NRRWM 21/11/01 11:21 am Page 1

Workshop Manual (2006MY)

Service Procedures: SECTION 4 - Electrical
PART 412: CLIMATE CONTROL SYSTEM
WSM-6107 Range Rover L322 2006MY
Table of Contents

SECTION 4: Electrical
412: Climate Control System
412-00: Climate Control System - General Information
412-00-01: Air Conditioning (A/C) System Recovery, Evacuation and
Charging
412-01: Air Distribution and Filtering
412-01-01: General Specification
412-01-02: Description and Operation
412-01-03: Plenum Chamber (80.15.62)
412-01-04: Driver Side Register
412-01-05: Driver Side Register Trim Panel
412-01-06: Passenger Side Register Trim Panel
412-01-07: Passenger Side Register
412-02A: Heating and Ventilation
412-02A-01: Description and Operation
412-02B: Auxiliary Heating
412-02B-01: Description and Operation
412-02B-02: Fuel Fired Booster Heater V8 4.4L Petrol
412-03A: Air Conditioning
412-03A-01: General Specification
412-03A-02: Description and Operation
412-03A-03: Air Conditioning (A/C) Compressor V8 4.4L Petrol
412-03A-04: Condenser Core V8 4.4L Petrol
412-04: Control Components
412-04-01: Description and Operation
412-04-02: Ambient Air Temperature Sensor
412-04-03: Driver Side Temperature Blend Door Actuator
412-04-04: Instrument Panel Blend Door Actuator LHD AWD
Published: 11-May-2011
Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging
General Procedures

1.
WARNING: Servicing must be carried out by personnel
familliar 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.

NOTE: The receiver drier need only be changed under the

following circumstances: There is dirt in the refrigerant circuit ( eg.
compressor seizure ). The system is leaking and refrigerant has been
lost to atmosphere. Refrigerant circuit has been open more than 24
hours due to repair.

Refrigerant recovery.

2. Remove the dust covers from the high and low

pressure connections.

3. Connect the high and low pressure lines to the appropriate

connections.

4. Open the valves on the connections.

5. Turn the valves on the station to the correct positions.

6. Turn the process switch to the correct position.

7. Turn the main switch to 'ON'.

8.
WARNING: Refrigerant must always be recycled before
re-use to ensure that the purity of the refrigerantis 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 SEA J1991. Other equipment may
not recycle refrigerant to the required level of purity. R143a
Refrigerant Recover Recycling Recharging station must not be used
with any other type of refrigerant.Refrigerant R134a from domestic
and comercial sources must not be used in motor vehicles air
conditioning systems.

Allow the system to recover the refrigerant from the system.

9. Close the valves on the refrigerant station.

10. Turn the main switch 'OFF'.

11. Close the valves on the connections.

12. Disconnect the high and low pressure connections.

13. Install the dust covers to the connectors.

14. Open the tap at the rear of the station to drain the refrigerant oil.

15. Measure and record the quantity of refrigerant oil recovered from
the system.

16. Close the tap at the rear of the station.

17. Evacuation.

18. Remove the dust covers from the high and low pressure
connections.

19. Connect the high and low pressure lines to the appropriate
connections.

20. Open the valves on the connections.

21. Turn the valves on the station to the correct positions.

22. Turn the process switch to the correct position.

23. Turn the main switch to 'ON'.

24. Allow the station to evacuate the A/C system.

25.
CAUTION: The system must be evacuated immediatley
before recharging commences. Delay between evacuation and
recharging is not permitted

Recharging

26. Close the valves on the refrigerant station.

27. Close the valve on the oil charger.

28. Disconnect the yellow line from the refrigerant station.

29. Remove the cover from the oil charger.

30. Pour the correct quantity of refrigerant oil into the oil charger.
31. Install the cover to the oil charger.

32. Connect the yellow line to the refrigerant station.

33. Open the valve on the oil charger.

34. Move the pointer on the refrigerant gauge to mark the position of
the refrigerant drop.

35. Slowly open the correct valve on the refrigerant to allow the
vacuum to pull the refrigerant into the system.

36. Close the valve on the refrigerant station when the correct
amount of refrigerant has been drawn into the air conditioning system.

37. Turn the main switch 'OFF'.

38. Close the valves on the connections.

39. Disconnect the high and low pressure connections.

Published: 11-May-2011
Air Distribution and Filtering -
Torque Specification
Description Nm lb-ft
Plenum chamber nuts 10 7
Battery positive cable to bulkhead 20 15
Published: 11-May-2011
Air Distribution and Filtering - Air Distribution and Filtering
Description and Operation

COMPONENT LOCATIONS

Item Description
1 Forced ventilation outlet
2 Windshield duct
3 Face level duct
4 Front footwell duct
5 Heater assembly
6 Rear footwell duct
7 Rear face duct
8 Rear blower (high line system only)
9 Rear face duct extension (low line system only)

GENERAL
The air distribution and filtering system controls the distribution and quality of air supplied to the vehicle interior. The system
consists of:

Air ducts.
Air registers and vents.
A cabin air filter.

AIR DUCTS

Air from the heater assembly is distributed around the vehicle interior through distribution ducts to outlets in the instrument
panel, the front and rear footwells, and the rear of the cubby box between the front seats.

Air Distribution

AIR REGISTERS AND VENTS

In the instrument panel, the air ducts are connected to fixed vents for the windshield and side windows and adjustable
registers for face level air. An adjustable register is also installed on the rear of the cubby box for rear face level air. The
footwell outlets are fixed vents formed in the end of the related air ducts.

CABIN AIR FILTER

 Item Description
1 Air outlet to heater assembly
2 Fixing lug
3 Door catch
4 Door
5 Particle or particle/odor filter
6 Inlet grille
7 Seal
The cabin air filter consists of a serviceable particle filter, or a particle/odor filter, which is installed in the air inlet duct. The
cabin air filter prevents odors and/or particulate matter from entering the vehicle with the fresh air.
Published: 11-May-2011
Air Distribution and Filtering - Plenum Chamber
Removal and Installation

Removal

1. Secure the hood in the service position.

Release the support struts.

2. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

3. Release the hood seal from the plenum chamber.

4. Disconnect the battery positive cable from the bulkhead.

Release the cover.
Remove the nut.

5. Remove the plenum chamber.

Remove the 2 nuts.

6.
NOTE: Do not disassemble further if the component is
removed for access only.

Remove the air intake cover.

Remove the 3 screws.

7. Remove the pollen filter.

Installation

1. Install the pollen filter.

2. Install the air intake cover.

Tighten the screws.

3. Install the plenum chamber.

Tighten the nuts to 10 Nm (7 lb.ft).

4. Connect the battery positive cable.

Tighten the nut to 20 Nm (15 lb.ft).
Secure the cover.

5. Attach the hood seal.

6. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

7. Connect the hood support struts.

Published: 11-May-2011
Air Distribution and Filtering - Driver Side Register
Removal and Installation

Removal

1.
CAUTION: Care must be taken to avoid
damaging the register internal components.

Remove the register.

Carefully release the 4 internal clips, apply a even
outward pressure until the last clip is released.
Disconnect the electrical connector.

Installation

1. Install the register.

Connect the electrical connector.
Position and secure the clips.
Published: 11-May-2011
Air Distribution and Filtering - Driver Side Register Trim Panel
Removal and Installation

Removal

1. Remove the driver's side register.

For additional information, refer to: Driver Side Register (412-01 Air
Distribution and Filtering, Removal and Installation).

2. Remove the A-pillar upper trim panel.

For additional information, refer to: A-Pillar Trim Panel (501-05
Interior Trim and Ornamentation, Removal and Installation).

3.
CAUTION: Protect the surrounding trim from
damage when changing the component.

Remove the instrument panel end trim panel.

Open the front door for access.
Release sufficient door aperture seal for access.
Carefully release the 4 clips.

4. Remove the driver side register trim panel.

Remove the 3 Torx screws.
Carefully release the trim and disconnect the
switch electrical connector.
Disconnect the footwell lamp electrical connector.

5.
NOTE: Do not disassemble further if the component is
removed for access only.

Remove the lamp switch assembly.

Installation

1. Install the lamp switch assembly.

2. Install the driver side register trim panel.

Connect the electrical connectors.
Install the Torx screws.

3. Install the instrument panel end trim panel.

Carefully align and secure the clips.
Install the aperture seal.
4. Install the A-pillar upper trim panel.
For additional information, refer to: A-Pillar Trim Panel (501-05
Interior Trim and Ornamentation, Removal and Installation).

