardwired connection to the air intake door motor to the air intake
door motor. A Hall effect sensor located within the motor informs the ATCM that movement of the motor is taking place.

Air Temperature Control - Single Zone Manual System

Cabin temperature selection is made by turning the left rotary controller to the required position. Turning the controller
counter clockwise will lower the temperature of the air exiting the heater assembly; turning the controller clockwise will raise
the temperature of the air exiting the heater assembly.

Maximum heating and cooling is represented on the control panel by a red and blue dot respectively. When either maximum
heating or cooling is selected, the 'comfort' algorithm in the MTCM will adopt a suitable strategy for air source, air distribution
and blower speed to maintain maximum heating or cooling within the cabin.

The MTCM adjusts the temperature of the air exiting the heater assembly by moving the position of the temperature blend
door. The temperature blend door directs a proportion of cooled air from the evaporator through the heater core to produce
the required temperature output. The MTCM adjusts the position of the temperature blend door by providing LIN bus
messages to the blend door motor. A Hall effect sensor located within the motor informs the MTCM that movement of the
motor is taking place.

Temperature Control - Dual Zone Automatic System

Dual zone systems feature 2 rotary heating controllers, which allow individual climate control for the left and right sides of the
cabin. Temperature selection can be made by turning the controller to the required temperature marked on the control panel.
Turning either controller past the 16°C (61°F) mark will initiate the maximum cooling strategy; turning either controller past
the 28°C (82°F) mark will initiate the maximum heating strategy.

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NOTE: Maximum cooling or heating can only be achieved if both rotary controllers are set to the same position.

The ATCM is able to maintain constant temperatures in both sides of the cabin by monitoring the feedback from the in-vehicle
temperature sensor. Unless any manual overrides have been selected, the ATCM will automatically control the intake air
source, air distribution into the cabin and blower speed to maintain the required temperatures.

Dual zone systems feature 2 temperature blend doors, allowing individual temperature output for the left and right sides of
the cabin.

NOTE: The driver's side temperature setting has priority over the passenger's side temperature setting.

The temperature blend doors are mounted on the left side of the heater assembly and direct a proportion of cooled air from
the evaporator through the heater core to provide the required temperature outputs. The ATCM controls the position of the
temperature blend doors by providing LIN bus messages to the blend door motors. Hall effect sensors located within the
motors inform the ATCM that movement of the motors is taking place.

Blower Control - Single Zone Manual System

Blower speed is set by turning the right rotary controller to the required position. Turning the controller fully counter clockwise
will turn the blower off.

Operation of the blower is controlled by the MTCM via the blower control module. The MTCM provides a Pulse Width
Modulation (PWM) signal to the blower control module based on the selected blower speed. The blower control module
interprets the PWM signal as a blower speed and controls the voltage to the blower accordingly.

Blower Control - Dual Zone Automatic System

Blower speed is controlled automatically by the ATCM unless a manual override has been requested. Manual overrides to
blower speed can be made by turning the central rotary controller to the required position. The rotary controller allows the
manual selection of blower speeds. Turning the controller fully counter clockwise will turn the blower off. When a manual
override has been made, the 'AUTO' LED will extinguish.

The blower can be returned to automatic control by pressing the 'AUTO' switch. Under automatic control, the ATCM varies the
speed of the blower in line with its 'comfort' algorithm to maintain the required cabin temperature. The ATCM will also vary
the blower speed to compensate for the ram effect on intake air produced by forward movement of the vehicle.

Operation of the blower is controlled by the ATCM via the blower control module. The ATCM provides a PWM signal to the
blower control module based on the required blower speed. The blower control module interprets the PWM signal as a blower
speed and controls the voltage to the Blower accordingly.

Air Distribution Control - Single Zone Manual System

Air distribution into the cabin can be adjusted by turning the central rotary controller to the required position. The MTCM
adjusts the position of the air distribution door to the required position via a hardwired connection to the air distribution door
motor. A Hall effect sensor located within the motor informs the MTCM that movement of the motor is taking place.
Air Distribution Control - Dual Zone Automatic System

Air distribution into the cabin is controlled automatically by the ATCM unless any manual overrides have been requested.
Manual overrides can be made by pressing the air distribution switch on the ATCM. If a manual override has been requested,
the 'AUTO' LED will extinguish.

Air distribution can be returned to automatic control by pressing the 'AUTO' switch. This will illuminate the 'AUTO' LED and
allow the ATCM to control air distribution in line with its 'comfort' algorithm.

Air distribution is controlled by 2 air distribution doors. The ATCM controls the position of the air distribution doors by
providing LIN bus messages to the door motors. Hall effect sensors located within the motors inform the ATCM that
movement of the motors is taking place.

Air Conditioning (A/C) On/Off - Single Zone Manual System

Pressing the A/C On/Off switch on the MTCM will switch off the A/C system. When selected, the MTCM will transmit a message
over the HS CAN powertrain bus to the ECM requesting the A/C compressor is disabled. The ECM disables the compressor by
de-energizing the A/C compressor control relay. The tell-tale LED in the switch will illuminate to alert the vehicle occupants
that the A/C system is switched off.

When A/C system is switched off, temperature control is still available but no cooling of intake air will take place. The
minimum output air temperature from the system will be ambient air temperature plus any heat pick up in the air intake path.

A/C can be switched back on by pressing the A/C On/Off switch a second time. This will also extinguish the 'A/C' LED.

A/C On/Off - Dual Zone Automatic System

Pressing the A/C On/Off switch on the ATCM will switch off the A/C system. When selected, the ATCM will transmit a message
over the HS CAN powertrain bus to the ECM requesting the A/C compressor is disabled. The ECM disables the compressor by

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de-energizing the A/C compressor control relay. The tell-tale LED in the switch will illuminate to alert the vehicle occupants
that the A/C system is switched off.

When A/C system is switched off, temperature control is still available but no cooling of intake air will take place. The
minimum output air temperature from the system will be ambient air temperature plus any heat pick up in the air intake path.

A second press of the will extinguish the 'A/C' LED and illuminate the 'OFF' LED. When in 'OFF' mode the ATCM sets the blower
speed to 0. Air distribution into the cabin will remain as previously selected. All LED's on the control panel will be
extinguished, although night time illumination will remain active.

NOTE: When in 'OFF' mode, the heated seat, heated windshield and heated rear window functions will still be available.

A third press of the A/C On/Off switch returns the system to normal (A/C) operation and extinguishes the 'OFF' LED. The
system can be returned to automatic operation at any time by pressing the 'AUTO' switch.

Programmed Defrost (dual zone automatic system only)

The function is selected by pressing the 'MAX' momentary switch on the ATCM. When selected, the ATCM provides maximum
windshield defrosting/demisting by configuring the system as follows:

'AUTO' mode off

Intake air set to fresh air
Air distribution set to windshield
Blower motor speed set to maximum
Heated windshield on
Rear window heater on.

When programmed defrost is selected, the set temperature will remain unchanged. Programmed defrost can be cancelled by
any of the following methods:

Pressing any air distribution momentary switch

Pressing the 'AUTO' switch
Pressing the 'MAX' momentary switch a second time.

NOTE: NOTE: Blower motor speed can be adjusted without terminating programmed defrost.

Heated Windshield (Where Fitted)

Heated windshield operation is only enabled when the engine is running. The manual / automatic temperature control module
controls operation of the heated windshield using a relay in the Battery Junction Box (BJB). When a request is made for
heated windshield operation, the manual / automatic temperature control module broadcasts a message to the GWM on the
MS CAN comfort bus, the GWM then relays this message on to the CJB using the MS CAN body bus. On receipt of the
message, the CJB energizes the relay by providing a ground path for the relay coil. This allows a battery feed to flow across
the relay to power the left and right heater elements.

There are 2 modes of heated windshield operation; manual and automatic.

Manual operation is activated by pressing the heated windshield switch. When the switch is pressed, the status LED in the
switch illuminates and the windshield heater elements are energized. Manual operation is discontinued when the heated
windshield switch is pressed a second time, between 2 and 5 minutes have elapsed (dependent on ambient air temperature),
or the engine stops. If manual operation is discontinued by the engine stopping, the previous heating phase is resumed if the
engine is re-started within 30 seconds.

There are 2 variants of automatic operation; automatic operation at the start of a journey and automatic operation during a
journey.

Automatic operation at the start of a journey is initiated for between 2 and 5 minutes have elapsed (dependent on ambient air
temperature). The warmer the ambient air temperature, the shorter the time. In this instance, the switch LED is illuminated
and the heater elements are energized. In addition to shorter operating times in temperate winter conditions, there are
condition qualifiers to prevent subsequent operations once the cabin, engine or screen is warm, or there is a significant
sunload. Automatic operation is discontinued if the heated windshield switch is pressed or the engine stops.

NOTE: This feature can be selected on and off on the Settings page of the Climate menu in the touch screen.

Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been traveling for a set period of time above a threshold speed. In this instance, no feedback is given to inform the driver that
the heated windshield is operational (the switch LED is not illuminated) and the duration of operation is variable depending
upon the ambient air temperature, vehicle speed and the amount of time the vehicle has been travelling.

Heated Rear Window

Heated rear window operation is only enabled when the engine is running. The manual / automatic temperature control
module controls operation of the heated rear window using a relay in the CJB. When a request is made for heated rear window
operation, the manual / automatic temperature control module broadcasts a message to the Gateway Module (GWM) on the
MS CAN comfort bus, the GWM then relays this message on to the CJB using the MS CAN body bus. On receipt of this

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message, the CJB energizes the relay by providing a ground path for the relay coil. This allows a battery feed to flow across
the relay to power the heater element.

There are 2 modes of heated rear window operation; manual and automatic.

Manual operation is activated by pressing the heated rear window switch. When the switch is pressed, the status Light
Emitting Diode (LED) in the switch illuminates and the rear window heater element is energized. Manual operation is
discontinued when the heated rear window switch is pressed a second time, between 5 and 21 minutes have elapsed
(dependent on ambient air temperature), or the engine stops. If manual operation is discontinued by the engine stopping, the
previous heating phase is resumed if the engine is re-started within 30 seconds.

There are 2 variants of automatic operation; automatic operation at the start of a journey and automatic operation during a
journey.

Automatic operation at the start of a journey is initiated for between 5 and 21 minutes (dependent on ambient air
temperature). The warmer the ambient air temperature, the shorter the time. In this instance, the switch LED is illuminated
and the heater element is energized. In addition to shorter operating times in temperate winter conditions, there are condition
qualifiers to prevent subsequent operations once the cabin or engine is warm, or there is a significant sunload. Automatic
operation is discontinued if the heated rear window switch is pressed or the engine stops

NOTE: This feature can be selected on and off on the Settings page of the Climate menu in the touch screen.

Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been traveling for a set period of time above a threshold speed. In this instance, no feedback is given to inform the driver that
the heated rear window is operational (the switch LED is not illuminated) and the duration of operation is variable depending
upon the ambient air temperature, vehicle speed and the amount of time the vehicle has been travelling.

Door Mirror Heaters

The operation of the door mirror heaters are activated by pressing of the rear window heater switch, which is located on
manual / automatic temperature control module. The door mirror heaters will then remain active for the rest of the ignition
cycle, based upon ambient air temperature and PWM (Pulse Width Modulation) percentage level. If the ambient air
temperature is less than 8°C (46°F) the door mirror heaters work on 50%, between 8°C and 16°C they work on 33% and
over 16°C they go to 0% when does not rain and 25% when rains. The ambient air temperature value is provided by the ECM
on the HS CAN Powertrain bus. On receipt of this temperature value, the manual / automatic temperature control module
calculate the required PWM percentage.

The CJB requests door mirror heating by transmitting a medium speed CAN Body bus message to both the drivers and
passenger door modules. The door modules provide feed and ground paths to the respective door mirror heating elements.
When ambient and engine coolant temperature rises above the values stated earlier, the CJB transmits a CAN bus message to
the door modules cancelling the heating request.

Seat Heaters

The operation of the seat heaters is controlled by the manual / automatic temperature control module on receipt of a heating
request from either of the seat heater momentary switches located on the control panel. The switches are mounted in the
manual / automatic temperature control module. A single press of a seat heater switch will implement high level heating and
illuminate a tell-tale LED. A second press of the switch will implement mid-level heating and illuminate 2 tell-tale LED's. A
third press of the switch will implement low level heating and illuminate 3 tell-tale LED's. A fourth press of the switch will turn
the seat heater off.

Seat heating requests are transmitted from the manual / automatic temperature control module to the seat heater control
modules on the LIN bus. Two seat heater control modules are fitted, one under each front seat. The seat heater control
modules provide an electrical supply to the seat heater elements and a temperature sensor located in the seat cushion.

The seat heater control module provides a 5 V reference feed to the seat heater temperature sensor. The seat heater
temperature sensor is an NTC thermistor. By monitoring the returned voltage, the control module can calculate the
temperature of the seat. If the temperature rises above the target temperature, the control module will disable operation of
the heater elements.

Climate seats are controlled via the manual / automatic temperature control module and the touch screen display.
For additional information, refer to: Seats (501-10 Seating, Description and Operation).