5. Install the driver's side register.

For additional information, refer to: Driver Side Register (412-01 Air
Distribution and Filtering, Removal and Installation).
Published: 11-May-2011
Air Distribution and Filtering - Passenger Side Register Trim Panel
Removal and Installation

Removal

1. Remove the A-pillar upper trim panel.

For additional information, refer to: A-Pillar Trim Panel (501-05
Interior Trim and Ornamentation, Removal and Installation).

2. Remove the passenger side register.

For additional information, refer to: Driver Side Register (412-01 Air
Distribution and Filtering, Removal and Installation).

3.
CAUTION: Protect the surrounding trim from
damage when changing the component.

Remove the instrument panel end trim panel.

Open the front door for access.
Release sufficient door aperture seal for access.
Carefully release the 4 clips.

4. Release the cup holder.

Remove the Torx screw.

5. Remove the passenger side register trim panel.

Remove the 3 Torx screws.

6.
NOTE: Do not disassemble further if the component is
removed for access only.

Remove the cup holder.

Depress the 4 clips.

Installation

1. Install the cup holder.

Secure the clips.

2. Install the passenger side register trim panel.

Install the Torx screws.
Install the cup holder Torx screw at the rear of the assembly.
3. Install the instrument panel end trim panel.
Carefully align and secure the clips.
Install the aperture seal.

4. Install the passenger side register.

For additional information, refer to: Driver Side Register (412-01 Air
Distribution and Filtering, Removal and Installation).

5. Install the A-pillar upper trim panel.

For additional information, refer to: A-Pillar Trim Panel (501-05
Interior Trim and Ornamentation, Removal and Installation).
Published:
Air Distribution and Filtering - Passengers Side Register
Removal and Installation

Removal

1.
CAUTION: Care must be taken to avoid
damaging the register internal components.

Remove the register.

Carefully release the 4 internal clips, apply a even
outward pressure until the last clip is released.
Disconnect the electrical connector.

Installation

1. Install the register.

Connect the electrical connector.
Position and secure the clips.
Published: 11-May-2011
Heating and Ventilation - Heating and Ventilation
Description and Operation

COMPONENT LOCATIONS

Item Description
1 Forced ventilation outlet
2 Windshield duct
3 Face level duct
4 Front footwell duct
5 Heater assembly
6 Rear footwell duct
7 Rear face duct
8 Rear blower (automatic system only)
9 Rear face duct extension (manual system only)

GENERAL
The heating and ventilation system controls the temperature and flow of air supplied to the vehicle interior. The system
consists of:

An air inlet duct.

A heater.
A rear blower (automatic system only).
Two ventilation outlets.

Fresh or recirculated air flows into the heater from the inlet duct. The blower, and ram effect when the vehicle is moving,
forces the air through the heater. Air from the cabin exhausts through the ventilation outlets.

AIR INLET DUCT

Item Description
1 Air outlet to heater assembly
2 Fixing lug
3 Door catch
4 Door
5 Particle or particle/odor filter
6 Inlet grille
7 Seal
The air inlet duct directs fresh air from above the hood into the heater. The air inlet duct is centrally mounted on the engine
bulkhead, below a ventilation grill in the hood, and secured to the bulkhead closing panels.

The cabin air filter is installed in the air inlet duct behind a hinged door.
For additional information, refer to: Air Distribution and Filtering (412-01 Air Distribution and Filtering, Description and
Operation).

HEATER

The heater controls the temperature, volume and distribution of air supplied to the distribution ducts as directed by selections
made on the automatic temperature control (ATC) module control panel. The heater is installed on the vehicle center-line,
between the fascia and the engine bulkhead. The heater consists of a casing formed from a series of plastic moldings. Internal
passages integrated into the casing guide the air through the casing and separate it into two flows, one for the left-hand (LH)
outlets and one for the right-hand (RH) outlets. Two drain outlets at the bottom of the casing are connected to overboard
drain hoses in the sides of the transmission tunnel.

The heater incorporates:

 A blower.
A blower motor control module.
A heater core.
Control doors.
Control door motors.
The thermostatic expansion valve and the evaporator of the air conditioning (A/C) system.
For additional information, refer to: Air Conditioning (412-03 Air Conditioning, Description and Operation).
The evaporator temperature sensor and either one (manual system) or two (automatic system) heater temperature
sensors.
For additional information, refer to: Control Components (412-04 Control Components, Description and Operation).

Manual Heater

Item Description
1 Fresh air inlet
2 Fresh/Recirculated air door
3 Face level temperature blend door control
4 Insulated refrigerant pipes
5 Windshield air outlet
6 Face level air outlets
7 Front footwell air outlet
 8 Rear face level air outlet
9 Rear footwell air outlet
10 Water drain
11 Coolant pipes
12 Fresh/Recirculated air doors motor
13 Distribution doors motor
Automatic Heater

Item Description
1 Fresh air inlet
2 Fresh/Recirculated air door
3 Ram air door
4 Face level temperature blend door control
5 Rear face level temperature blend motor
6 Insulated refrigerant pipes
7 Ram air doors motor
8 Windshield air outlet
 9 Face level air outlets
10 Front footwell air outlet
11 Footwell air doors motor
12 Rear face level air outlet
13 Face level air doors motor
14 Rear footwell air outlet
15 Water drain
16 Windshield distribution motor
17 Coolant pipes
18 Fresh/Recirculated air door motor
Blower

The blower is installed between the air inlets and the evaporator, and consists of two open hub, centrifugal fans powered by a
single electric motor. Operation of the electric motor is controlled by the ATC module via the blower motor control module
(voltage amplifier) installed in the outlet of the RH fan.

To produce the seven blower speeds the ATC module outputs a stepped control voltage between 0 and 8 V to the blower
motor control module, which regulates a battery power feed from the central junction box (CJB) to the blower. The control
voltage changes, in 1 V steps, between 2 V (blower speed 1) and 8 V (blower speed 7). If the control voltage is less than 2 V
the blower is off.

Blower Motor Control Module

Heater Core

The same heater core is used in both the manual and automatic heaters. The heater core is internally divided into two
separate halves, with separate coolant inlets for each half and a common coolant outlet. On the manual system, the two
coolant inlets are connected to a common feed from the single coolant valve. On the automatic system, each coolant inlet pipe
is connected to a feed from a separate coolant valve.

Heater Core Assembly

 Item Description
1 Manual system connecting pipes
2 Automatic connecting pipes
Control Doors

Control doors in the heater control the source of inlet air and the distribution and temperature of outlet air.

On both the manual and automatic heaters, a fresh/recirculated air door is installed in the air inlet on each side of the heater.
A stepper motor drives the LH fresh/recirculated air door and a Bowden cable transmits the drive from the LH to the RH
fresh/recirculated air door. On the automatic system, a ram air door is installed inside each fresh/recirculated air door. A
stepper motor drives the RH ram air door and a Bowden cable transmits the drive from the RH to the LH ram air door.

Each side of the heater contains separate distribution doors for the footwell, face level and windshield. The related doors on
each side of the heater are installed on common drive spindles. On the manual heater, the distribution doors are driven by
Bowden cables connected to a cam mechanism, which, in turn, is driven by a stepper motor. On the automatic heater, each
set of distribution doors is driven by a separate stepper motor.

On both the manual and automatic heaters, a blend door is installed below the face level registers. The blend door is driven by
a Bowden cable connected to a thumbwheel on the center face level registers in the fascia, and allows the temperature of face
level air to be modified with cold air direct from the evaporator.

Fascia Center Face Level Register

Item Description
1 RH air control thumbwheel
2 Temperature control thumbwheel
3 LH air control thumbwheel
On models with an automatic climate control system, the heater incorporates an additional blend door for the air directed to
the rear passenger face level register. This allows the temperature of rear face level air to be adjusted independently from the
temperatures selected on the control panel of the ATC module. The blend door is driven by a stepper motor controlled by a
thumbwheel on the rear passenger face level register. The blend door is also used to close off the rear passenger face level
register when maximum air output is required for the front outlets, e.g. when defrost is selected.

Rear Passenger Face Level Register

 Item Description
1 Blower control
2 Temperature control
Control Door Motors

Two types of electrical stepper motor are used to operate the control doors in the heater. A conventional 500 Hz stepper
motor operates the recirculation doors on the manual and automatic systems. On the automatic system, five bus controlled
200 Hz stepper motors operate the ram air, distribution (windshield, face level and footwell) and the rear face level
temperature control doors. On the manual system a bus controlled stepper motor operates the distribution doors cam
mechanism. All of the stepper motors are controlled by the ATC module. None of the stepper motors are interchangeable.

Typical Control Door Motor

Item Description
1 Electrical connector
2 Release clip
3 Output shaft
Each bus controlled stepper motor incorporates a microprocessor and is connected to an M bus from the ATC module, which
consists of three wires making up power, ground and signal circuits. The microprocessor in each bus controlled stepper motor
is programmed with a different address. Each M bus message from the ATC module contains the address of an individual bus
controlled stepper motor, so only that motor responds to the message.

None of the stepper motors incorporate a feedback potentiometer. Instead, the ATC module determines the positions of the
doors by using either their closed or open position as a datum and memorizing the steps that it drives the individual stepper
motors. Each time the ignition is switched on, the ATC module checks the memorized position of the stepper motors against
fixed values for the current system configuration. If there is an error (e.g. after a power supply failure during operation or
after replacement of the ATC module), the ATC module calibrates the applicable stepper motors, to re-establish the datums,
by driving them fully closed or open before re-setting them to their nominal position. A calibration run can also be invoked
using T4.

When any of the control doors are set to fully closed or open, the ATC module signals the related stepper motor to move the
appropriate number of steps in the applicable direction. To accommodate build tolerances and wear, and to ensure the doors
are held in the selected position, every 20 seconds the ATC module signals the stepper motor to move an additional 10 steps
in the relevant direction.

REAR BLOWER (AUTOMATIC SYSTEM ONLY)

The blower is installed between the front seats, in the rear face air duct, and consists of an open hub, centrifugal fan powered
by an electric motor. Operation of the electric motor is controlled by a thumbwheel on the rear passenger face vent via the
ATC module and a blower motor control module (voltage amplifier) installed in the outlet of the fan.

The thumbwheel operates a variable potentiometer, which outputs between 1.25 V (blower off) and 5 V (maximum blower
speed) to the ATC module. The ATC module then outputs a proportional control voltage between 0 and 5 V to the blower
motor control module, which regulates a battery power feed from the rear blower relay to the blower to produce the related
blower speed.

The rear blower relay is installed in the AJB (auxiliary junction box) and energized while the ignition is on.

Rear Blower Motor Control Module

VENTILATION OUTLETS

The ventilation outlets promote the free flow of air through the passenger compartment. The outlets are installed in the LH
and RH rear quarter body panels and vent passenger compartment air into the sheltered area between the rear quarter body
panels and the rear bumper.
Published: 11-May-2011
Auxiliary Heating - Auxiliary Heater
Description and Operation

COMPONENT LOCATION

Item Description
1 Fuel Fired Booster Heater (FFBH) fuel pipe tank connection
2 FFBH receiver (where fitted)
 3 Changeover valve (where fitted)
4 FFBH fuel pump
5 FFBH unit

OVERVIEW

The system consists of a FFBH unit and a FFBH fuel pump. On vehicles with the remote operation feature, the system also
includes a changeover valve, a FFBH receiver and a remote handset.

Fuel for the FFBH system is taken from the vehicle fuel tank, through a line attached to the fuel tank top flange assembly, and
supplied via the FFBH fuel pump to the FFBH unit. In the FFBH unit, the fuel delivered by the FFBH fuel pump is burned and
the resultant heat output is used to heat the engine coolant.

Where fitted, the changeover valve allows the heater coolant circuit to be isolated from the engine coolant circuit during
parked heating.

A control module integrated into the FFBH unit controls the operation of the FFBH unit and the FFBH fuel pump. The automatic
temperature control (ATC) module controls the changeover valve. System operation is initiated by:

The instrument cluster, via the ATC module, for parked heating selections made on the Touch Screen Display (TSD).
For additional information, refer to: Audio System (415-01 Audio Unit, Description and Operation).
The remote handset, via the Television (TV) system antenna and antenna amplifier, and the FFBH receiver, for remote
activation of parked heating.
The ATC module, for additional heating while the engine is running.

FFBH FUEL PUMP

The FFBH fuel pump regulates the fuel supply to the FFBH unit. The FFBH fuel pump is installed at the right-hand (RH) rear of
the fuel tank, in a rubber mounting attached to the rear subframe. The pump is a self priming, solenoid operated plunger
pump. The control module in the FFBH unit outputs a pulse width modulation (PWM) signal to control the operation of the
pump. When the pump is de-energized, it provides a positive shut-off of the fuel supply to the FFBH unit.

Sectioned View of FFBH Fuel Pump

Item Description
1 Solenoid coil
2 Plunger
3 Filter insert
4 Fuel line connector
5 O-ring seal
6 Spring
7 Piston
8 Bush
9 Fuel line connector
10 Non return valve
The solenoid coil of the FFBH 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
line to the FFBH unit. 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.

FFBH UNIT

The FFBH unit is installed in the passenger side rear of the engine compartment, below the battery. It is connected in series
with the coolant supply to the heater assembly. Two electrical connectors on the FFBH unit connect it to the vehicle wiring.

FFBH Unit Components

Item Description
1 Coolant outlet hose
2 Electrical connectors
3 Air inlet filter
4 Mounting bracket
5 Exhaust pipe
6 Fuel supply line
7 Coolant inlet hose
Sectioned View of FFBH Unit
Item Description
1 Combustion air fan
2 Burner housing
3 Control module
4 Heat exchanger
5 Burner insert
6 Exhaust
7 Glow plug/flame sensor
8 Evaporator
9 Coolant inlet
10 Circulation pump
11 Fuel inlet
12 Coolant outlet
13 Air inlet
Circulation Pump
The circulation pump is installed at the coolant inlet to the FFBH unit to assist the coolant flow through the FFBH unit and the
heater assembly. The pump runs continuously while the FFBH unit is in standby or active operating modes. While the FFBH
unit is inactive, coolant flow is reliant on the engine coolant pump and the auxiliary coolant pump.

Combustion Air Fan

The combustion air fan regulates the flow of air into the unit to support combustion of the fuel supplied by the FFBH pump and
to purge and cool the FFBH unit. A canister type filter is included in the air inlet supply line to prevent particulates entering
and contaminating the FFBH unit.

Burner Housing

The burner housing contains the burner insert and also incorporates connections for the exhaust pipe, the coolant inlet from
the circulation pump and the coolant outlet to the heater assembly. The exhaust pipe directs exhaust combustion gases to
atmosphere through a pipe below the FFBH unit.

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

Control Module/Heat Exchanger

The control module controls and monitors operation of the FFBH system. Ventilation of the control module is provided by an
internal flow of air from the combustion air fan. The heat exchanger transfers heat generated by combustion to the coolant. A
sensor in the heat exchanger provides the control module with an input of heat exchanger casing temperature, which the
control module relates to coolant temperature and uses to control system operation. The temperature settings in the control
module are calibrated to compensate for the difference between coolant temperature and the heat exchanger casing
temperature detected by the sensor. Typically, as the coolant temperature increases, the coolant will be approximately 7 °C
(12.6 °F) hotter than the temperature detected by the sensor; as the coolant temperature decreases, the coolant will be
approximately 2 °C (3.6 °F) cooler than the temperature detected by the sensor.

CHANGEOVER VALVE

The changeover valve is a normally open solenoid valve installed between the supply and return sides of the heater coolant
circuit. The changeover valve is located in the engine compartment on the engine bulkhead. When de-energized, the
changeover valve connects the heater coolant circuit to the engine coolant circuit. When energized, the changeover valve
isolates the heater coolant circuit from the engine coolant circuit.

The changeover valve is controlled by a power feed from the ATC module.

FFBH RECEIVER

The FFBH receiver translates the FFBH request radio signals, relayed from the TV antenna amplifier, into a voltage output to
the FFBH unit. When a request for parked heating is received, the FFBH receiver outputs a battery power feed to the FFBH
unit. When a request to switch off parked heating is received, the FFBH receiver disconnects the power feed.

The FFBH receiver has a permanent power feed from the vehicle battery and is connected to the TV antenna amplifier by a
coaxial cable.

FFBH REMOTE HANDSET

Item Description
1 Antenna
2 Off button
3 On button
4 light emitting diode (LED)
The FFBH remote handset allows parked heating to be remotely controlled up to a minimum of 100 m (328 ft) from the
vehicle. On and off buttons activate and de-activate parked heating, a red LED illuminates to indicate when parked heating is
active and when the on/off signals have been received by the vehicle. The FFBH remote handset is powered by 2 serviceable
1.5 V batteries located under a cover on the rear of the handset.

CONTROL DIAGRAM

NOTE: A = Hardwired; B = K bus; F = RF transmission; K = I bus; M = P bus; N = Medium speed controller area
network (CAN) bus; P = MOST ring; T = Coaxial cable
 Item Description
1 FFBH remote handset
2 RH side window antenna
3 TV antenna amplifier
4 FFBH receiver
5 Passenger door mirror
6 FFBH fuel pump
7 Passenger door module
8 generic electronic module (GEM)
9 Driver door module
10 Changeover valve
11 Driver door mirror
12 TSD
13 IHU
14 ATC module
15 Instrument cluster
16 Diagnostic socket
17 FFBH
18 Fuse 59, central junction box (CJB)

PRINCIPLES OF OPERATION

The FFBH system operates in two modes:

Parked heating, to heat the passenger compartment while the vehicle is parked with the engine off.
Additional heating, to boost heater performance while the engine is running.