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Published: 22-Jul-2015
Climate Control - Air Conditioning (A/C) Compressor Clutch INGENIUM I4 2.0L
Diesel
Removal and Installation

Removal

CAUTIONS:

The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.

Make sure that all openings are sealed. Use new blanking caps.

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

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

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stands.

Raise and support the vehicle.

2. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).

3. Refer to: Accessory Drive Belt (303-05A Accessory Drive -

INGENIUM I4 2.0L Diesel, Removal and Installation).

4.

5.
NOTE: Discard the bolt after removal.

Torque: 14 Nm
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6.
WARNING: Wear safety goggles.

NOTE: Discard the retaining clip.

7.
WARNING: Wear safety goggles.

NOTES:

Note the orientation of the component prior to

removal.

Discard the retaining clip.

Note the fitted position.

 8.
Note the fitted position.

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Installation

1.
NOTE: Make sure that the component is
installed to the position noted on removal.

Note the fitted position.

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2.
WARNING: Wear safety goggles.

NOTE: Install a new retaining clip.

Note the fitted position.

Fit new circlip.

3.
WARNING: Wear safety goggles.

Fit new circlip.

4.

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5.
CAUTION: Make sure that a new bolt is
installed.

Torque: 14 Nm
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6.

7.

8. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).

Published: 13-Jul-2015
Accessory Drive - INGENIUM I4 2.0L Diesel - Accessory Drive Belt
Removal and Installation

Removal

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

Engine shown removed for clarity.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Remove the front right wheel and tire.

Refer to: Wheel and Tire (204-04, Removal and Installation).

4.
CAUTION: Take extra care not to damage the

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component.

5.
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6. Insert a suitable tool, where illustrated, to prevent
tension being applied to the accessory belt.

7.
NOTE: Note the fitted position of the accessory
drive belt.
Installation

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1.
CAUTION: Make sure that the accessory drive belt is
correctly aligned to the pulleys. Failure to follow this instruction may
result in damage to the vehicle.

To install, reverse the removal procedure.

Published: 01-Oct-2013
Front End Body Panels - Engine Undershield
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

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.
NOTE: Loosen the bolt, but do not fully remove.

Torque: 10 Nm
3. Torque: 10 Nm

4.
NOTE: Do not disassemble further if the
component is removed for access only.
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Installation

1. To install, reverse the removal procedure.

cardiagn.com
Published: 14-Jul-2015
Climate Control - Air Conditioning (A/C) Compressor INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

cardiagn.com
4. Refer to: Engine Undershield (501-02 Front End Body Panels,
Removal and Installation).

5. Refer to: Accessory Drive Belt (303-05A Accessory Drive -

INGENIUM I4 2.0L Diesel, Removal and Installation).

6. CAUTIONS:

Make sure that all openings are sealed. Use new

blanking caps.

Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

Torque: 25 Nm

7.
 8. Torque: 25 Nm

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Installation

1. To install reverse the removal procedure.

Published: 13-Jul-2015
Accessory Drive - INGENIUM I4 2.0L Diesel - Accessory Drive Belt
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

Engine shown removed for clarity.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Remove the front right wheel and tire.

Refer to: Wheel and Tire (204-04, Removal and Installation).

4.
CAUTION: Take extra care not to damage the
component.

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5.
 cardiagn.com
6. Insert a suitable tool, where illustrated, to prevent
tension being applied to the accessory belt.

7.
NOTE: Note the fitted position of the accessory
drive belt.
Installation

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1.
CAUTION: Make sure that the accessory drive belt is
correctly aligned to the pulleys. Failure to follow this instruction may
result in damage to the vehicle.

To install, reverse the removal procedure.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect

CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.

NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring 6. Install the battery cover
system (BMS) module electrical
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
8. Switch the ignition on
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release
switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector

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8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,
release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.
Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

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pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
 equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

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8. Following the A/C Charging Trolley manufacturer's instructions,
evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

 4. Disconnect the A/C Charging Trolley high and low pressure
connections.

Vehicles without auxiliary climate control

5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

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Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Activation

1. Authoring Template

Published: 01-Oct-2013
Front End Body Panels - Engine Undershield
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.
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.
NOTE: Loosen the bolt, but do not fully remove.

Torque: 10 Nm

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3. Torque: 10 Nm

4.
NOTE: Do not disassemble further if the
component is removed for access only.
Installation

cardiagn.com
1. To install, reverse the removal procedure.
Published: 14-Oct-2014
Climate Control - Air Conditioning (A/C) Pressure Transducer
Removal and Installation

Removal

WARNING: Wear safety goggles and protective gloves.

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Refer to: Plenum Chamber (412-01, Removal and Installation).

2. CAUTIONS:

Extreme cleanliness must be exercised when

handling these components.

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Make sure that all openings are sealed. Use new
blanking caps.

Torque: 8 Nm

Installation

1. To install, reverse the removal procedure.

Published: 17-Nov-2014
Climate Control - Ambient Air Quality Sensor
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2. Refer to: Central Junction Box (CJB) (418-00, Removal and

Installation).

3.

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4. Torque: 10 Nm

5.
 cardiagn.com
6.

7.
NOTE: LH illustration shown, RH is similar.
 cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Climate Control - Ambient Air Temperature Sensor
Removal and Installation

Removal

1.
The ambient air temperature sensor is an integral part of the
door mirror and cannot be removed. A new door mirror must be
installed.

Refer to: Exterior Mirror (501-09, Removal and Installation).

Installation

1. To install, reverse the removal procedure.

cardiagn.com
Published: 17-Nov-2014
Climate Control - Blower Motor Resistor RHD AWD/RHD FWD
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2. Refer to: Glove Compartment (501-12, Removal and Installation).

3. Torque: 1.5 Nm

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Installation

1. To install, reverse the removal procedure.

Published: 16-Oct-2014
Climate Control - Climate Control Assembly
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

Some components shown removed for clarity.

Removal steps in this procedure may contain installation details.

1. Refer to: Floor Console Upper Section (501-12, Removal and

Installation).

2.

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3.

4.
NOTE: Repeat the step for the other side.
5.
NOTE: Repeat the step for the other side.

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6.
NOTE: Repeat the step for the other side.

7.
 NOTE: Repeat the step for the other side.

8.

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9.

10.
 NOTE: Repeat the step for the other side.

11.

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12.

13.
 NOTE: Do not disassemble further if the
component is removed for access only.

Installation

cardiagn.com
1. To install, reverse the removal procedure.
Published: 12-Aug-2015
Climate Control - Condenser INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -

cardiagn.com
General Information, General Procedures).

3.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

4. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and

Installation).

5. Torque: 10 Nm

6.
CAUTION: Extreme cleanliness must be
exercised when handling these components.

NOTES:

Remove and discard the O-ring seals.

 Lubricate the O-ring seals with clean refrigerant
oil.

Torque: 24 Nm

7.

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8.
CAUTION: Take extra care not to damage the
component.

Torque: 5 Nm
 cardiagn.com
9.
NOTE: This step is only required if a new
component is installed.

Torque: 6 Nm

Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Bumpers - Front Bumper Cover
Removal and Installation

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

1.

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2.

3.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

4.
NOTE: The step must be carried out on both sides.

Refer to: Fender Splash Shield (501-02, Removal and Installation).

5.

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6.

7.
CAUTION: Be prepared to collect escaping
fluids.
 8. Torque: 10 Nm

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9.
NOTE: The step must be carried out on both
sides.

Torque: 10 Nm

10.
 CAUTION: Protect the surrounding paintwork to avoid
damage.

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11. NOTES:

The step must be carried out on both sides.

Do not disassemble further if the component is

removed for access only.
12.

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13.
NOTE: The step must be carried out on both
sides.

Torque: 2 Nm

14.
16.
15.

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17.

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18.
CAUTION: Make sure that the component is
correctly located on the locating dowels.

NOTE: Note the orientation of the component prior

to removal.
 cardiagn.com
19.
NOTE: The step must be carried out on both
sides.

20.
NOTE: The step must be carried out on both
sides.
 cardiagn.com
21.
NOTE: The step must be carried out on both
sides.

Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect

CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.

NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1

cardiagn.com
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring
system (BMS) module electrical 6. Install the battery cover
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
8. Switch the ignition on
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release
switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector
8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,
release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
 12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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

cardiagn.com
away from open flame and heat sources.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.

Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

pressure connections.
All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the

cardiagn.com
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.
 8. Following the A/C Charging Trolley manufacturer's instructions,
evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

cardiagn.com
Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

4. Disconnect the A/C Charging Trolley high and low pressure

connections.

Vehicles without auxiliary climate control

5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm
Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high

cardiagn.com
and low pressure connections.

Torque: 6 Nm

Activation

1. Authoring Template
Published: 12-Jan-2015
Climate Control - Defrost Vent/Register Blend Door Actuator RHD AWD/RHD FWD
Removal and Installation

Removal

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

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00, Description and

Operation).

2. Refer to: Steering Column (211-04, Removal and Installation).

3.

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Installation

1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Land Rover

approved diagnostic equipment.
Published: 30-Sep-2014
Climate Control - Demist Duct
Removal and Installation

Removal

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

1. Refer to: Specifications (414-01, Specifications).

2. Refer to: Standard Workshop Practices (100-00, Description and

Operation).

3. Refer to: Instrument Panel Upper Section (501-12, Removal and

Installation).

4. Torque: 1.5 Nm

cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 01-Jun-2016
Climate Control - Desiccant Bag INGENIUM I4 2.0L Diesel
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: Condenser - INGENIUM I4 2.0L Diesel (412-01 Climate

Control, Removal and Installation).

3. Torque: 11 Nm

cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 15-Oct-2014
Climate Control - Driver Side Register
Removal and Installation

Removal

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

1.
NOTE: Right illustration shown, Left is similar

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2.

3. Torque: 6 Nm
 cardiagn.com
4.
CAUTION: Care must be taken to avoid
damaging the driver side register internal components.

Torque: 1.5 Nm

Installation

1. To install, reverse the removal procedure.

cardiagn.com
Published: 17-Nov-2014
Climate Control - Evaporator Vehicles With: 9HP48 9-Speed Automatic Transmission
- AWD, RHD
Removal and Installation

Removal

NOTES:

The removal of this component involves cutting an aperture in the evaporator housing wall and cutting through the high
and low pressure A/C lines. A service repair kit is supplied to cover this procedure.

Removal steps in this procedure may contain installation details.

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00 General Information,

Description and Operation).

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General

cardiagn.com
Information, General Procedures).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

3. Refer to: Steering Column (211-04 Steering Column, Removal and

Installation).

4. Refer to: Thermostatic Expansion Valve - GTDi 2.0L Petrol/GTDi

2.0L Petrol - SULEV (412-01 Climate Control, Removal and
Installation).
Refer to: Thermostatic Expansion Valve - INGENIUM I4 2.0L Diesel
(412-01 Climate Control, Removal and Installation).

5. Refer to: Floor Console Upper Section (501-12 Instrument Panel

and Console, Removal and Installation).

6. Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake

Actuation, Removal and Installation).

7.
 8.

9.

10.
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13.
12.
11.

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16.
15.
14.

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 17.

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18.
CAUTION: Make sure that the area around the
component is clean and free of foreign material.

Installation

1. To install, reverse the removal procedure.

2.
Apply the foam strips from the service kit to the
evaporator core.

3.

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4.

5.
NOTE: Install new O-ring seals.

Torque: 5 Nm
Published: 30-Sep-2014
Steering Column - Steering Column
Removal and Installation

Removal

CAUTION: Make sure that the road wheels are in the straight ahead position.

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

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00 General Information,

Description and Operation).

2. Refer to: Steering Wheel (211-04 Steering Column, Removal and

Installation).

3. Refer to: Driver Lower Air Bag Module (501-20B, Removal and
Installation).

4.

5.
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6.

7. Torque: 10 Nm
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8.

9.
CAUTION: Discard the bolt.

Torque: 30 Nm
 10. Torque: 25 Nm

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11.
NOTE: Do not disassemble further if the
component is removed for access only.

Using a suitable stud extraction tool, remove the tamper

proof bolts.

Installation
 1.
WARNING: Make sure that a new steering column flexible
coupling bolt is installed.

CAUTION: Tighten the new tamper proof bolts until the hexagon
shears.

To install, reverse the removal procedure.

2. If a new component is installed, the soft lock stop reset routine

should be completed on the power steering system, using the
approved diagnostic tool.

Published: 14-Oct-2014
Climate Control - Thermostatic Expansion Valve GTDi 2.0L Petrol/GTDi 2.0L Petrol -
SULEV
Removal and Installation

Removal

NOTES:

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Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).

3. Refer to: Engine Control Module (ECM) (303-14A Electronic Engine

Controls - INGENIUM I4 2.0L Diesel, Removal and Installation).

4. CAUTIONS:

Make sure that all openings are sealed. Use new

blanking caps.

Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

Torque: 9 Nm
 5. Torque: 4 Nm

Installation

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1. To install, reverse the removal procedure.

Published: 20-Oct-2014
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging GTDi 2.0L Petrol
General Procedures

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.
Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

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pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
 equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

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8. Following the A/C Charging Trolley manufacturer's instructions,
evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV
(412-01, Removal and Installation).