The ATC module disables FFBH operation if battery voltage is too low:

When the engine is off the low voltage limit is 11.4 V for more than 10 seconds; the system is re-enabled if battery
voltage increases to 12.2 V.
When the engine is running the low voltage limit varies with ambient temperature, from 11.1 V at -25°C (-13°F) and
below to 11.7 V at 15 °C (59 °F) and above; if battery voltage is below the limit for 2 minutes the system is disabled
for the remainder of the ignition cycle.

During FFBH operation, with or without the engine running, the coolant valves of the climate control system remain
de-energized and heater core temperature is directly related to the temperature of the coolant coming from the FFBH unit.

Parked Heating/Ventilation

Parked heating works in conjunction with parked ventilation. When parked heating/ventilation is selected, the vehicle interior
is either heated by parked heating or cooled by parked ventilation, depending on the ambient temperature. Parked heating
occurs if the ambient temperature is less than 16 °C (61 °F); parked ventilation occurs if the ambient temperature is 16 °C
(61 °F) or more.

Parked heating/ventilation is controlled by direct selection on the TSD, by using the TSD to program one or two on/off cycle
times in the following 24 hour period, or by using the FFBH remote handset. The direct selection and programmed time modes
of operation are selected when the engine is stopped and the ignition switch is in position I. If required the key can then be
removed from the ignition switch and the vehicle locked. In all operating modes, parked heating/ventilation is automatically
de-activated after 30 minutes to prevent excessive drain on the battery. Parked ventilation is automatically de-activated when
the ignition is switched on.

When programmed times for parked heating/ventilation are entered on the TSD, the times are stored in the memory of the
instrument cluster and the climate set indicator, on the TSD, is permanently illuminated.

If the engine is started while parked heating is on:

If the engine coolant temperature is equal to or more than the heater coolant temperature, parked heating is switched
off.
If the engine coolant temperature is less than the heater coolant temperature, parked heating remains on until the
engine coolant temperature reaches the heater coolant temperature.

Programmed and TSD Selected Parked Heating/Ventilation

At a programmed parked heating/ventilation start time, or when parked heating/ventilation is selected on using the TSD, the
instrument cluster outputs:

A parked heating/ventilation request to the TSD via the medium speed CAN bus, the Integrated Head Unit (IHU) and
the Media Orientated System Transport (MOST) ring.
 A parked heating/ventilation request to the ATC module and the GEM on the K bus.
The ambient and engine coolant temperatures to the ATC module and GEM on the K bus.

On receipt of the messages:

The climate set indicator on the TSD panel flashes at 2 Hz to indicate that parked heating/ventilation is active.
If the ambient temperature is less than 5 °C (41 °F), the GEM activates the door mirror heaters for 3 minutes.
If parked heating is activated, the ATC module:
- Energizes the changeover valve.
- Sends a K bus message to activate the FFBH.
- Operates the blower at speed 1.
- Opens the windscreen distribution doors in the heater assembly and closes the face and footwell doors.
If parked ventilation is activated, the ATC module:
- Operates the blower at speed 1.
- Opens the face level distribution doors in the heater assembly and closes the windscreen and footwell doors.

When parked heating/ventilation is selected off, or after 30 minutes has elapsed, the instrument cluster sends parked
heating/ventilation off messages on the medium speed CAN bus and the K bus. On receipt of the messages:

The TSD switches off the climate set indicator.

If parked heating is active, the ATC module:
- Sends a K bus message to de-activate the FFBH.
- Switches off the blower.
- Returns the distribution doors to the previous settings.
- After 3 minutes, de-energizes the changeover valve.
If parked ventilation is active, the ATC module:
- Switches off the blower.
- Returns the distribution doors to the previous settings.

Remotely Selected Parked Heating/Ventilation

When parked heating/ventilation is selected on with the remote handset, the request is received by the FFBH receiver via the
TV antenna and TV antenna amplifier. The FFBH receiver relays the request as a hardwired signal to the FFBH control module.
On receipt of the request, the FFBH control module sends the request to the ATC module and the instrument cluster on the K
bus. Parked heating/ventilation then operates as detailed above.

Heater Coolant Circuit

 Item Description
1 Coolant valve (manual system)
2 Heater core
3 Coolant valves (automatic system)
4 Auxiliary coolant pump
5 Engine cooling system
6 ATC module
7 Changeover valve (where fitted)
8 FFBH unit
Additional Heating

On diesel vehicles, additional heating reduces the heater warm-up time and is also used to maintain heater performance
throughout the drive cycle. On petrol vehicles, additional heating is only used to reduce the heater warm-up time at the
beginning of the drive cycle, and only occurs if parked heating is already active when the engine starts.

The ATC module activates the additional heating mode when the engine is running and the following conditions coexist:

The ambient temperature is less than 8 °C (41 °F).

The engine coolant temperature is less than 75 °C (167 °F).
The heater coolant temperature is less than 70 °C (158 °F).
 The reference temperature is 100%.
The blower is on.

To activate the additional heating mode, the ATC module energizes the auxiliary coolant pump and sends K bus messages to
the FFBH unit to start/continue operation (the changeover valve remains de-energized).

The ATC module stops the FFBH and de-energizes the auxiliary coolant pump when any of the following occur:

The engine stops.

The ambient temperature increases to more than 15 °C (46 °F).
The engine coolant temperature increases to more than 75 °C (167 °F).
The heater coolant temperature increases to more than 70 °C (158 °F).
The reference temperature decreases to less than 90%.
The blower is selected off.

FFBH Unit

Once initiated by a message from the ATC module, FFBH operation is controlled by the control module in the FFBH unit. The
control module controls the FFBH unit at one of two heat output levels, 2.5 kW at part load combustion and 5 kW at full load
combustion.

Start Sequence: At the beginning of the start sequence the control module energizes the glow plug function of the glow
plug/flame sensor, to preheat the combustion chamber, starts the combustion air fan at slow speed and energizes the coolant
circulation pump. After approximately 30 seconds, the control module energizes the FFBH fuel pump at the starting sequence
speed. The fuel delivered by the FFBH fuel pump evaporates in the combustion chamber, mixes with air from the combustion
air fan and is ignited by the glow plug/flame sensor. The control module then progressively increases the speed of the FFBH
fuel pump and the combustion air fan. Once combustion is established the control module switches the glow plug/flame
sensor from the glow plug function to the flame sensing function to monitor combustion. From the beginning of the start
sequence to stable combustion takes approximately 90 seconds for a start to part load combustion and 150 seconds for a
start to full load combustion.

Coolant Temperature Control: When the control module first enters the active mode, it initiates a start to full load combustion.
Full load combustion continues until the heat exchanger casing temperature reaches 72 °C (162 °F), at this point the control
module decreases the speed of the FFBH fuel pump and the combustion air fan to half speed, to produce part load
combustion. The control module maintains part load combustion while the heat exchanger casing temperature remains
between 68 and 76 °C (154 and 169 °F). If the heat exchanger casing temperature decreases to 68 °C (154 °F), the control
module switches the system to full load combustion again. If the heat exchanger casing temperature increases to 76 °C (169
°F), the control module enters a control idle phase of operation.

On entering the control idle phase, the control module immediately switches the FFBH 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 heat exchanger casing temperature remains above 71 °C (160
°F). If the heat exchanger casing temperature decreases to 71 °C (160 °F), within 15 minutes of the control module entering
the control idle phase, the control module initiates a start to part load combustion. If more than 15 minutes elapse before the
heat exchanger casing temperature decreases to 71 °C (160 °F), the control module initiates a start to full load combustion.

In order to limit the build up of carbon deposits on the glow plug/flame sensor, the control module also enters the control idle
phase if the continuous part and/or full load combustion time exceeds 72 minutes. After the cool down period, if the heat
exchanger casing is still in the temperature range that requires additional heat, the control module initiates an immediate
restart to part or full load combustion as appropriate.

Shutdown: When the ATC module sends a K bus message to de-activate the FFBH operation, the control module de-energizes
the FFBH fuel pump to stop combustion, but continues operation of the combustion air fan and the circulation pump to cool
down the FFBH unit. The cool down time depends on the combustion load at the time the message is received.