All vehicles

10.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

11. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

12.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

13. Disconnect the A/C Charging Trolley high and low pressure
connections.

Vehicles without auxiliary climate control

 14. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Vehicles with auxiliary climate control

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15. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Published: 05-Jul-2013
General Information - Standard Workshop Practices
Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

- Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle moving
forwards or backwards.
- Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
- If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust fumes.
- There is adequate room to raise the vehicle and remove the wheels, if necessary.
- Fender covers are always installed if any work is to be carried out in the engine compartment.
- Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is
raised.

CAUTION: Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery
disconnection/connection.
For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a
surge of current causing damage to the internal components of the generator.

- If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Battery - General

CAUTION: Prior to carrying out any procedures which involve disconnecting/ or connecting the battery, refer to the
Electrical Section of this manual - Battery disconnection/connection.

For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

CAUTIONS:

A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be
an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper
cables are connected.

While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only
practical way to mobilize a vehicle. Prior to attempting a jump start, reference must be made to the Electrical Section of this
manual - Jump Starting.

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Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged off the
vehicle as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of
eight hours continuous driving with no additional loads placed on the battery.

- Always make sure that the jumper cables are adequate for the task.
- Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be
connected in parallel.
- Always make sure that switchable electric circuits are switched off before connecting jumper cables. This reduces the
risk of arcing occurring when the final connection is made.

Towing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section of this
Manual.

When the vehicle is being towed dock the remote control and switch on the ignition. (steering lock released and warning lights
illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these
instructions may result in personal injury. It must be noted that with the engine not running, the power steering and brake
booster will be inoperative therefore, greater effort will be needed to steer the vehicle and apply the brakes.

General Installation Instructions

Component removal

Whenever possible, clean components and the surrounding area before removal.

Blank off openings exposed by component removal.

Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
Seal open ends of exposed oilways using suitable tapered hardwood plugs or conspicuous plastic plugs.
Immediately a component is removed, place it in a suitable container; use a separate container for each component
and its associated parts.
Clean bench and provide marking materials, labels and containers before disassembling components.

Disassembling

Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or hydraulic
system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if trapped in these
systems.

Blow out all tapped holes, crevices, oilways and fluid passages with dry, compressed air.

WARNING: Suitable eye protection must be worn.

Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate cracks or
distortion.
 Wire or tape mating parts together where necessary to prevent accidental interchange.
Suitably identify parts which are to be renewed and to those parts requiring further inspection. Keep these parts
separate.
To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until after
comparing it with the new part.

Cleaning Components

Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned. NEVER use
gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned is compatible with the
cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the environment in
which the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.

General Inspection of Components

All components should be inspected for wear or damage before reassembling.

Always make sure that component to be inspected is clean and free from oil or grease.
When a component is to be checked dimensionally against design specified values, use the appropriate measuring
equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
Always make sure that all measuring equipment is correctly calibrated before use.
Reject a component which is not within specified values/limits or if it appears to be damaged.
A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in
an undamaged condition.
Bearing journal clearances should be checked where necessary using Plastigauge.

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Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install O-rings
using the fingers only.

Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.

CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.

Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with its part
number will be found listed in the relevant repair operation and also in the sealants table.

CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified solvents
where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Make sure that sealing surfaces are free from oil or grease as sealants will not adhere properly to contaminated surfaces.

Do not allow sealant to enter tapped holes or oilways.

Locking Devices

Always replace locking devices with one of the same design and of the correct size.

Tab washers

Always release locking tabs before loosening fixings, do not reuse tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips

Always install new circlips ensuring that they are of the correct size for the groove.

Woodruff keys

Woodruff keys may be reused provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins
Never attempt to straighten and reuse a split pin, always make sure that replacement pins are of the correct size for the hole
in which they are to be installed.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap
or die impairs the strength and fit of the threads and is not recommended.

NOTES:

During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this
is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and
thread is used.

New Taptite bolts when used cut their own threads on the first application.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts
having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the
repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread
locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque

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reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or
faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages,
these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve
tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.

Where it is stated that bolts and screws may be reused, the following procedures must be carried out:

Check that threads are undamaged.

Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.

Make sure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M
or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the strength
grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol stamped on the
flats of the hexagon.

Encapsulated ('Patched') bolts and screws

Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture. Most thread
locking agents are colored, the band of color extending for 360 degrees around the thread. Some locking agents however, are
neutral in color and may not be so easily identified apart from a slightly darker area of thread where the locking agent has
been applied. The locking agent is released and activated by the tightening process and is then chemically cured to provide
the locking action.

Self-locking bolts and screws

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Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can be reused
provided that resistance is felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are identified
by the presence of a colored section of thread extending approximately 180 degrees around the thread or by a colored plug
inserted into the bolt.

Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into which it is
screwed.

CAUTION: Do Not reuse self-locking fasteners in critical locations e.g. drive plates/flywheel or engine bearings. Do not
install non self-locking fasteners where a self-locking fastener is specified.

Trilobular bolts should not be used as a substitute for patched bolts.

Nut identification
A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol 8, 12,
14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the hexagonal flat
opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external chamfers or a
face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two dots
identify the 12 o'clock position.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should be
selected.

Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.

Self-locking nuts

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Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and strength grade
installed.

Ball and Roller Bearings

When removing and installing bearings, make sure that the following practices are observed to make sure component
serviceability:

CAUTION: Service tools have been developed for removing the majority of bearings; these must always be used where
specified.

Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute cleanliness
throughout operations.
Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or inner surfaces of
inner rings. Reject any bearings found to be marked since marking in these areas indicates onset of wear.
Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it revolves
absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check or obstruction to
rotation. Reject bearing if movement is not absolutely smooth.
Check bearing for blueing or signs of overheating.
Lubricate bearing with the specified lubricant.
Inspect bearing surface of shaft and bearing housing for discoloration or other markings which indicate overheating of
bearing or movement between bearing and seating.
Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair unless it is
suspected that one bearing may have been faulty when installed, was installed incorrectly or the fault arose due to oil
seal failure.
Never reinstall a bearing unless it is in a fully serviceable condition.
 When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing a bearing into a
housing, only apply force to the outer ring of the bearing.

CAUTION: Service tools have been developed for installing the majority of bearings; these must always be used where
specified.

In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the recommended
grade of grease before installing the seal.

CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that grease does not

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contaminate the running surface of the seal.

Always make suitable reference marks between the components of separable bearings e.g. taper roller bearings when
disassembling to make sure correct location of components when assembling. Never install new rollers in an outer
ring, always install a new bearing assembly.

Brake Pads and Linings

Always install the correct grade and specification of brake pads and linings. When replacing these items, always replace as
complete axle sets.

Brake Hydraulics

Always observe the following recommendations when working on the braking system:

WARNING: Do not intermix brake fluid of different specifications.

Always use two spanners when loosening or tightening brake pipes or hose connections.
Make sure that hoses run in a natural curve and are not kinked or twisted.
Install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact a potential
chafing point.
Containers used for brake fluid must be kept absolutely clean.
Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of the
fluid.
Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake fluid in a
container which has previously been used for storing other fluids.
Do not reuse brake fluid which has been bled from the system.
Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
Always install blanking plugs to hoses, pipes or components immediately after disconnection.
Check thread compatibility of original equipment with replacement components.
Observe absolute cleanliness when working with hydraulic components.

Pipes and Hoses

When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are observed to make
sure component serviceability:

Prior to removal, clean area around hose or pipe end which is to be disconnected.
Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that connections can
be plugged immediately following disconnection.
Always install blanking plugs or caps to pipes and unions immediately following disconnection.
Clean hose or pipe and blow through with an air line.

WARNING: Suitable eye protection must be worn.

 Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace faulty
hoses.
Check pipes for signs of corrosion and chafing, replace as necessary.

CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further problems in service.

When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked, twisted or
positioned close to potential chafing points.
When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
Always replace sealing washers installed to banjo bolts, sealing plugs etc.
Always use a backing spanner when tightening unions and do not overtighten union nuts or banjo bolts.
After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working pressure to
the brake pedal or operates the system that has been worked on.

Fuel system hoses

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All fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core. Whenever a hose is
removed, make sure that the inner bore is inspected to check that the viton lining has not become separated from the outer
sleeve.

WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors the fuel hose and connectors must
be replaced as an assembly.

Fuel system hose clips

Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip is
tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new clips on
reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by any other
method, do not install any other type of clip.

Cooling system hoses

CAUTION: The following precautions must be observed to make sure that the integrity of the cooling system hoses and
their connection to the system is maintained.

Hose orientation and connection

Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or damaged through
contact with adjacent components.
Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when the hose
is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe provides a positive
indicator.

Hose clips

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Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position the clip
directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the crimped side of the
drive housing facing towards the end of the hose or the hose may become pinched between the clip and the stub pipe
retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft). Make sure that hose clips do not
foul adjacent components.

Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be reused.
When installing new clips, make sure clip is positioned on hose before tightening and make sure that when clip is tightened,
the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).

Heat protection

Always make sure that heatshields and protective sheathing are in good condition; replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine components such as the exhaust manifolds and exhaust gas
recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement is taken into account when
routing and securing hoses.

Electrical Precautions

General
The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the electrical and
electronic components of this vehicle.

Equipment

Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working correctly and
that any harness or connectors are in good condition. It is particularly important to check the condition of all plugs and leads
of mains operated equipment.

Polarity

Never reverse connect the vehicle battery and always make sure the correct polarity when connecting test equipment.

High voltage circuits

Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to contact
other components, particularly ECU's.

Vehicles installed with Bi-Xenon headlamp bulbs

WARNING: The following precautions must be observed as failure to comply may result in exposure to ultra-violet rays,
severe electric shock, burns or risk of an explosion.

Safety goggles and gloves must be worn.

Make sure that headlamps are switched off before removing bulbs.
Do not touch the glass portion of the bulb.
On no account should headlamps be switched on with the bulb removed from the headlamp.

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Bulb testing may only be carried out with the bulb installed in the headlamp.
Bulbs must be disposed of in accordance with the local authority bye-laws.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always
observe the following:

Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other liquid
contamination. Any such contamination could impair performance or lead to component failure.
Never force connectors apart or pull on the wiring harness.
Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that correct
orientation is achieved before connection.
Make sure that any protection covers, insulation etc. are replaced if disturbed.

Having confirmed that a component is faulty, carry out the following:

Switch off the ignition and disconnect the battery.

Remove the component and support the disconnected harness.
When replacing electrical components, keep oily hands away from electrical connections and make sure that locking
tabs on connectors are fully engaged.

Battery Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery Connection/Disconnection prior to attempting to connect or
disconnect the battery.
For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

Fuel Handling Precautions

The following information lists basic precautions which must be observed if fuel is to be handled safely. It also outlines other
areas of risk which must not be ignored. As this information is issued for basic guidance only, consult your local Fire
Department where any doubt as to personal and environmental safety exists - See also Health and Safety Precautions.

General precautions

Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or draining
fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.

Make sure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Make sure that any leadlamps are flameproof and kept clear of spillage.

WARNINGS:
 Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.

Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this manual.

WARNINGS:

Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be carried
out in a well ventilated area.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

Containers used for storing fuel must be clearly marked with the contents and placed in a safe storage area which
meets the requirements of the local authority.

CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no attempt
must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.

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Always release pipe clips fully before attempting to disconnect fuel pipes.

Fuel tank repairs

CAUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a new tank
must be installed.

Oil seals

Never use a seal which has been improperly stored or handled.

Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
Carefully examine seal before installing to make sure that it is clean and undamaged.
Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or
scratches. Renew the component if the sealing surface cannot be restored.
Special tools and protection sleeves are provided for installing the majority of seals and must be used when specified.
Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing. Always check
the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals with oily hands
as the oil will contaminate the protective coating and affect the sealing properties of the seal; also, make sure that
installing tools and protection sleeves are free from oil and grease. Seals which must be lubricated prior to installing
should have the recommended lubricant applied to the areas specified in the repair procedure.
Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards the
lubricant which it is sealing.
When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to be
installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft to rest
on the seal.

Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use a
suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use adhesive tape on
the shaft to protect the sealing lip of the seal.
 Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the housing
where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.

Supplementary Restraint System (SRS) Precautions

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The following
guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the importance of
ensuring the integrity of the SRS components installed to the vehicle.

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WARNING: The following precautions MUST be adhered to when working on the SRS system:

The correct procedures must always be used when working on SRS components.
Persons working on the SRS system must be fully trained and have been issued with the safety guidelines.
The airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids or heavy
metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contact with electricity
before the unit has been deployed.
Always replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing shows
signs of fraying.
Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with an SRS
system.

CAUTION: Do not expose airbag modules or seat belt pre-tensioners to temperatures exceeding 85° C (185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The
same care should be exercised when working on ancillary systems and components located in the vicinity of SRS components;
these include but are not limited to:

Steering wheel airbag, rotary coupler.

Passenger front airbag.
Side curtain airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.
Side (thorax) air bags.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the following
operations:

Remove the remote control.

Disconnect battery, earth lead first.
Wait 2 minutes for the SRS power circuit to discharge before commencing work.

NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure under
crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to avoid the risk of
accidental deployment.

Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is
ready for effective operation in the event of a collision. Carefully inspect SRS components before installation. Do not install a
part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.
 WARNING: The integrity of the SRS systems is critical for safety reasons. Make sure the following precautions are
always adhered to:

Do not install accessories or other objects to trim panels which cover airbags.
Never install used SRS components from another vehicle or attempt to repair an SRS component.
When repairing an SRS system, only use genuine new parts.
Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure.
Special fixings are necessary for installing an airbag module – do not use other fixings.
Always use new fixings when replacing an SRS component and make sure that all fixings are tightened to the correct
torque.

CAUTIONS:

Take care not to trap airbag modules when installing interior trim components.

Make sure SRS components are not contaminated by oil or grease.

NOTES:

Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but will need to
be replaced as soon as possible to make sure full SRS protection. Do not use the seat belts if the retraction mechanism is not
working correctly.

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If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following :

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only Land Rover
approved diagnostic equipment to diagnose system faults.

WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the SRS
components, it may cause accidental deployment and injury.

Handling and storage

Always observe the following precautions when handling SRS components:

 Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and must be
handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to a strong shock.
Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the cover
uppermost and the base away from your body.

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Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle. Always
transport airbag modules or seat belt pretensioners in their original packaging in the luggage compartment of the
vehicle.
Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow anything to
rest on top of an airbag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
Always store an airbag module with the deployment side uppermost. If it is stored deployment side down, accidental
deployment will propel the airbag module with sufficient force to cause serious injury.
Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the empty
packaging for carriage.

WARNINGS:

When handling a side curtain airbag module, hold by the gas generator housing, DO NOT hold by the airbag. Do not
wrap the thumb around the gas generator while holding. Do not drape airbag over shoulder or around neck. For seat buckle
type pre-tensioners, hold by the piston tube, with the open end of the piston tube pointing towards the ground and the buckle
facing away from your body. Do not cover the end of the piston tube. DO NOT hold buckle type pre-tensioners by the bracket
assembly or cable. Never point the piston tube towards your body or other people.

Airbag modules and seat belt pre-tensioners are classed as explosive devices. For overnight and longer term storage,
they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has been registered
with the local authority.

Store airbag modules or seat belt pre-tensioners in a designated storage area. If there is no designated storage area
available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.
 CAUTION: Improper handling or storage can internally damage the airbag module making it inoperative. If you suspect
the airbag module has been damaged, install a new module and refer to the deployment/disposal procedures for disposal of
the damaged module.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

Never attempt to modify, splice or repair SRS wiring.

Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in such a
way that it could generate electrical interference in the airbag harness. Seek specialist advice when installing such

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equipment.

NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used).

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS wiring.

WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses. Look for
possible chafing points.

Side impact crash sensor inspection

After any degree of side body damage, inspect the side impact crash sensors. Replace a crash sensor if there is any sign of
damage.

CAUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the crash sensors. Avoid
direct exposure of the crash sensors or link harnesses to heat guns, welding or spraying equipment. Take care not to damage
sensor or harness when reinstalling components.

Clock spring

CAUTION: Always follow the procedure for installing and checking the clock spring as instructed in the SRS repairs
section. Comply with all safety and installation procedures to make sure the system functions correctly. Observe the following
precautions:

Do not unlock and rotate the clock spring when it is removed from the vehicle.
Do not turn the road wheels when the clock spring is removed from the vehicle.
Always make sure the clock spring is removed and installed in its central position and with the front road wheels in the
straight ahead position - refer to SRS repair section for the correct removal and installation procedure.
If a new clock spring is being installed, make sure the locking tab holding the coupler's rotational position is not
broken; units with a broken locking tab must not be used.

Airbag and pre-tensioner deployment

WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes after
deployment before touching the airbag module.

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Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who have
undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The following
precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been designated
for the purpose.
Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner units.
When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away from
the deployment zone.
Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of
this manual. In particular, make sure deployment tool is NOT connected to battery supply before connecting to airbag
module connector.
When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and seal
deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be replaced.
DO NOT reuse or salvage any parts of the SRS system.
Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this case
airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its correct mounting
position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped,
deploy the module outside of the vehicle.

SRS Component Replacement Policy

CAUTIONS:

The restraints control module (RCM) must be replaced after every time any SRS component has been deployed.

The SRS side impact sensor must be replaced if there are any signs of physical damage or if the RCM is registering a
fault.

The following information details the policy for replacement of SRS components as a result of a vehicle accident.

Impacts which do not deploy the airbags or pre-tensioners

Check for structural damage in the area of the impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Impacts which deploy the airbags or pre-tensioners

The replacement and inspection policy is dependent on the type and severity of the crash condition. The following guidelines
are the minimum that should be exercised as a result of the deployment of specific SRS components.
Check for structural damage in the area of impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Front Airbag Deployment - Driver and Passenger

CAUTION: If the front airbags are deployed, the following components must be replaced:

Driver airbag module

Steering wheel
Passenger airbag module
Instrument panel
Fly leads (where applicable) connecting front airbag modules to SRS harness
All seat belt buckle pre-tensioner
All occupied seats at the time of the crash should have their seat belts replaced
Any seat belt with a deployed retractor pretensioner should be replaced.
Rotary coupler
Any front impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
Front seat frames and head restraints
Steering column - if adjustment is lost or if there are signs of collapse
Seat belt height adjusters
Rear seat belts

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Side Air Bags

CAUTION: If the side (thorax) air bags are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side (thorax) airbag

Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Front seat frame and head restraints
Door trim casing
Seat belt height adjusters
Rear seat belts

Side Curtain Airbag Modules

CAUTION: If the head airbag modules are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side curtain airbag modules

Headliner and all pillar trims
Link lead between airbag gas generator and RCM harness
Airbag retaining clips
Front seat belt buckle pre-tensioners
Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Component mounting brackets

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Seat belt height adjusters

Rear impacts

CAUTION: If the seat belt pre-tensioners are deployed during a rear impact, the following components must be
replaced:

Seat belt pre-tensioners

Front and rear seat belt retractors used during the impact
 RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Seat belt height adjusters

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning System Precautions

The air conditioning system contains fluids and components which could be potentially hazardous to the service engineer or
the environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer to
potential sources of danger and emphasise the importance of ensuring the integrity of the Air Conditioning operating
conditions and components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the Health and
Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the air conditioning system is HFC-134a (Hydrofluorocarbon) R134a.

WARNINGS:

Servicing must only be carried out by personnel familiar with both the 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.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn when

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carrying out operations on the air conditioning system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any part of
the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys when discharging
will freeze skin to them if contact is made.

If an accident involving R134a should occur, conduct the following remedial actions:

If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate medical attention.
If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the temperature.
Implement the same action if the skin comes in contact with discharging cylinders. Wrap the contaminated body parts
in blankets (or similar materials) and seek immediate medical attention.
If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or oxygen
and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the air conditioning system:

Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or
restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make sure that all clips and
supports are utilised.
Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected by heat
shielding.
Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components
and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An
additional spanner must be used to hold the union to prevent twisting of the pipe when tightening connections.
Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings, BUT NOT
to the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of moisture
from the air that enters it.
When disconnecting, immediately plug or cap all air conditioning pipes to prevent ingress of dirt and moisture into the
system.
Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 20 minutes or
longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A receiver/drier
that has been left uncapped for longer than 20 minutes must not be used; install a new unit.
The receiver/drier should be the last component connected to the system to make sure optimum dehydration and
maximum moisture protection of the system.
 Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new receiver/drier
unit.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Make sure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this manual
for the correct procedure.

Refrigerant oil

CAUTION: Refrigerant oil easily absorbs water and must not be stored for long periods. Do not pour unused refrigerant
oil back into the container. Always use an approved refrigerant oil.

When replacing components in the air conditioning system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See Air Conditioning
Compressor Replacement in this Section.

Compressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release the sealing
cap; gas pressure should be heard to vent as the seal is broken.

CAUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas. To avoid possible oil
loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the air conditioning
pipes to the compressor.

Rapid refrigerant discharge

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If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will discharge
rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must
be removed and all the remaining oil in the compressor drained and refilled as instructed in the air conditioning section of this
manual.

Precautions for refrigerant recovery, recycling and recharging

When the air conditioning system is recharged, any existing refrigerant is first recovered from the system and recycled. The
system is then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before reuse to make sure that the purity of the refrigerant is 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 SAE J1991. Other equipment may not recycle refrigerant to the
required level of purity.

CAUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of refrigerant.
Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle air conditioning systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation and recharging is
not permitted.

Air Conditioning Compressor Replacement

A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil to be
drained:

Remove the drain plug from the old compressor.

Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor clutch to
make sure the compressor is completely drained.
Note the quantity of oil drained (Y cm³).
Calculate the quantity of oil to be drained from the new compressor using the following formula: X cm³ — (Y cm³ + 20
cm³) = Q cm³
Remove the drain plug from the new compressor and drain Q cm3 of oil. install and tighten the compressor drain plug.

Vehicle Weights

Item kg lb
Maximum Gross Vehicle Weight (GVW) - All models (1) 2505 5511
Approximate unladen weight (2):
3.2 Petrol 1825 4015
2.2 Diesel 1820 4004
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum towable weight (mass) - Trailers with overrun brakes:
On-road 2000 4400
Off-road 2000 4400
Gross train weight - Trailers with overrun brakes (3):
On-road 4505 9911
Off-road 4505 9911
Nose weight:
On-road 150 330
Off-road 150 330
Maximum front axle load - All models (4) 1310 2882
Maximum rear axle load - All models (4) 1360 2992
Maximum roof rack load - All models (5) 75 165
(1) The maximum permissible weight of the vehicle including passengers and load.

(2) This figure includes the toolkit, all fluids to the correct levels and spare wheel but excludes the driver and passengers.

(3) The maximum permissible weight of the vehicle and braked trailer and their respective loads.

(4) The front and rear maximum loads cannot be reached simultaneously as this will exceed the GVW limit. When calculating
rear axle loading, remember that the trailer nose weight, the load in the vehicle's luggage area, weight on the roof rack, and
the weight of rear seat passengers must all be added together.

(5) This figure includes the weight of the roofrack.

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Vehicle Dimensions
Item mm in
Length - excluding license plate plinth - All models 4500 177.2
Width - All models:
Mirrors extended 2180 85.83
Mirrors folded 2005 78.95
Maximum height - including roof rails - All models 1820 71.65
Wheelbase - All models 2660 104.7
Track:
Front with 16" wheels 1611 63.43
Front with 17"/18"/19" wheels 1601 63.03
Rear with 16" wheels 1624 63.94
Rear with 17"/18"19" wheels 1614 63.54
Vehicle ride height (1):
Front 490.7±12 19.32±0.47
Rear 504.6±12 19.87±0.47
Underbody running clearance to exhaust - Minimum - Kerb weight 229 9.0
Front axle to underbody clearance 216 8.5
Rear axle to differential casing clearance 267 10.5
Suspension travel from kerb - ROW (unladen): 227 8.9
Front (bump/rebound) 105/80 4.13/3.15
Rear (bump/rebound) 130/90 5.12/3.54
Total articulation 335 13.2
Suspension travel from kerb - NAS (unladen):
Front (bump/rebound) 102/76 4/3
Rear (bump/rebound) 127/89 5/3.5
Total articulation 330 13.2
Wading depth 500 19.7
Departure angle - Towbar NOT installed 34°
Departure angle - Fixed height towbar - NOT NAS vehicles 19°
Departure angle - Detachable towbar installed - NOT NAS vehicle 18°
Departure angle - Towbar installed - NAS vehicles 19°
Approach angle 31°
Breakover angle 157°
Maximum gradient for continuous operation 30°
Maximum gradient for drive through operation (2) 45°
(1) Ride height is measured vertically from wheel center to underside of wheelarch. All figures are with vehicle at 'Showroom'
height - full fluids, full tank of fuel, no occupants/luggage, tires inflated to normal pressures.

(2) 5 seconds maximum duration.

Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.

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Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

pressure connections.
 All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of

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refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

8. Following the A/C Charging Trolley manufacturer's instructions,

evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles
 1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

4. Disconnect the A/C Charging Trolley high and low pressure

connections.

Vehicles without auxiliary climate control

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5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm
 Activation

1. Authoring Template

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Published: 22-Jul-2015
Climate Control - Thermostatic Expansion Valve INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Engine Control Module (ECM) (303-14A Electronic Engine

Controls - INGENIUM I4 2.0L Diesel, Removal and Installation).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

3. Refer to: Engine Control Module (ECM) (303-14B Electronic Engine

Controls - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and
Installation).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).

4. CAUTIONS:

Make sure that all openings are sealed. Use new

blanking caps.

Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

 Torque: 9 Nm

5. Torque: 4 Nm

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Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Hydraulic Brake Actuation - Brake Pedal and Bracket
Removal and Installation

Removal

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

All vehicles

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00, Description and

Operation).
 2. Refer to: Driver Lower Air Bag Module (501-20, Removal and
Installation).

3. Refer to: Accelerator Pedal (310-02, Removal and Installation).

4.

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Left-hand drive vehicles

5. Torque: 25 Nm

6.
NOTE: Do not disassemble further if the
component is removed for access only.
Right-hand drive vehicles

7. Torque: 25 Nm

8.