Cool Down Times

Combustion Load Cool Down Time, Seconds
Part 100
Full 175
Diagnostics: The control module monitors the FFBH system for faults. Any faults detected are stored in a volatile memory in
the control module, which can be interrogated using the Land Rover approved diagnostic system. A maximum of 3 faults and
associated freeze frame data can be stored at any one time. If a further fault is detected, the oldest fault is overwritten by the
new fault.

The control module also incorporates an error lockout mode of operation that inhibits system 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 circulation pump after a cool down time of approximately 2 minutes. Error
lockout occurs for start sequence failures and/or combustion flameouts, heat exchanger casing overheat and out of limit input
voltage. 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.

Start Failure/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 or flameout, and decreased by one if
a subsequent start is successful. If the event timer increases to three (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 casing temperature exceeds 105 °C (221 °F).

Out of Limit Voltage: The control module enters the error lockout mode if the battery or alternator power input is less than
10.5 ± 0.3 V for more than 20 seconds, or more than 15.5 ± 0.5 V for more than 6 seconds.
Published: 06-May-2015
Auxiliary Heating - Fuel Fired Booster Heater V8 4.4L Petrol
Removal and Installation

Removal

CAUTIONS:

RHD illustration shown, LHD is similar.

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

NOTE: Removal steps in this procedure may contain installation details.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-00, Specifications).

2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

4. Refer to: Cooling System Draining, Filling and Bleeding (303-03B

Engine Cooling - V8 4.4L Petrol, General Procedures).

5. Torque: 10 Nm

6. Torque: 10 Nm
7.
CAUTION: Be prepared to collect escaping
fluids.

8. Torque: 10 Nm
 9.
NOTE: Do not disassemble further if the
component is removed for access only.

Torque: 10 Nm

Installation

1. To install, reverse the removal procedure.

2.
NOTE: Only carry out this step if a new fuel fired booster
heater (FFBH) has been installed.

Using the Land Rover approved diagnostic system, follow the

on-screen instructions and configure the auxiliary heater control
module (AHCM).

3. Connect the Land Rover approved diagnostic equipment to the

vehicle and carry out the Fuel fired burner heater activation test.
Published: 11-May-2011
Air Conditioning -
Lubricant
Item Specification
Compressor oil Sanden SP-10 PAG oil
Total system capacity 120 cm³ (4.2 fluid ounces)
Additional amount of oil to be added to system if a component is replaced:
Condenser 30 cm³ (1.05 fluid ounces)
Evaporator 20 cm³ (0.7 fluid ounces)
Pipe or hose 10 cm³ (0.35 fluid ounces)

System Refrigerant Specification/Capacity

Item Specification
Refrigerant type R134A
Total system capacity 700 grammes (24.69 ounces)

General Specification
Item Description
Compressor:
Make Sanden
Type PXV 16

Torque Specifications
Description Nm lb-ft
Compressor mounting bolts 25 18
Compressor mounting bracket bolts 25 18
Refrigerant line bolts 10 7
Accessory drive belt tensioner bolt 40 30
Published: 11-May-2011
Air Conditioning - Air Conditioning
Description and Operation

COMPONENT LOCATIONS - 3.0L DIESEL

Item Description
1 High pressure servicing connection
2 Low pressure servicing connection
3 Thermostatic expansion valve
4 Evaporator
5 Receiver drier module
6 Condenser
7 air conditioning (A/C) compressor
COMPONENT LOCATIONS - 4.2L and 4.4L
 Item Description
1 Thermostatic expansion valve
2 Evaporator
3 Low pressure servicing connection
4 A/C compressor
5 Receiver drier module
6 Condenser
7 High pressure servicing connection
8 Refrigerant pressure sensor (reference)

GENERAL

The A/C system transfers heat from the vehicle interior to the outside atmosphere to provide the heater assembly with
dehumidified cool air. The system comprises:

An A/C compressor.
A condenser and receiver drier.
A thermostatic expansion valve.
An evaporator.
Refrigerant lines.

The system is a sealed, closed loop, filled with a charge weight of R134a refrigerant as the heat transfer medium. Oil is added
to the refrigerant to lubricate the internal components of the A/C compressor.

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 pressure/temperature regimes, the refrigerant changes state, during which
process maximum heat absorption or release occurs. The low pressure/temperature regime is from the thermostatic
expansion valve, through the evaporator to the A/C compressor; the refrigerant decreases in pressure and temperature at the
thermostatic expansion valve, then changes state from liquid to vapor in the evaporator, to absorb heat. The high
pressure/temperature regime is from the A/C compressor, through the condenser and receiver drier to the thermostatic
expansion valve; the refrigerant increases in pressure and temperature as it passes through the A/C compressor, then
releases heat and changes state from vapor to liquid in the condenser.

A/C COMPRESSOR

The A/C compressor circulates the refrigerant around the system by compressing low pressure, low temperature vapor from
the evaporator and discharging the resultant high pressure, high temperature vapor to the condenser. The A/C compressor
installed on 3.0L Diesel models is different to the one installed on 4.2L and 4.4L models.
3.0L Diesel A/C Compressor

Item Description
1 Clutch connector
2 Pulley
3 Outlet port
4 Inlet port
On 3.0L Diesel models, the A/C compressor is a fixed displacement unit attached to a mounting bracket on the front right side
of the engine. A dedicated drive belt, driven by the engine crankshaft, drives the A/C compressor via a pulley and an
electromagnetic clutch. Operation of the clutch is controlled by a power feed from the automatic temperature control (ATC)
module.

4.2L and 4.4L A/C Compressor

 Item Description
1 Pulley
2 Clutch connector
3 Outlet port
4 Inlet port
5 Pressure relief valve
On 4.2L and 4.4L models, the A/C compressor is a variable displacement unit attached to a mounting bracket on the front left
side of the engine. The secondary accessory drive belt, driven by the engine crankshaft, drives the A/C compressor via a
pulley and an electromagnetic clutch. Operation of the clutch is controlled by a power feed from the ATC module.

The A/C compressor is a 7 cylinder swashplate unit with a minimum displacement of 5.5 cm³/rev (0.34 in³/rev) and maximum
displacement of 163 cm³/rev (9.95 in³/rev). A control valve in the A/C compressor automatically adjusts the displacement
(i.e. flow of refrigerant), between the minimum and maximum values, to match the thermal load of the evaporator. By
matching the refrigerant flow to the thermal load of the evaporator, the variable A/C compressor maintains a relatively
constant evaporator temperature of approximately 3 to 4°C (37 to 39°F).

To protect the refrigerant system from unacceptably high pressure, a pressure relief valve is installed in the outlet side of the
A/C compressor. The pressure relief valve is set to open at 3.5 to 4.1 MPa (508 to 595 lbf/in²) and vents excess pressure into
the engine compartment. The pressure relief valve closes again when the pressure decreases to 3.01 MPa (437 lbf/in²).

The clutch of the A/C compressor incorporates a thermal cut-off fuse, which disconnects the power feed from the ATC module
if the temperature increases to 182 ± 5 °C (360 ± 9 °F).

CONDENSER AND RECEIVER DRIER

 Item Description
1 Cap
2 Spring clip
3 Sealing plug
4 Desiccant module
5 Condenser
6 Outlet pipe
7 Inlet pipe
The condenser transfers heat from the refrigerant to the surrounding air to convert the vapor from the A/C compressor into a
liquid. A receiver drier module, integrated onto the left-hand (LH) side of the condenser, incorporates a filter and a desiccant
to remove solid impurities and moisture from the refrigerant. The receiver drier module also functions as a reservoir for liquid
refrigerant, to accommodate changes of heat load at the evaporator.

The condenser is installed immediately in front of the radiator. The condenser on 3.0L diesel models has a smaller frontal area
than those on 4.2L and 4.4L models, but is of a similar design.

The condenser is classified as a sub-cooling condenser and consists of a fin and tube heat exchanger installed between two
end tanks. Divisions in the end tanks separate the heat exchanger into a three pass upper (condenser) section and a single
pass lower (sub-cooler) section, which are interconnected by the receiver drier module. The desiccant cluster and the filter in
the receiver drier module are serviceable items retained in position by a threaded plug.

THERMOSTATIC EXPANSION VALVE

The thermostatic expansion valve meters the flow of refrigerant into the evaporator, to match the refrigerant flow with the
heat load of the air passing through the evaporator matrix.

The temperature and pressure of the refrigerant leaving the evaporator act on the thermostatic expansion valve to control the
volume of refrigerant flowing through the evaporator. The warmer the air flowing through the evaporator matrix, the more
heat available to evaporate refrigerant and thus the greater the volume of refrigerant allowed through the metering valve.

EVAPORATOR

Evaporator and Thermostatic Expansion Valve

 Item Description
1 Insulated connecting pipes
2 Thermostatic expansion valve
3 Evaporator
The evaporator is installed in the heater assembly between the blower and the heater matrix, to absorb heat from the exterior
or recirculated 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 through the floorpan to the
underside of the vehicle through two drain tubes.

REFRIGERANT LINES

To maintain similar flow velocities around the system, the diameter of the refrigerant lines varies to suit the two
pressure/temperature regimes. The larger diameters are installed in the low pressure/temperature regime and the smaller
diameters are installed in the high pressure/temperature regime.

Low and high pressure charging connections are incorporated into the refrigerant lines near the front RH corner of the engine
compartment.

REFRIGERANT SYSTEM SCHEMATIC

NOTE: A = Refrigerant liquid; B = Refrigerant vapor

Item Description
1 Evaporator
2 Thermostatic expansion valve
3 Desiccant (in modulator)
4 Filter (in modulator)
5 Electric cooling fan
6 Refrigerant pressure sensor
7 Condenser
8 A/C compressor
9 High pressure servicing connection
10 Low pressure servicing
11 Blower
12 Air flows: Ambient air flow through condenser
13 Fresh/Recirculated air flow through blower
14 Cooled air flow to vehicle interior
Published: 11-May-2011
Air Conditioning - Air Conditioning (A/C) Compressor V8 4.4L Petrol
Removal and Installation

Removal

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

2. Recover the air conditioning (A/C) refrigerant.

For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System -
General Information, General Procedures).

3. Remove the air cleaner.

For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and Installation).

4. Disconnect the A/C clutch electrical connector.

5.
CAUTION: Make sure that all openings are
sealed. Use new blanking caps.

Disconnect the refrigerant lines from the A/C

compressor.
Remove the 2 bolts.
Remove and discard the 2 O-ring seals.

6.
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.

7. Remove the radiator splash shield.

For additional information, refer to: Radiator Splash Shield (501-02
Front End Body Panels, Removal and Installation).

8. Release the accessory drive belt.

Rotate the tensioner assembly counter-clockwise.
 Release the accessory drive belt from the power
steering pump pulley.

9.
NOTE: 1 A/C compressor bolt will remain
captive until the A/C compressor mounting bracket is
repositioned.

Release the A/C compressor.

Fully loosen the upper front bolt.
Remove the remaining 2 bolts.

10. Reposition the A/C compressor mounting bracket.

Remove the 2 bolts.

11. Remove the A/C compressor.

Remove the bolt.

Installation

1. Install the A/C compressor.

Install the upper front bolt.

2.
NOTE: The upper front A/C compressor bolt must be installed
to the A/C compressor mounting bracket before the A/C compressor
mounting bracket is secured.
Secure the A/C compressor mounting bracket.
Tighten the bolts to 25 Nm (18 lb.ft).

3. Secure the A/C compressor.

Tighten the bolts to 25 Nm (18 lb.ft).

4. Secure the accessory drive belt.

Rotate the tensioner assembly counter-clockwise.

5. Install the radiator splash shield.

For additional information, refer to: Radiator Splash Shield (501-02
Front End Body Panels, Removal and Installation).

6.
CAUTION: Lubricate the new seals with clean refrigerant oil.

NOTE: Remove and discard the blanking caps.

Connect the refrigerant lines to A/C compressor.

Clean the component mating faces.
Install the new O-ring seals.
Tighten the bolts to 10 Nm (7 lb.ft).

7. Connect the A/C clutch electrical connector.

8. Install the air cleaner.

For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and Installation).

9. Recharge the A/C system.

For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System -
General Information, General Procedures).

10. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).
Published: 11-May-2011
Air Conditioning - Condenser Core V8 4.4L Petrol
Removal and Installation

Removal

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).

2.
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.

3. Remove the radiator assembly.

For additional information, refer to: Radiator (303-03B Engine Cooling
- V8 4.4L Petrol, Removal and Installation).

4. Remove the condenser core.

Remove the Torx screw.

Installation

1. Install the condenser core.

Tighten the Torx screw.

2. Install the radiator assembly.

For additional information, refer to: Radiator (303-03B Engine Cooling
- V8 4.4L Petrol, Removal and Installation).

3. Connect the battery ground cable.

For additional information, refer to: Specifications (414-00 Battery and
Charging System - General Information, Specifications).
Published: 11-May-2011
Control Components - Control Components
Description and Operation

COMPONENT LOCATIONS

Item Description
1 Sunlight sensor (automatic system only)
2 In-vehicle temperature sensor
 3 automatic temperature control (ATC) module (automatic version shown)
4 Single coolant valve (manual system only)
5 Dual coolant valve (automatic system only)
6 Auxiliary coolant pump
7 Refrigerant pressure sensor
8 Pollution sensor, 3.0L Diesel models (automatic system only)
9 Pollution sensor, 4.2L and 4.4L models (automatic system only)
10 Evaporator temperature sensor
11 Steering wheel recirculation switch (where fitted)
12 Heater temperature sensor (left-hand (LH) on manual system, LH and right-hand (RH) on automatic system)

GENERAL

The control system operates the air conditioning (A/C) system and the heating and ventilation system to control the
temperature, volume and distribution of air from the heater.

Either a manual or an automatic control system is installed in the vehicle. The manual system maintains a constant heater
outlet temperature, to both sides of the passenger compartment, with manual control of the intake air source, blower speed
and air distribution. The automatic system automatically adjusts the temperature, volume and distribution of the air from the
heater to maintain the individual temperature levels selected for the LH and RH sides of the passenger compartment. The
automatic system also has manual overrides for the intake air source, blower speed and air distribution.

Both the manual and the automatic systems incorporate:

An in-vehicle temperature sensor.

A refrigerant pressure sensor.
An evaporator temperature sensor.
A heater temperature sensor.
An auxiliary coolant pump.
A coolant valve.

The automatic system also incorporates:

A second heater temperature sensor.

A sunlight sensor.
A pollution sensor.

ATC MODULE

The ATC module is installed in the center of the fascia. An integral control panel contains push switches and rotary
switches/knobs for system control inputs. Orange tell-tale light emitting diode (LED)s in the switches and switch surrounds
illuminate to indicate the current settings of the system. The rotary temperature switch is graduated in degrees Celsius,
except on USA vehicles, where it is graduated in degrees Fahrenheit.

An in-vehicle temperature sensor and associated electric fan are installed behind a grille in the control panel.

The ATC module processes inputs from the control panel switches and system sensors, then outputs the appropriate signals to
control the A/C system. In addition to controlling the A/C system, the ATC module also controls the following:

The heated windshield and windshield wiper parking area heater (optional fit, not available on vehicles with infra red
protection glass).
The windshield washer jet heaters.
The HRW (heated rear window).
The front seat heaters.

Manual Control Panel

 Item Description
1 Heated windshield switch
2 LH front seat heater switch
3 Temperature switch
4 Blower switch
5 RH front seat heater switch
6 Distribution control knob
7 A/C switch
8 Recirculation switch
9 In-vehicle temperature sensor
10 HRW switch
The switches on the manual control panel have the following functions:

Heated windshield Switch: Enabled only with the engine running. Pressing the switch energizes the heated windshield
and the windshield wiper parking area heater for a set time period, until the switch is pressed again or until the engine
stops, whichever occurs first. A LED above the switch is illuminated while the heaters are on.
LH and RH Seat Heater Switches: Activates the heater elements in the seat cushion and seat back at one of two heat
levels. The first press of the switch energizes the heater elements at the higher heat setting and illuminates two LED in
the switch. A second press of the switch sets the heater elements to the lower heat setting and extinguishes one of the
LEDs. A further press of the switch de-energizes the heater elements and extinguishes the second LED. The seat
heaters remain on until selected off or the ignition is switched off.
Temperature Switch: Adjusts the passenger compartment nominal temperature setting between 16 and 28 °C (60 and
84 °F). The temperature range is engraved on the switch surround (°F for NAS, °C for rest of world). A pointer on the
switch indicates the selected temperature. In the minimum and maximum temperature positions, the temperature is
set to maximum cooling or maximum heating respectively.
Blower Switch: For manual adjustment of blower speed. Up to seven LEDs in the switch surround illuminate to indicate
the selected blower speed.
Distribution Control Knob: For manual adjustment of air distribution. Includes AUTO setting where distribution doors
are set to a nominal comfort position.
A/C Switch: Activates the A/C compressor. Allows the A/C compressor to be selected off for economy operation. A LED
above the switch is illuminated when the A/C compressor is selected on.
Recirculation Switch: For manual selection of fresh or recirculated air. A LED above the switch is illuminated when
recirculated air is selected.
HRW Switch: Enabled only with the engine running. Pressing the switch energizes the HRW for a set time period, until
the switch is pressed again or until the engine stops, whichever occurs first. A LED above the switch is illuminated
while the heater is on.