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Installation

1. To install, reverse the removal procedure.

Published: 15-Sep-2014
Instrument Panel and Console - Floor Console Upper Section
Removal and Installation

Removal

CAUTIONS:

Protect the surrounding components.

Use a suitable trim tool.

All vehicles

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

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2.

Vehicles with manual transmission

3.
WARNING: The selector lever knob will be
released suddenly, keep face clear during removal.
4.

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5.
NOTE: Do not disassemble further if the
component is removed for access only.
 cardiagn.com
Vehicles with automatic transmission

6.

7.
 NOTE: Do not disassemble further if the
component is removed for access only.

Torque: 1.5 Nm

8.

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All vehicles

9. Torque: 1.1 Nm
 10. Torque: 1.1 Nm

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11.
 cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 17-Nov-2014
Climate Control - Evaporator LHD
Removal and Installation

Removal

NOTES:

The removal of this component involves cutting an aperture in the evaporator housing wall and cutting through the high
and low pressure A/C lines. A service repair kit is supplied to cover this procedure.

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

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Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

3. Refer to: Thermostatic Expansion Valve - GTDi 2.0L Petrol/GTDi

2.0L Petrol - SULEV (412-01 Climate Control, Removal and
Installation).
Refer to: Thermostatic Expansion Valve - INGENIUM I4 2.0L Diesel
(412-01 Climate Control, Removal and Installation).

4. Refer to: Floor Console Upper Section (501-12 Instrument Panel

and Console, Removal and Installation).

5. Refer to: Central Junction Box (CJB) (418-00 Module

Communications Network, Removal and Installation).

6.
 7.

9.
8.

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 cardiagn.com
10.

11. Torque: 10 Nm
14.
13.
12.

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17.
16.
15.

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18.

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19.

20.
CAUTION: Make sure that the area around the
component is clean and free of foreign material.
Installation

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1. Apply the foam strips from the service kit to the
evaporator core.

2.

3.
 4.
NOTE: Install new O-ring seals.

Torque: 5 Nm

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5. To install, reverse the removal procedure.

Published: 14-Oct-2014
Climate Control - Thermostatic Expansion Valve GTDi 2.0L Petrol/GTDi 2.0L Petrol -
SULEV
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).

3. Refer to: Engine Control Module (ECM) (303-14A Electronic Engine

Controls - INGENIUM I4 2.0L Diesel, Removal and Installation).

4. CAUTIONS:
 Make sure that all openings are sealed. Use new
blanking caps.

Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

Torque: 9 Nm

5. Torque: 4 Nm

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Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect
 CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.

NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring
system (BMS) module electrical 6. Install the battery cover
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
8. Switch the ignition on

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9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release
switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector
8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,
release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 20-Oct-2014
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging GTDi 2.0L Petrol
General Procedures

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.

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Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:
 Refrigerant must always be recycled before re-use to make sure
that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

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Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

8. Following the A/C Charging Trolley manufacturer's instructions,

evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV
(412-01, Removal and Installation).

All vehicles

10.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

11. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.
 12.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

13. Disconnect the A/C Charging Trolley high and low pressure
connections.

Vehicles without auxiliary climate control

14. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

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Vehicles with auxiliary climate control

15. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Published: 30-Sep-2014
Module Communications Network - Central Junction Box (CJB)
Removal and Installation

Removal
CAUTIONS:

If a new component is to be installed, the Land Rover approved diagnostic equipment must be connected prior to
removal, the data must then be downloaded from it and the keys (remote control handsets) set into default mode. Failure to
follow this instruction will result in permanent damage to the keys.

A maximum of 4 remote transmitters can be programmed to the anti-theft alarm and double locking module.
Programming for all remote transmitters must be carried out at the same time.

NOTES:

Removal steps in this procedure may contain installation details.

Make sure that all keys (remote control handsets) are present when performing this procedure.

1. If a new Central Junction Box (CJB) is to be installed, use Land

Rover approved equipment to download the stored data.

2. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

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3. Refer to: Glove Compartment (501-12, Removal and Installation).

4.

5.
6.

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7. Torque: 8 Nm
 8.

Installation

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1. To install, reverse the removal procedure.

2. If a new Central Junction Box (CJB) is to be installed, use Land

Rover approved equipment to upload the stored data.

Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.
Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

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pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
 equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

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8. Following the A/C Charging Trolley manufacturer's instructions,
evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

 4. Disconnect the A/C Charging Trolley high and low pressure
connections.

Vehicles without auxiliary climate control

5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

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Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Activation

1. Authoring Template

Published: 22-Jul-2015
Climate Control - Thermostatic Expansion Valve INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

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

 1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Engine Control Module (ECM) (303-14A Electronic Engine

Controls - INGENIUM I4 2.0L Diesel, Removal and Installation).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

3. Refer to: Engine Control Module (ECM) (303-14B Electronic Engine

Controls - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and
Installation).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).

4. CAUTIONS:

Make sure that all openings are sealed. Use new

blanking caps.

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Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

Torque: 9 Nm

5. Torque: 4 Nm

Installation

1. To install, reverse the removal procedure.

Published: 15-Sep-2014
Instrument Panel and Console - Floor Console Upper Section
Removal and Installation

Removal

CAUTIONS:

Protect the surrounding components.

Use a suitable trim tool.

All vehicles

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2.

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Vehicles with manual transmission

3.
WARNING: The selector lever knob will be
released suddenly, keep face clear during removal.
 4.

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5.
NOTE: Do not disassemble further if the
component is removed for access only.

Vehicles with automatic transmission

6.

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7.
NOTE: Do not disassemble further if the
component is removed for access only.

Torque: 1.5 Nm

8.
 cardiagn.com
All vehicles

9. Torque: 1.1 Nm

10. Torque: 1.1 Nm

 11.

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Installation

1. To install, reverse the removal procedure.

Published: 17-Nov-2014
Climate Control - Evaporator Temperature Sensor
Removal and Installation

Removal

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

All vehicles

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

Left-hand drive vehicles

2.

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Right-hand drive vehicles

3.
NOTE: Left hand illustration shown, Right hand
is similar.
 cardiagn.com
All vehicles

4.

5.
 cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 12-Jan-2015
Climate Control - Footwell Vent/Duct Blend Door Actuator RHD AWD/RHD FWD
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2. Refer to: Glove Compartment (501-12, Removal and Installation).

3.

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4.

Installation
1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Land Rover

approved diagnostic equipment.

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Published: 17-Nov-2014
Climate Control - Heater Core and Evaporator Core Housing
Removal and Installation

Removal

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

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00 General Information,

Description and Operation).

2. Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

3. Refer to: Instrument Panel - INGENIUM I4 2.0L Diesel (501-12

Instrument Panel and Console, Removal and Installation).
Refer to: Instrument Panel - GTDi 2.0L Petrol (501-12 Instrument
Panel and Console, Removal and Installation).

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4.

5.
 cardiagn.com
6. Torque: 1.5 Nm

7.
9.
8.

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11.
10.

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12.

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13. Torque: 6 Nm
 cardiagn.com
14.
NOTE: With assistance remove the component.

Torque: 6 Nm
 15.

16. Torque: 2 Nm

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17.
NOTE: With assistance remove the
component.

Torque: 7 Nm

Installation
 1. To install, reverse the removal procedure.

Published: 26-Mar-2015
Instrument Panel and Console - Instrument Panel INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

CAUTION: Use a suitable trim tool.

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

All vehicles

1. Make the supplementary restraint system (SRS) system safe.

Refer to: Standard Workshop Practices (100-00 General Information,

Description and Operation).

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2. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

3. Refer to: Cooling System Partial Draining and Vacuum Filling

(303-03B Engine Cooling - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV,
General Procedures).
Refer to: Cooling System Partial Draining and Vacuum Filling (303-03B
Engine Cooling - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, General
Procedures).

4. Refer to: Windshield Wiper Motor (501-16 Wipers and Washers,

Removal and Installation).

5. Refer to: Thermostatic Expansion Valve - INGENIUM I4 2.0L Diesel

(412-01 Climate Control, Removal and Installation).

6.
NOTE: The step must be carried out on both sides.

Refer to: Front Door (501-03 Body Closures, Removal and

Installation).

7.
NOTE: The step must be carried out on both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation,
Removal and Installation).

8. Refer to: Steering Column (211-04 Steering Column, Removal and

Installation).

9.
NOTE: The step must be carried out on both sides.

Refer to: Front Seat - Vehicles With: Power Seats (501-10 Seating,
Removal and Installation).
 10.
NOTE: The step must be carried out on both sides.

Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).

Vehicles with manual transmission

11. Refer to: Gearshift Lever (308-06 Manual Transmission/Transaxle

External Controls, Removal and Installation).

All vehicles

12.

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13. Torque:
Screw 1.5 Nm
M6 6 Nm
 cardiagn.com
14. Torque: 6 Nm

15.
16. Torque: 1.5 Nm

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17. Torque: 6 Nm
18. Torque: 1.5 Nm

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19.
 20. Torque: 6 Nm

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21.
 cardiagn.com
22.
NOTE: The step must be carried out on both sides.

Torque: 6 Nm
23.
NOTE: The step must be carried out on both sides.

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24.
NOTE: The step must be carried out on both sides.
 cardiagn.com
25.
NOTE: The step must be carried out on both
sides.

Torque: 9 Nm

26.
NOTE: The step must be carried out on both
sides.
29.
28.
27.

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 NOTE: If equipped.

30.

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31.
33.
32.

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35.
34.

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36.

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37.
CAUTION: Make sure that all openings are
sealed. Use new blanking caps.

38. Torque: 40 Nm
 39. Torque: 24 Nm

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40.
NOTE: The step must be carried out on both
sides.

Torque: 24 Nm

41.
 NOTE: The step must be carried out on both sides.

Torque: 40 Nm

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42. Torque: 6 Nm
 43.
CAUTION: Protect the surrounding trim to avoid damage.

NOTE: This step requires the aid of another technician.

Torque: 24 Nm

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Installation

1. To install, reverse the removal procedure.

2. Check and top-up the coolant if required.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect

CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.
 NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring
system (BMS) module electrical 6. Install the battery cover
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
8. Switch the ignition on
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release

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switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector
8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,
release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 05-Jul-2013
General Information - Standard Workshop Practices
Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

- Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle moving
forwards or backwards.
- Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
 - If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust fumes.
- There is adequate room to raise the vehicle and remove the wheels, if necessary.
- Fender covers are always installed if any work is to be carried out in the engine compartment.
- Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is
raised.

CAUTION: Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery
disconnection/connection.

For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a
surge of current causing damage to the internal components of the generator.

- If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Battery - General

CAUTION: Prior to carrying out any procedures which involve disconnecting/ or connecting the battery, refer to the
Electrical Section of this manual - Battery disconnection/connection.

For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

CAUTIONS:

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A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be
an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper
cables are connected.

While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only
practical way to mobilize a vehicle. Prior to attempting a jump start, reference must be made to the Electrical Section of this
manual - Jump Starting.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged off the
vehicle as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of
eight hours continuous driving with no additional loads placed on the battery.

- Always make sure that the jumper cables are adequate for the task.
- Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be
connected in parallel.
- Always make sure that switchable electric circuits are switched off before connecting jumper cables. This reduces the
risk of arcing occurring when the final connection is made.

Towing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section of this
Manual.

When the vehicle is being towed dock the remote control and switch on the ignition. (steering lock released and warning lights
illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these
instructions may result in personal injury. It must be noted that with the engine not running, the power steering and brake
booster will be inoperative therefore, greater effort will be needed to steer the vehicle and apply the brakes.

General Installation Instructions

Component removal

Whenever possible, clean components and the surrounding area before removal.

Blank off openings exposed by component removal.

Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
Seal open ends of exposed oilways using suitable tapered hardwood plugs or conspicuous plastic plugs.
Immediately a component is removed, place it in a suitable container; use a separate container for each component
and its associated parts.
Clean bench and provide marking materials, labels and containers before disassembling components.

Disassembling
Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or hydraulic
system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if trapped in these
systems.

Blow out all tapped holes, crevices, oilways and fluid passages with dry, compressed air.

WARNING: Suitable eye protection must be worn.

Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate cracks or
distortion.
Wire or tape mating parts together where necessary to prevent accidental interchange.
Suitably identify parts which are to be renewed and to those parts requiring further inspection. Keep these parts
separate.
To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until after
comparing it with the new part.

Cleaning Components

Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned. NEVER use
gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned is compatible with the
cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the environment in
which the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.

General Inspection of Components

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All components should be inspected for wear or damage before reassembling.

Always make sure that component to be inspected is clean and free from oil or grease.
When a component is to be checked dimensionally against design specified values, use the appropriate measuring
equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
Always make sure that all measuring equipment is correctly calibrated before use.
Reject a component which is not within specified values/limits or if it appears to be damaged.
A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in
an undamaged condition.
Bearing journal clearances should be checked where necessary using Plastigauge.

Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install O-rings
using the fingers only.

Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.

CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.

Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with its part
number will be found listed in the relevant repair operation and also in the sealants table.

CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified solvents
where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Make sure that sealing surfaces are free from oil or grease as sealants will not adhere properly to contaminated surfaces.

Do not allow sealant to enter tapped holes or oilways.

Locking Devices

Always replace locking devices with one of the same design and of the correct size.

Tab washers

Always release locking tabs before loosening fixings, do not reuse tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips
Always install new circlips ensuring that they are of the correct size for the groove.

Woodruff keys

Woodruff keys may be reused provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and reuse a split pin, always make sure that replacement pins are of the correct size for the hole
in which they are to be installed.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap
or die impairs the strength and fit of the threads and is not recommended.

NOTES:

During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this
is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and
thread is used.

New Taptite bolts when used cut their own threads on the first application.

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Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts
having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the
repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread
locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque
reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or
faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages,
these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve
tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.

Where it is stated that bolts and screws may be reused, the following procedures must be carried out:

Check that threads are undamaged.

Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.

Make sure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M
or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the strength
grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol stamped on the
flats of the hexagon.

Encapsulated ('Patched') bolts and screws

Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture. Most thread
locking agents are colored, the band of color extending for 360 degrees around the thread. Some locking agents however, are
neutral in color and may not be so easily identified apart from a slightly darker area of thread where the locking agent has

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been applied. The locking agent is released and activated by the tightening process and is then chemically cured to provide
the locking action.

Self-locking bolts and screws

Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can be reused
provided that resistance is felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are identified
by the presence of a colored section of thread extending approximately 180 degrees around the thread or by a colored plug
inserted into the bolt.

Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into which it is
screwed.

CAUTION: Do Not reuse self-locking fasteners in critical locations e.g. drive plates/flywheel or engine bearings. Do not
install non self-locking fasteners where a self-locking fastener is specified.

Trilobular bolts should not be used as a substitute for patched bolts.

Nut identification
A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol 8, 12,
14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the hexagonal flat
opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external chamfers or a
face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two dots
identify the 12 o'clock position.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should be

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selected.

Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.

Self-locking nuts

Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and strength grade
installed.

Ball and Roller Bearings

When removing and installing bearings, make sure that the following practices are observed to make sure component
serviceability:

CAUTION: Service tools have been developed for removing the majority of bearings; these must always be used where
specified.

Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute cleanliness
throughout operations.
Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or inner surfaces of
inner rings. Reject any bearings found to be marked since marking in these areas indicates onset of wear.
Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it revolves
absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check or obstruction to
rotation. Reject bearing if movement is not absolutely smooth.
Check bearing for blueing or signs of overheating.
Lubricate bearing with the specified lubricant.
Inspect bearing surface of shaft and bearing housing for discoloration or other markings which indicate overheating of
bearing or movement between bearing and seating.
Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
 If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair unless it is
suspected that one bearing may have been faulty when installed, was installed incorrectly or the fault arose due to oil
seal failure.
Never reinstall a bearing unless it is in a fully serviceable condition.

When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing a bearing into a
housing, only apply force to the outer ring of the bearing.

CAUTION: Service tools have been developed for installing the majority of bearings; these must always be used where
specified.

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In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the recommended
grade of grease before installing the seal.

CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that grease does not
contaminate the running surface of the seal.

Always make suitable reference marks between the components of separable bearings e.g. taper roller bearings when
disassembling to make sure correct location of components when assembling. Never install new rollers in an outer
ring, always install a new bearing assembly.

Brake Pads and Linings

Always install the correct grade and specification of brake pads and linings. When replacing these items, always replace as
complete axle sets.

Brake Hydraulics

Always observe the following recommendations when working on the braking system:

WARNING: Do not intermix brake fluid of different specifications.

Always use two spanners when loosening or tightening brake pipes or hose connections.
Make sure that hoses run in a natural curve and are not kinked or twisted.
Install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact a potential
chafing point.
Containers used for brake fluid must be kept absolutely clean.
Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of the
fluid.
Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake fluid in a
container which has previously been used for storing other fluids.
Do not reuse brake fluid which has been bled from the system.
Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
Always install blanking plugs to hoses, pipes or components immediately after disconnection.
Check thread compatibility of original equipment with replacement components.
Observe absolute cleanliness when working with hydraulic components.

Pipes and Hoses

When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are observed to make
sure component serviceability:

Prior to removal, clean area around hose or pipe end which is to be disconnected.
Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that connections can
be plugged immediately following disconnection.
Always install blanking plugs or caps to pipes and unions immediately following disconnection.
 Clean hose or pipe and blow through with an air line.

WARNING: Suitable eye protection must be worn.

Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace faulty
hoses.
Check pipes for signs of corrosion and chafing, replace as necessary.

CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further problems in service.

When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked, twisted or
positioned close to potential chafing points.
When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
Always replace sealing washers installed to banjo bolts, sealing plugs etc.
Always use a backing spanner when tightening unions and do not overtighten union nuts or banjo bolts.
After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working pressure to
the brake pedal or operates the system that has been worked on.

Fuel system hoses

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All fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core. Whenever a hose is
removed, make sure that the inner bore is inspected to check that the viton lining has not become separated from the outer
sleeve.

WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors the fuel hose and connectors must
be replaced as an assembly.

Fuel system hose clips

Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip is
tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new clips on
reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by any other
method, do not install any other type of clip.

Cooling system hoses

CAUTION: The following precautions must be observed to make sure that the integrity of the cooling system hoses and
their connection to the system is maintained.

Hose orientation and connection

Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or damaged through
contact with adjacent components.

Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when the hose
is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe provides a positive
indicator.

Hose clips

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Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position the clip
directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the crimped side of the
drive housing facing towards the end of the hose or the hose may become pinched between the clip and the stub pipe
retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft). Make sure that hose clips do not
foul adjacent components.

Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be reused.
When installing new clips, make sure clip is positioned on hose before tightening and make sure that when clip is tightened,
the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).

Heat protection

Always make sure that heatshields and protective sheathing are in good condition; replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine components such as the exhaust manifolds and exhaust gas
recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement is taken into account when
routing and securing hoses.

Electrical Precautions
General

The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the electrical and
electronic components of this vehicle.

Equipment

Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working correctly and
that any harness or connectors are in good condition. It is particularly important to check the condition of all plugs and leads
of mains operated equipment.

Polarity

Never reverse connect the vehicle battery and always make sure the correct polarity when connecting test equipment.

High voltage circuits

Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to contact
other components, particularly ECU's.

Vehicles installed with Bi-Xenon headlamp bulbs

WARNING: The following precautions must be observed as failure to comply may result in exposure to ultra-violet rays,
severe electric shock, burns or risk of an explosion.

Safety goggles and gloves must be worn.

Make sure that headlamps are switched off before removing bulbs.

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Do not touch the glass portion of the bulb.
On no account should headlamps be switched on with the bulb removed from the headlamp.
Bulb testing may only be carried out with the bulb installed in the headlamp.
Bulbs must be disposed of in accordance with the local authority bye-laws.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always
observe the following:

Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other liquid
contamination. Any such contamination could impair performance or lead to component failure.
Never force connectors apart or pull on the wiring harness.
Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that correct
orientation is achieved before connection.
Make sure that any protection covers, insulation etc. are replaced if disturbed.

Having confirmed that a component is faulty, carry out the following:

Switch off the ignition and disconnect the battery.

Remove the component and support the disconnected harness.
When replacing electrical components, keep oily hands away from electrical connections and make sure that locking
tabs on connectors are fully engaged.

Battery Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery Connection/Disconnection prior to attempting to connect or
disconnect the battery.
For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

Fuel Handling Precautions

The following information lists basic precautions which must be observed if fuel is to be handled safely. It also outlines other
areas of risk which must not be ignored. As this information is issued for basic guidance only, consult your local Fire
Department where any doubt as to personal and environmental safety exists - See also Health and Safety Precautions.

General precautions

Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or draining
fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.

Make sure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Make sure that any leadlamps are flameproof and kept clear of spillage.

WARNINGS:
 Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.

Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this manual.

WARNINGS:

Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be carried
out in a well ventilated area.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

Containers used for storing fuel must be clearly marked with the contents and placed in a safe storage area which
meets the requirements of the local authority.

CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no attempt
must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.

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Always release pipe clips fully before attempting to disconnect fuel pipes.

Fuel tank repairs

CAUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a new tank
must be installed.

Oil seals

Never use a seal which has been improperly stored or handled.

Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
Carefully examine seal before installing to make sure that it is clean and undamaged.
Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or
scratches. Renew the component if the sealing surface cannot be restored.
Special tools and protection sleeves are provided for installing the majority of seals and must be used when specified.
Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing. Always check
the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals with oily hands
as the oil will contaminate the protective coating and affect the sealing properties of the seal; also, make sure that
installing tools and protection sleeves are free from oil and grease. Seals which must be lubricated prior to installing
should have the recommended lubricant applied to the areas specified in the repair procedure.
Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards the
lubricant which it is sealing.
When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to be
installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft to rest
on the seal.

Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use a
suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use adhesive tape on
the shaft to protect the sealing lip of the seal.
 Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the housing
where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.

Supplementary Restraint System (SRS) Precautions

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The following
guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the importance of

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ensuring the integrity of the SRS components installed to the vehicle.

WARNING: The following precautions MUST be adhered to when working on the SRS system:

The correct procedures must always be used when working on SRS components.
Persons working on the SRS system must be fully trained and have been issued with the safety guidelines.
The airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids or heavy
metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contact with electricity
before the unit has been deployed.
Always replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing shows
signs of fraying.
Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with an SRS
system.

CAUTION: Do not expose airbag modules or seat belt pre-tensioners to temperatures exceeding 85° C (185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The
same care should be exercised when working on ancillary systems and components located in the vicinity of SRS components;
these include but are not limited to:

Steering wheel airbag, rotary coupler.

Passenger front airbag.
Side curtain airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.
Side (thorax) air bags.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the following
operations:

Remove the remote control.

Disconnect battery, earth lead first.
Wait 2 minutes for the SRS power circuit to discharge before commencing work.

NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure under
crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to avoid the risk of
accidental deployment.

Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is
ready for effective operation in the event of a collision. Carefully inspect SRS components before installation. Do not install a
part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.
 WARNING: The integrity of the SRS systems is critical for safety reasons. Make sure the following precautions are
always adhered to:

Do not install accessories or other objects to trim panels which cover airbags.
Never install used SRS components from another vehicle or attempt to repair an SRS component.
When repairing an SRS system, only use genuine new parts.
Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure.
Special fixings are necessary for installing an airbag module – do not use other fixings.
Always use new fixings when replacing an SRS component and make sure that all fixings are tightened to the correct
torque.

CAUTIONS:

Take care not to trap airbag modules when installing interior trim components.

Make sure SRS components are not contaminated by oil or grease.

NOTES:

Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but will need to
be replaced as soon as possible to make sure full SRS protection. Do not use the seat belts if the retraction mechanism is not
working correctly.

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If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following :

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only Land Rover
approved diagnostic equipment to diagnose system faults.

WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the SRS
components, it may cause accidental deployment and injury.

Handling and storage

Always observe the following precautions when handling SRS components:

 Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and must be
handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to a strong shock.
Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the cover
uppermost and the base away from your body.

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Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle. Always
transport airbag modules or seat belt pretensioners in their original packaging in the luggage compartment of the
vehicle.
Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow anything to
rest on top of an airbag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
Always store an airbag module with the deployment side uppermost. If it is stored deployment side down, accidental
deployment will propel the airbag module with sufficient force to cause serious injury.
Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the empty
packaging for carriage.

WARNINGS:

When handling a side curtain airbag module, hold by the gas generator housing, DO NOT hold by the airbag. Do not
wrap the thumb around the gas generator while holding. Do not drape airbag over shoulder or around neck. For seat buckle
type pre-tensioners, hold by the piston tube, with the open end of the piston tube pointing towards the ground and the buckle
facing away from your body. Do not cover the end of the piston tube. DO NOT hold buckle type pre-tensioners by the bracket
assembly or cable. Never point the piston tube towards your body or other people.

Airbag modules and seat belt pre-tensioners are classed as explosive devices. For overnight and longer term storage,
they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has been registered
with the local authority.

Store airbag modules or seat belt pre-tensioners in a designated storage area. If there is no designated storage area
available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.
 CAUTION: Improper handling or storage can internally damage the airbag module making it inoperative. If you suspect
the airbag module has been damaged, install a new module and refer to the deployment/disposal procedures for disposal of
the damaged module.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

Never attempt to modify, splice or repair SRS wiring.

Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in such a
way that it could generate electrical interference in the airbag harness. Seek specialist advice when installing such

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equipment.

NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used).

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS wiring.

WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses. Look for
possible chafing points.

Side impact crash sensor inspection

After any degree of side body damage, inspect the side impact crash sensors. Replace a crash sensor if there is any sign of
damage.

CAUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the crash sensors. Avoid
direct exposure of the crash sensors or link harnesses to heat guns, welding or spraying equipment. Take care not to damage
sensor or harness when reinstalling components.

Clock spring

CAUTION: Always follow the procedure for installing and checking the clock spring as instructed in the SRS repairs
section. Comply with all safety and installation procedures to make sure the system functions correctly. Observe the following
precautions:

Do not unlock and rotate the clock spring when it is removed from the vehicle.
Do not turn the road wheels when the clock spring is removed from the vehicle.
Always make sure the clock spring is removed and installed in its central position and with the front road wheels in the
straight ahead position - refer to SRS repair section for the correct removal and installation procedure.
If a new clock spring is being installed, make sure the locking tab holding the coupler's rotational position is not
broken; units with a broken locking tab must not be used.