Automatic System Control Panel

 Item Description
1 Heated windshield switch
2 LH front seat heater switch
3 LH temperature switch
4 Automatic mode switch
5 Blower switch
6 RH front seat heater switch
7 RH temperature switch
8 A/C switch
9 Recirculation switch
10 Maximum A/C switch
11 Windshield distribution switch
12 Face distribution switch
13 Footwell distribution switch
14 In-vehicle temperature sensor
15 Defrost program switch
16 HRW switch
The switches on the automatic system control panel have the following functions:

Heated Windshield Switch: Energizes the heated windshield and the windshield wiper parking area heater for a set
time period, until the switch is pressed again or until the engine stops, whichever occurs first. A LED above the switch
is illuminated while the heaters are on.
LH and RH Seat Heater Switches: Activates the heater elements in the seat cushion and seat back at one of two heat
levels. The first press of the switch energizes the heater elements at the higher heat setting and illuminates two LEDs
in the switch. A second press of the switch sets the heater elements to the lower heat setting and extinguishes one of
the LEDs. A further press of the switch de-energizes the heater elements and extinguishes the second LED. The seat
heaters remain on until selected off or the ignition is switched off.
LH and RH Temperature Switches: Adjusts the nominal temperature settings of the LH and RH sides of the passenger
compartment between 16 and 28 °C (60 and 84 °F). The temperature range is engraved on the switch surrounds. A
pointer on each switch indicates the selected temperature. In the minimum and maximum temperature positions, the
system operates at maximum cooling or maximum heating respectively.
Automatic Mode Switch: Activates the automatic modes for air volume and distribution and also activates the A/C
compressor. Separate LEDs in the automatic mode switch illuminate when the blower and the distribution control doors
are in automatic mode. Manually selecting the blower speed or a distribution switch extinguishes the related LED.
Blower Switch: For manual adjustment of blower speed. Up to seven LEDs in the switch surround illuminate to indicate
the selected blower speed.
A/C Switch: Controls activation of the A/C compressor. Allows the A/C compressor to be selected off for economy
operation. A LED above the switch is illuminated when the A/C compressor is selected on.
Recirculation Switch: For manual or automatic selection of fresh or recirculated air. Two LEDs above the switch
illuminate to indicate the mode and position of the recirculation doors. The first press of the switch sets the
recirculation doors to automatic mode and illuminates the LHLED. A second press of the switch manually sets the
recirculation doors to the recirculation position, extinguishes the LHLED and illuminates the RHLED. A further press of
the switch manually sets the recirculation doors to the fresh air position and extinguishes the RHLED.
 Maximum A/C Switch: For selection of maximum A/C when the ignition is on or rest heating when the ignition is off. A
LED above the switch is illuminated when maximum cooling or rest heating is selected.
Distribution Switches (Windshield, Face and Footwell): For manual selection of air distribution in any combination of
windshield, face and footwell outlets. A LED above each switch illuminates when a selection is made.
Defrost Program Switch: Activates a program that automatically selects the heated windshield on, activates the A/C
compressor and changes the system settings to direct dry heat to the windshield. A LED above the switch is
illuminated while the defrost program is active.
HRW Switch: Enabled only with the engine running. Pressing the switch energizes the HRW for a set time period, until
the switch is pressed again or until the engine stops, whichever occurs first. A LED above the switch is illuminated
while the heater is on.

Inputs and Outputs

Five electrical connectors provide the interface between the ATC module and the vehicle/heater assembly wiring.

Both the manual and automatic systems receive ambient temperature, engine coolant temperature, engine speed and vehicle
speed inputs in K bus messages from the instrument cluster. If the K bus messages are missing or faulty, the ATC module
adopts the following default values:

Ambient temperature = 0 °C (32 °F).

Engine coolant temperature = 80 °C (176 °F).
Engine speed = 800 rev/min.
Vehicle speed = zero.

If a fault develops in the input from the temperature selector switch on the control panel, the ATC module adopts a default
value of 24 °C (75 °F).

ATC Module Harness Connector C0249 Pin Details

System
Pin No. Description Input/Output
Manual Automatic
1 Front seat heating battery power supply Yes Yes Input
2 LH front seat heater power supply Yes Yes Output
3 RH front seat heater power supply Yes Yes Output

ATC Module Harness Connector C0923 Pin Details

System
Pin No. Description Input/Output
Manual Automatic
1 Rear blower control voltage No Yes Output
2 Rear blower switch signal No Yes Input
3 Not used - - -
4 LH heater temperature sensor No Yes Input
5 RH heater temperature sensor Yes Yes Input
6 Evaporator temperature sensor Yes Yes Input
7 Blower control voltage Yes Yes Output
8 Rear temperature switch No Yes Input
Sensor ground (evaporator, heater temperature sensors, rear passenger face register,
9 Yes Yes -
as applicable)
10 to
Not used - - -
12
13 Recirculation door motor signal 2 Yes Yes Input
14 Recirculation door motor signal 2 Yes Yes Output
15 Recirculation door motor signal 1 Yes Yes Output
16 Recirculation door motor signal 1 Yes Yes Input
17 Rear blower switch and rear temperature switch power supply No Yes Output
18 Not used - - -

ATC Module Harness Connector C1629 Pin Details

System
Pin No. Description Input/Output
Manual Automatic
1 Ignition power supply Yes Yes Input
2 Sunlight sensor ground No Yes -
3 K bus Yes Yes Input/Output
4 Delayed accessory power Yes Yes Input
5 LH coolant valve Yes Yes Output
6 RH coolant valve No Yes Output
7 HRW relay Yes Yes Output
8 Windshield washer jets heater relay Yes Yes Output
9 Auxiliary coolant pump Yes Yes Output
10 Refrigerant pressure sensor signal Yes Yes Input
11 Not used - - -
12 Pollution sensor signal No Yes Input
13 Pollution sensor power supply No Yes Output
14 Heated windshield relay Yes Yes Output
15 LH seat heating temperature sensor Yes Yes Output
16 RH seat heating temperature sensor Yes Yes Output
17 Engine full load signal Yes Yes Input
18 LH sunlight sensor signal No Yes Input
19 RH sunlight sensor signal No Yes Input
20 Refrigerant pressure sensor ground Yes Yes -
21 Refrigerant pressure sensor power supply Yes Yes Output
22 Coolant changeover valve Yes Yes Output
23 Instrument illumination Yes Yes Input
24 Sunlight sensor power supply No Yes Output
25 Pollution sensor heater ground No Yes -
26 Pollution sensor heater power supply No Yes Output

ATC Module Harness Connector C1630 Pin Details

System
Pin No. Description Input/Output
Manual Automatic
1 Battery power supply Yes Yes Input
2 A/C compressor clutch Yes Yes Output
3 System ground Yes Yes -

ATC Module Harness Connector C2295 Pin Details

System
Pin No. Description Input/Output
Manual Automatic
1 M bus power supply No Yes Output
2 M bus ground No Yes -
3 M bus interface line No Yes Input/Output

IN-VEHICLE TEMPERATURE SENSOR

The in-vehicle temperature sensor is an encapsulated negative temperature coefficient (NTC) thermistor that provides the ATC
module with an input of passenger compartment air temperature. The in-vehicle temperature sensor is installed behind a
grille in the ATC module control panel. An electric fan in the ATC module runs continuously, while the ignition is on, to draw
air through the grille and across the in-vehicle temperature sensor.

The ATC module uses the signal from the in-vehicle temperature sensor for control of the coolant temperature valve(s),
blower speed and air distribution.

The signal voltage from the in-vehicle temperature sensor is between 0 and 5 V. The ATC module monitors the signal voltage
and defaults to a temperature of 20 °C (68 °F) if it goes out of the range 0.573 - 4.882 V:

If the signal voltage is less than 0.573 V, the ATC module assumes there is a short circuit to ground.
If the signal voltage is more than 4.882 V, the ATC module assumes there is an open circuit or a short circuit to
battery.

REFRIGERANT PRESSURE SENSOR

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

The ATC module supplies a 5 V reference voltage to the refrigerant pressure sensor and receives a return signal voltage,
between 0 and 5 V, related to system pressure.

The ATC module uses the signal from the refrigerant pressure sensor to protect the system from extremes of pressure and to
calculate A/C compressor load on the engine for idle speed control. The ATC module also transfers the pressure value to the
engine control module (ECM), via the K bus, instrument cluster and controller area network (CAN) bus, for use in controlling
the speed of the engine cooling fan.