Airbag and pre-tensioner deployment

WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes after
deployment before touching the airbag module.

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Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who have
undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The following
precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been designated
for the purpose.
Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner units.
When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away from
the deployment zone.
Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of
this manual. In particular, make sure deployment tool is NOT connected to battery supply before connecting to airbag
module connector.
When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and seal
deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be replaced.
DO NOT reuse or salvage any parts of the SRS system.
Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this case
airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its correct mounting
position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped,
deploy the module outside of the vehicle.

SRS Component Replacement Policy

CAUTIONS:

The restraints control module (RCM) must be replaced after every time any SRS component has been deployed.

The SRS side impact sensor must be replaced if there are any signs of physical damage or if the RCM is registering a
fault.

The following information details the policy for replacement of SRS components as a result of a vehicle accident.

Impacts which do not deploy the airbags or pre-tensioners

Check for structural damage in the area of the impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Impacts which deploy the airbags or pre-tensioners

The replacement and inspection policy is dependent on the type and severity of the crash condition. The following guidelines
are the minimum that should be exercised as a result of the deployment of specific SRS components.
Check for structural damage in the area of impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Front Airbag Deployment - Driver and Passenger

CAUTION: If the front airbags are deployed, the following components must be replaced:

Driver airbag module

Steering wheel
Passenger airbag module
Instrument panel
Fly leads (where applicable) connecting front airbag modules to SRS harness
All seat belt buckle pre-tensioner
All occupied seats at the time of the crash should have their seat belts replaced
Any seat belt with a deployed retractor pretensioner should be replaced.
Rotary coupler
Any front impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
Front seat frames and head restraints
Steering column - if adjustment is lost or if there are signs of collapse
Seat belt height adjusters
Rear seat belts

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Side Air Bags

CAUTION: If the side (thorax) air bags are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side (thorax) airbag

Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Front seat frame and head restraints
Door trim casing
Seat belt height adjusters
Rear seat belts

Side Curtain Airbag Modules

CAUTION: If the head airbag modules are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side curtain airbag modules

Headliner and all pillar trims
Link lead between airbag gas generator and RCM harness
Airbag retaining clips
Front seat belt buckle pre-tensioners
Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Component mounting brackets

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Seat belt height adjusters

Rear impacts

CAUTION: If the seat belt pre-tensioners are deployed during a rear impact, the following components must be
replaced:

Seat belt pre-tensioners

Front and rear seat belt retractors used during the impact
 RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Seat belt height adjusters

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning System Precautions

The air conditioning system contains fluids and components which could be potentially hazardous to the service engineer or
the environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer to
potential sources of danger and emphasise the importance of ensuring the integrity of the Air Conditioning operating
conditions and components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the Health and
Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the air conditioning system is HFC-134a (Hydrofluorocarbon) R134a.

WARNINGS:

Servicing must only be carried out by personnel familiar with both the 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.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn when

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carrying out operations on the air conditioning system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any part of
the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys when discharging
will freeze skin to them if contact is made.

If an accident involving R134a should occur, conduct the following remedial actions:

If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate medical attention.
If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the temperature.
Implement the same action if the skin comes in contact with discharging cylinders. Wrap the contaminated body parts
in blankets (or similar materials) and seek immediate medical attention.
If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or oxygen
and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the air conditioning system:

Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or
restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make sure that all clips and
supports are utilised.
Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected by heat
shielding.
Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components
and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An
additional spanner must be used to hold the union to prevent twisting of the pipe when tightening connections.
Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings, BUT NOT
to the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of moisture
from the air that enters it.
When disconnecting, immediately plug or cap all air conditioning pipes to prevent ingress of dirt and moisture into the
system.
Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 20 minutes or
longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A receiver/drier
that has been left uncapped for longer than 20 minutes must not be used; install a new unit.
The receiver/drier should be the last component connected to the system to make sure optimum dehydration and
maximum moisture protection of the system.
 Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new receiver/drier
unit.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Make sure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this manual
for the correct procedure.

Refrigerant oil

CAUTION: Refrigerant oil easily absorbs water and must not be stored for long periods. Do not pour unused refrigerant
oil back into the container. Always use an approved refrigerant oil.

When replacing components in the air conditioning system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See Air Conditioning
Compressor Replacement in this Section.

Compressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release the sealing
cap; gas pressure should be heard to vent as the seal is broken.

CAUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas. To avoid possible oil
loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the air conditioning
pipes to the compressor.

Rapid refrigerant discharge

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If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will discharge
rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must
be removed and all the remaining oil in the compressor drained and refilled as instructed in the air conditioning section of this
manual.

Precautions for refrigerant recovery, recycling and recharging

When the air conditioning system is recharged, any existing refrigerant is first recovered from the system and recycled. The
system is then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before reuse to make sure that the purity of the refrigerant is 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 SAE J1991. Other equipment may not recycle refrigerant to the
required level of purity.

CAUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of refrigerant.
Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle air conditioning systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation and recharging is
not permitted.

Air Conditioning Compressor Replacement

A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil to be
drained:

Remove the drain plug from the old compressor.

Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor clutch to
make sure the compressor is completely drained.
Note the quantity of oil drained (Y cm³).
Calculate the quantity of oil to be drained from the new compressor using the following formula: X cm³ — (Y cm³ + 20
cm³) = Q cm³
Remove the drain plug from the new compressor and drain Q cm3 of oil. install and tighten the compressor drain plug.

Vehicle Weights

Item kg lb
Maximum Gross Vehicle Weight (GVW) - All models (1) 2505 5511
Approximate unladen weight (2):
3.2 Petrol 1825 4015
2.2 Diesel 1820 4004
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum towable weight (mass) - Trailers with overrun brakes:
On-road 2000 4400
Off-road 2000 4400
Gross train weight - Trailers with overrun brakes (3):
On-road 4505 9911
Off-road 4505 9911
Nose weight:
On-road 150 330
Off-road 150 330
Maximum front axle load - All models (4) 1310 2882
Maximum rear axle load - All models (4) 1360 2992
Maximum roof rack load - All models (5) 75 165
(1) The maximum permissible weight of the vehicle including passengers and load.

(2) This figure includes the toolkit, all fluids to the correct levels and spare wheel but excludes the driver and passengers.

(3) The maximum permissible weight of the vehicle and braked trailer and their respective loads.

(4) The front and rear maximum loads cannot be reached simultaneously as this will exceed the GVW limit. When calculating
rear axle loading, remember that the trailer nose weight, the load in the vehicle's luggage area, weight on the roof rack, and
the weight of rear seat passengers must all be added together.

(5) This figure includes the weight of the roofrack.

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Vehicle Dimensions
Item mm in
Length - excluding license plate plinth - All models 4500 177.2
Width - All models:
Mirrors extended 2180 85.83
Mirrors folded 2005 78.95
Maximum height - including roof rails - All models 1820 71.65
Wheelbase - All models 2660 104.7
Track:
Front with 16" wheels 1611 63.43
Front with 17"/18"/19" wheels 1601 63.03
Rear with 16" wheels 1624 63.94
Rear with 17"/18"19" wheels 1614 63.54
Vehicle ride height (1):
Front 490.7±12 19.32±0.47
Rear 504.6±12 19.87±0.47
Underbody running clearance to exhaust - Minimum - Kerb weight 229 9.0
Front axle to underbody clearance 216 8.5
Rear axle to differential casing clearance 267 10.5
Suspension travel from kerb - ROW (unladen): 227 8.9
Front (bump/rebound) 105/80 4.13/3.15
Rear (bump/rebound) 130/90 5.12/3.54
Total articulation 335 13.2
Suspension travel from kerb - NAS (unladen):
Front (bump/rebound) 102/76 4/3
Rear (bump/rebound) 127/89 5/3.5
Total articulation 330 13.2
Wading depth 500 19.7
Departure angle - Towbar NOT installed 34°
Departure angle - Fixed height towbar - NOT NAS vehicles 19°
Departure angle - Detachable towbar installed - NOT NAS vehicle 18°
Departure angle - Towbar installed - NAS vehicles 19°
Approach angle 31°
Breakover angle 157°
Maximum gradient for continuous operation 30°
Maximum gradient for drive through operation (2) 45°
(1) Ride height is measured vertically from wheel center to underside of wheelarch. All figures are with vehicle at 'Showroom'
height - full fluids, full tank of fuel, no occupants/luggage, tires inflated to normal pressures.

(2) 5 seconds maximum duration.

Published: 26-Mar-2015
Instrument Panel and Console - Instrument Panel GTDi 2.0L Petrol
Removal and Installation

Removal

CAUTION: Use a suitable trim tool.

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

1. Make the supplementary restraint system (SRS) system safe.

Refer to: Standard Workshop Practices (100-00 General Information,

Description and Operation).

2. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

3. Refer to: Cooling System Partial Draining and Vacuum Filling

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(303-03B, General Procedures).

4. Refer to: Windshield Wiper Motor (501-16 Wipers and Washers,

Removal and Installation).

5. Refer to: Thermostatic Expansion Valve - GTDi 2.0L Petrol/GTDi

2.0L Petrol - SULEV (412-01 Climate Control, Removal and
Installation).

6.
NOTE: The procedure must be carried out on both sides.

Refer to: Front Door (501-03 Body Closures, Removal and

Installation).

7.
NOTE: The procedure must be carried out on both sides.

Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation,
Removal and Installation).

8. Refer to: Steering Column (211-04 Steering Column, Removal and

Installation).

9.
NOTE: The procedure must be carried out on both sides.

Refer to: Front Seat - Vehicles With: Power Seats (501-10 Seating,
Removal and Installation).

10.
NOTE: The step must be carried out on both sides.

Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).

11.
12. Torque:
Screw 1.5 Nm
M6 6 Nm

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13. Torque: 6 Nm
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14.

15. Torque: 1.5 Nm

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16. Torque: 6 Nm

17. Torque: 1.5 Nm

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18.

19. Torque: 6 Nm
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20.

21.
NOTE: The step must be carried out on both sides.
Torque: 6 Nm

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22.
NOTE: The step must be carried out on both sides.
23.
NOTE: The step must be carried out on both sides.

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24.
NOTE: The step must be carried out on both
sides.

Torque: 9 Nm

25.
NOTE: The step must be carried out on both
sides.
28.
27.
26.

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 NOTE: If equipped.

29.

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30.
32.
31.

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34.
33.

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35.

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36.
CAUTION: Make sure that all openings are
sealed. Use new blanking caps.

37. Torque: 40 Nm
 38. Torque: 24 Nm

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39.
NOTE: The step must be carried out on both
sides.

Torque: 24 Nm

40.
 NOTE: The step must be carried out on both sides.

Torque: 40 Nm

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41. Torque: 6 Nm
 42.
CAUTION: Protect the surrounding trim to avoid damage.

NOTE: This step requires the aid of another technician.

Torque: 24 Nm

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Installation

1. To install, reverse the removal procedure.

2. Check and top-up the coolant if required.

Published: 22-Jul-2015
Climate Control - Heater Core INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Cooling System Partial Draining and Vacuum Filling

(303-03B Engine Cooling - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV,
General Procedures).
Refer to: Cooling System Partial Draining and Vacuum Filling (303-03B
Engine Cooling - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, General
Procedures).

3. Refer to: Electric Booster Heater (412-02 Auxiliary Climate Control,

Removal and Installation).

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4.
CAUTION: Be prepared to collect escaping
coolant.

5.
 6.
CAUTION: Be prepared to collect escaping
coolant.

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Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect
 CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.

NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring
system (BMS) module electrical 6. Install the battery cover
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
8. Switch the ignition on

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9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release
switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector
8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,
release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 29-Jul-2015
Engine Cooling - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV - Cooling System Partial
Draining and Vacuum Filling
General Procedures

Special Tool(s)
 HU-919
Coolant System Vacuum Refill Kit

JLR-303-1634
Adaptor, Cooling System Vacuum Refill Kit

Draining

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.

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CAUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with
water.

1.
WARNING: Do not work on or under a vehicle supported only
by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2.
WARNING: Since injury such as scalding could
be caused by escaping steam or coolant, do not remove
the filler cap from the coolant expansion tank while the
system is hot.

3. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).
 4. Position a container to collect the fluid.

5. NOTES:

Some components shown removed for clarity.

Collect the coolant in a clean container and reuse.

Attach a hose to the radiator drain tap.

Open the radiator drain tap.
Drain the coolant from the radiator.

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6. Close the radiator drain tap and remove the hose.

Filling

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.

CAUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with
water.

1. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).

2. Prepare a sufficient amount of coolant to the specified

concentration.

3.
NOTES:

Make sure the coolant supply valve is in the closed

position on the special tool.

The special tool needs an air pressure of 6 to 8 bar (87 to

116 psi) to operate correctly.

Small diameter or long airlines may restrict airflow to the

coolant vacuum fill tool.

Special Tool(s): HU-919 , JLR-303-1634

1. Position the hose from the special tool into a container of
clean coolant.
2. Connect a regulated compressed air supply to the special
tool.
 3. Move the special tool to the expansion tank.

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4. NOTES:

Make sure the coolant supply valve is in the closed position on

the special tool.

The coolant vacuum fill tool needs an air pressure of 6 to 8 bar

(87 to 116 psi) to operate correctly.

Small diameter or long airlines may restrict airflow to the

coolant vacuum fill tool.

Open the air supply valve until -0.8 (-12 psi) Bar is shown on the
gauge.

Special Tool(s): HU-919 , JLR-303-1634

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5.
Special Tool(s): HU-919 , JLR-303-1634
Close the air supply valve.
Allow 1 minute to check the vacuum is held.
6. NOTES:

The coolant is to be reused.

Close the coolant supply valve when the coolant expansion tank
MAX mark is reached or coolant movement has stopped.

Open the coolant supply valve and allow the coolant to be drawn into
the system.

Special Tool(s): HU-919 , JLR-303-1634

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7. Remove the special tool.

8. Connect exhaust extraction hoses to the tail pipes.

9. Start and run the engine.

10. Install the coolant expansion tank cap.

11. Hold the engine speed at 2000 revolutions per minute (RPM) until
warm air is expelled from the heater.

12. Switch the engine off and allow to cool.

13. Clean any spilt or excess coolant from the vehicle.

14.
 WARNING: Since injury such as scalding could be caused by
escaping steam or coolant, allow the vehicle cooling system to cool
prior to carrying out this procedure.

Check and top-up the coolant if required.

Published: 02-Dec-2014
Auxiliary Climate Control - Electric Booster Heater
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

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Vehicles with automatic transmission

2. Refer to: Floor Console (501-12, Removal and Installation).

Vehicles with manual transmission

3. Refer to: Gearshift Lever (308-06, Removal and Installation).

All vehicles

4.

5.
 6.

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7. Torque: 2 Nm

Installation

1. To install, reverse the removal procedure.

Published: 15-Oct-2014
Climate Control - Passenger Side Register
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

Some components shown removed for clarity.

Removal steps in this procedure may contain installation details.

1. Refer to: Floor Console Upper Section (501-12, Removal and

Installation).

2.

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3.

4.
5.

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6. Torque: 1.5 Nm

7.
8.

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9.
CAUTION: Care must be taken to avoid
damaging the passenger side register internal
components.

Torque: 1.5 Nm
 cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 15-Oct-2014
Climate Control - Plenum Chamber
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

LHD illustration shown, RHD is similar.

All vehicles

1. Refer to: Wiper Pivot Arm (501-16, Removal and Installation).

2. Repeat the above procedure for the other wiper arm.

3.

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4.
5. Torque: 25 Nm

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6. Torque: 25 Nm

7.
 8.
NOTE: Repeat the step for the other side.

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9.
NOTE: Repeat the step for the other side.

Vehicles without heated washers

 10.
CAUTION: Be prepared to collect escaping
fluids.

Vehicles with heated washers

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11.
CAUTION: Be prepared to collect escaping
fluids.

All vehicles

12.
 13.
NOTE: Do not disassemble further if the component is
removed for access only.

Vehicles without heated washers

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14.
Vehicles with heated washers

15.

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All vehicles

16.
NOTE: Repeat the step for the other side.
 cardiagn.com
Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Climate Control - Pollen Filter
Removal and Installation

Removal

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

All vehicles

1.
NOTE: LHD illustration shown, RHD is similar.

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Left-hand drive vehicles

2.
CAUTION: Take extra care not to damage the
wiring harnesses.

Torque: 10 Nm
 All vehicles

3.
NOTE: LHD illustration shown, RHD is similar.

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4.
NOTE: LHD illustration shown, RHD is similar.

Installation

1.
CAUTION: Take extra care not to damage the pollen filter.

To install, reverse the removal procedure.

Published: 12-Jan-2015
Climate Control - Recirculation Blend Door Actuator
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2. Refer to: Central Junction Box (CJB) (418-00, Removal and

Installation).

3.

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4.
5. Torque: 10 Nm

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6.
 7.

8.
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 9.

10.
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Installation

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1. To install, reverse the removal procedure.
Published: 12-Jan-2015
Climate Control - Temperature Blend Door Actuator LH RHD AWD/RHD FWD
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01, Specifications).

2. Refer to: Glove Compartment (501-12, Removal and Installation).

3.

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4.

Installation
1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Land Rover

approved diagnostic equipment.

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Published: 17-Nov-2014
Climate Control - Temperature Blend Door Actuator RH
Removal and Installation

Removal

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

1. Make the SRS system safe.

Refer to: Standard Workshop Practices (100-00, Description and

Operation).

2. Refer to: Heater Core and Evaporator Core Housing (412-01,

Removal and Installation).

3.

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Installation

1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Land Rover

approved diagnostic equipment.
Published: 22-Jul-2015
Climate Control - Thermostatic Expansion Valve INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

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

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Engine Control Module (ECM) (303-14A Electronic Engine

Controls - INGENIUM I4 2.0L Diesel, Removal and Installation).
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - INGENIUM I4 2.0L Diesel (412-00 Climate Control System -
General Information, General Procedures).

3. Refer to: Engine Control Module (ECM) (303-14B Electronic Engine

Controls - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and
Installation).

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Refer to: Air Conditioning (A/C) System Recovery, Evacuation and
Charging - GTDi 2.0L Petrol (412-00 Climate Control System - General
Information, General Procedures).

4. CAUTIONS:

Make sure that all openings are sealed. Use new

blanking caps.

Lubricate the new seals with clean refrigerant oil.

NOTE: Install new O-ring seals.

Torque: 9 Nm

5. Torque: 4 Nm
Installation

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1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Battery, Mounting and Cables -
General Specification - Stop-start and timed climate models:
Item Specification
Battery:
Type H7 AGM (VRLA)
Capacity 80Ah/800CCA

General Specification - All except stop-start and timed climate models

Item Specification
Battery:
Type H7 Flooded
Capacity 80Ah/700CCA

Battery Disconnect/Connect

CAUTION: The vehicle status must be established before attempting battery disconnect/connect. Reference must be
then made to the following table to establish the relevant procedure to be followed.

NOTE: Make a note of the customers radio preset stations.

Vehicle status Procedure

Vehicle without Telematics 1
Vehicle with Telematics 2

Procedure 1
Disconnect battery Connect battery
1. Chock the wheels 1. Make sure that all electrical loads are switched OFF
2. Open the hood 2. Connect battery ground cable to the battery - 6Nm
3. Remove the battery cover 3. Connect the BMS electrical connector
4. Disconnect the engine wiring harness 4. Connect the battery ground to starter motor connector/terminal (if equipped) -
ground connector/terminal 10Nm
5. Disconnect the battery ground to
starter motor connector/terminal (if 5. Connect the engine wiring harness ground connector/terminal - 6Nm
equipped)
6. Disconnect the battery monitoring
system (BMS) module electrical 6. Install the battery cover
connector
7. Disconnect the battery ground cable
7. Close the hood
from the battery
 8. Switch the ignition on
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop, release
switch, reapply and hold for 1 second (relay in door will click). One touch should now
work

Procedure 2
Disconnect battery Connect battery
1. Make sure the customer has placed
stolen vehicle tracking into Service Mode 1. Make sure that all electrical loads are switched OFF
(if equipped)
2. Chock the wheels 2. Connect battery ground cable to the battery - 6Nm
3. Open the hood 3. Connect the BMS electrical connector
4. Connect the battery ground to starter motor connector/terminal (if equipped) -
4. Remove the battery cover
10Nm
5. Disconnect the engine wiring harness
5. Connect the engine wiring harness ground connector/terminal - 6Nm
ground connector/terminal
6. Disconnect the battery ground to starter
6. Install the battery cover
motor connector/terminal (if equipped)
7. Disconnect the battery monitoring
7. Close the hood
system (BMS) module electrical connector
8. Disconnect the battery ground cable
8. Switch the ignition on
from the battery
9. Reset radio station preset stations
10. Reset the clock
11. Reset electric window one-touch facility. Power window up to hard stop,

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release switch, reapply and hold for 1 second (relay in door will click). One touch
should now work
12. Request stolen vehicle tracking removed from Service Mode (if equipped)

Torque Specifications
Item Nm lb-ft lb-in
Vehicle body brace retaining bolts 25 18 -
Battery terminal nuts 6 - 53
Battery ground terminal nut - battery to starter motor retaining stud (if equipped) 10 7 -
Battery tray retaining bolts 10 7 -

Published: 20-Oct-2014
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging GTDi 2.0L Petrol
General Procedures

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.
Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

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pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
 equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

Always follow the health and safety precautions when handling

the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

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8. Following the A/C Charging Trolley manufacturer's instructions,
evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV
(412-01, Removal and Installation).

All vehicles

10.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

11. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.

12.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

13. Disconnect the A/C Charging Trolley high and low pressure
connections.

Vehicles without auxiliary climate control

 14. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Vehicles with auxiliary climate control

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15. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Published: 11-Jun-2015
Electronic Engine Controls - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV - Engine
Control Module (ECM)
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

Removal steps in this procedure may contain installation details.

If a new Engine Control Module (ECM) is installed, configure using Jaguar Land Rover approved diagnostic equipment.

All vehicles
 1. Refer to: Specifications (414-01 Battery, Mounting and Cables,
Specifications).

2. Refer to: Plenum Chamber (412-01 Climate Control, Removal and

Installation).

Vehicles with petrol engine

3.

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Vehicles with diesel engine

4.
 cardiagn.com
All vehicles

5. Torque: 7 Nm

6.
NOTE: Do not disassemble further if the
component is removed for access only.
 7. Torque: 7 Nm

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Installation

1. To install, reverse the removal procedure.

2. If a new Engine Control Module (ECM) is installed, configure using

Jaguar Land Rover approved diagnostic equipment.

Published: 16-Sep-2015
Electronic Engine Controls - INGENIUM I4 2.0L Diesel - Engine Control Module
(ECM)
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1. Disconnect the battery ground cable.

Refer to: Specifications (414-01 Battery, Mounting and Cables,

Specifications).

2. Refer to: Secondary Bulkhead Center Panel - GTDi 2.0L Petrol

(501-02 Front End Body Panels, Removal and Installation).

Left-hand drive vehicles

3.

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4.

5.
NOTE: If equipped.
 6. Torque: 7 Nm

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7.
NOTE: Do not disassemble further if the
component is removed for access only.

Torque: 7 Nm

Right-hand drive vehicles

8. Torque: 3.6 Nm

9.

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10.
 11. Torque: 7 Nm

12.
NOTE: Do not disassemble further if the
component is removed for access only.

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Torque: 7 Nm

Installation

1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Jaguar

approved diagnostic equipment.

Published: 17-Jul-2015
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging INGENIUM I4 2.0L Diesel
General Procedures

Draining

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
 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.

Refrigerant recovery.

Vehicles without auxiliary climate control

2. Remove the dust covers from the high and low

pressure connections.

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Vehicles with auxiliary climate control

3. Remove the dust covers from the high and low

pressure connections.

All vehicles

4. Connect the A/C Charging Trolley high and low pressure lines to the
appropriate connections.

5. WARNINGS:

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
 equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-134a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant. Refrigerant R-134a from domestic and commercial sources
must not be used in motor vehicles air conditioning systems.

Refrigerant must always be recycled before re-use to make sure

that the purity of the refrigerant is high enough for safe use in the air
conditioning (A/C) system. Recycling should always be carried out with
equipment which is design certified for compliance with SAE J2099 and
SAE J2788. Other equipment may not recycle refrigerant to the
required level of purity. A R-1234yf Refrigerant Recover Recycling
Re-charging station must not be used with any other type of
refrigerant. Refrigerant R-1234yf from domestic and commercial
sources must not be used in motor vehicles A/C systems.

Following the A/C Charging Trolley manufacturer's instructions,

recover the refrigerant from the A/C system.

6. CAUTIONS:

Make sure that all openings are sealed. Use new blanking caps.

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Always follow the health and safety precautions when handling
the refrigerant R-134a.

Always follow the health and safety precautions when handling

the refrigerant R-1234yf.

Collect the refrigerant in specialist equipment and reuse.

7. Evacuation.

8. Following the A/C Charging Trolley manufacturer's instructions,

evacuate the A/C system.

9.
NOTE: The desiccant bag need only be changed under the
following circumstances: There is dirt in the refrigerant circuit (For
example: 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.

Refer to: Desiccant Bag - INGENIUM I4 2.0L Diesel (412-01, Removal

and Installation).

Filling

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles

1.
CAUTION: The system must be evacuated for 30 minutes
immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

Recharging

2. Following the A/C Charging Trolley manufacturer's instructions,

make sure the correct amount of oil is added to the A/C system before
or during recharging.
 3.
CAUTION: Recharge the A/C system only through the
systems high pressure port.

Recharge the A/C system to the correct specification.

Refer to: Specifications (412-00, Specifications).

4. Disconnect the A/C Charging Trolley high and low pressure

connections.

Vehicles without auxiliary climate control

5. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

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Vehicles with auxiliary climate control

6. Install and firmly tighten the caps that cover the high
and low pressure connections.

Torque: 6 Nm

Activation

1. Authoring Template