To protect the system from extremes of pressure, the ATC module disengages the A/C compressor clutch if the pressure:

Decreases to 1.9 ± 0.2 bar (27.5 ± 3 lbf/in 2 ): the ATC module engages the A/C compressor clutch again when
pressure increases to 2.8 ± 0.2 bar (40.5 ± 3 lbf/in 2 ).
Increases to 33 ± 1 bar (479 ± 14.5 lbf/in 2 ): the ATC module engages the A/C compressor clutch again when
pressure decreases to 23.5 ± 1 bar (341 ± 14.5 lbf/in 2 ).

EVAPORATOR TEMPERATURE SENSOR

The evaporator temperature sensor is a NTC (negative temperature coefficient) thermistor that provides the ATC module with
a temperature signal from the air outlet side of the evaporator. The evaporator temperature sensor is installed in the RH side
of the heater assembly casing, and extends into the core of the evaporator.

The ATC module uses the input from the evaporator temperature sensor to control the engagement and disengagement of the
A/C compressor clutch, to prevent the formation of ice on the evaporator.
The signal voltage from the evaporator temperature sensor is between 0 and 5 V. The ATC module monitors the signal voltage
and defaults to a temperature of 0 °C (32 °F) if it goes out of the range 0.157 - 4.784 V:

If the signal voltage is less than 0.157 V, the ATC module assumes there is a short circuit to ground.
If the signal voltage is more than 4.784 V, the ATC module assumes there is an open circuit or a short circuit to
battery.

HEATER TEMPERATURE SENSOR

The heater temperature sensor is a NTC thermistor that provides the ATC module with a temperature signal from the air
outlet side of the heater core. On manual systems, a single sensor is installed in the rear of the heater assembly casing, to
the right of the center-line. On automatic systems, two sensors are installed, one each side of the center-line.

The ATC module uses the input from the heater temperature sensor(s) to control the operation of the coolant valve(s).

The signal voltage from each heater temperature sensor is between 0 and 5 V. The ATC module monitors the signal voltage
and defaults to a temperature of 55 °C (131 °F) if it goes out of the range 0.173 - 4.890 V:

If the signal voltage is less than 0.173 V, the ATC module assumes there is a short circuit to ground
If the signal voltage is more than 4.890 V, the ATC module assumes there is an open circuit or a short circuit to
battery.

AUXILIARY COOLANT PUMP

The auxiliary coolant pump is an electric pump that ensures there is a satisfactory flow rate through the heater core at low
engine speeds. The auxiliary coolant pump is installed in the engine compartment, in a rubber mounting attached to the side
of the LH suspension turret. Operation of the auxiliary coolant pump is controlled by a power supply from the ATC module.

COOLANT VALVE

The coolant valve controls the coolant flow to the heater core. A single coolant valve controls the coolant flow to both sides of
the heater core on manual systems. On automatic systems, separate coolant valves control the coolant flow to each side of
the heater core. The coolant valves are installed in the engine compartment on a bracket attached to the side of the LH
suspension turret.

Each coolant valve is a normally open solenoid valve controlled by a pulse width modulation (PWM) signal from the ATC
module. The ATC module changes the length of time the coolant valve is open each duty cycle between 0 second (valve
closed) and 3.6 seconds (valve held open). On the automatic system, the PWM (pulse width modulated) signals to the two
valves are phase offset by 1.8 seconds to reduce coolant flow fluctuations.

SUNLIGHT SENSOR

The sunlight sensor consists of two photoelectric cells that provide the ATC module with inputs of light intensity, one as
sensed coming from the left of the vehicle and one as sensed coming from the right. The inputs are a measure of the solar
heating effect on vehicle occupants and used by the ATC module to adjust blower speed, temperature and distribution to
improve comfort. The sensor is installed in the center of the fascia upper surface.

If one of the photoelectric cells is faulty, the output from the other photoelectric cell is used for both sides of the vehicle. If
both photoelectric cells are faulty, the ATC module uses a default value of zero.

POLLUTION SENSOR

The pollution sensor allows the ATC module to monitor the ambient air for the level of hydrocarbons and oxidized gases such
as nitrous oxides, sulphur oxides and carbon monoxide. The pollution sensor is installed at the rear of the radiator, on the
upper right side (3.0L Diesel) or upper left side (4.2L and 4.4L) of the fan cowl.

The ATC module outputs a battery power supply to heat the pollution sensor to operating temperature, and a 5 V reference
voltage for the signal. The signal voltage from the pollution sensor is between 0 and 5 V.

If there is a fault with the pollution sensor, the ATC module disables automatic closing of the recirculation doors on detection
of pollutants.

OPERATION

Both the manual and automatic systems operate on the reheat principle. The air entering the heater assembly is cooled to a
constant value by the evaporator and then reheated as necessary by the heater core to produce the temperature(s) selected
on the control panel.

To determine the various system settings, the ATC module derives a reference value (called the Y factor) from:

The temperature setting on the control panel.

The ambient temperature.
The in-vehicle temperature.
The reference value is measured in %, where -27.5% means maximum cooling is required and 100% means maximum
heating is required. On the automatic system, separate reference values are produced for the LH and RH sides of the heater
assembly.

On both the manual and automatic systems the reference value is used for temperature control. On the automatic system the
driver's side reference value is also used for door positioning and blower speed calculations.

When the ignition is turned off the ATC module memorizes the system settings and resumes the same settings the next time
the ignition is switched on.

A/C Compressor Control

The A/C compressor is engaged by pressing either the automatic mode switch, defrost switch, A/C switch or maximum A/C
switch. To prevent a dip in engine speed when the engine is at idle, a time delay of approximately 0.5 second is built into the
A/C compressor engagement process. The time delay allows the ECM to increase throttle angle and fueling in anticipation of
the additional load on the engine when the A/C compressor engages.

When it receives an input to engage the A/C compressor, the ATC module sends a message to the ECM, via the K bus,
instrument cluster and high speed CAN bus, to advise that it wants to engage the A/C compressor. Provided there are no
engine management problems, the ECM responds by increasing throttle angle and fueling and sending a message granting the
request to the ATC module over the CAN bus, instrument cluster and K bus. When it receives the grant message, the ATC
module energizes the A/C compressor clutch provided the following conditions exist:

Engine speed is more than 400 rev/min.

Evaporator temperature is more than 3 °C (37 °F).
The refrigerant pressure is within limits.
Battery voltage is less than 16 V.
The blower is running.
There are no faults detected by the ATC module.

The A/C compressor remains engaged until selected off or the required conditions no longer exist. If the evaporator
temperature decreases to approximately 2 °C (36 °F) the A/C compressor is disengaged, then re-engaged when the
evaporator temperature increases to more than 3 °C (37 °F) again. If battery voltage exceeds 16 V for more than 5 seconds
the A/C compressor is disengaged, then re-engaged when voltage decreases to less than 15.8 V.

The A/C compressor can also be disengaged by the ECM changing the grant message on the high speed CAN network to a
negative value, or by a 12 V hardwired signal to the ATC module from the ECM (3.0L Diesel models) or the instrument cluster
(4.2L and 4.4L models). Changing the grant message involves a time delay of up to 4 seconds before the ATC module
de-energizes the A/C compressor clutch. The time delay allows the ECM to decrease throttle angle and fueling, in anticipation
of the reduction in engine load when the A/C compressor disengages, to prevent a sudden increase in engine speed if the
engine is at idle. The hardwired signal is used to obtain instant disengagement of the A/C compressor to ensure maximum
acceleration when accelerator pedal demand suddenly goes from no load to full load.

Engine Idle Speed Control

The ATC module signals the ECM to increase engine idle speed settings if a high current application is switched on or if low
battery voltage is detected. The signal consists of a message transmitted via the K bus, instrument cluster and high speed
CAN bus, and increases idle speed between 100 and 200 rev/min. The ATC module requests the engine idle speed increase
when the following high current applications are switched on:

HRW.
Blower, at speed 6 or 7.
Headlamp main beam.

The engine idle speed increase is also requested if battery voltage decreases to less than 11.4 V. The speed increase request
is discontinued when battery voltage increases to more than 12.2 V again.

Engine Cooling Fan Control

The engine's electric cooling fan is controlled by the ECM. When the A/C compressor is engaged the ATC module sends a fan
speed message between 0 (off) and 15 (maximum speed) to the ECM, via the K bus, instrument cluster and high speed CAN
bus. The ATC module requests the cooling fan on when:

The vehicle speed is less than 70 km/h (44 mph).

There is no fault with the A/C compressor clutch circuit.
Battery voltage is less than 16 V.

The fan speed requested depends on the pressure in the refrigerant system. The higher the pressure the faster the fan speed
that is requested. When vehicle speed increases to more than 80 km/h (50 mph) the ATC module changes the fan speed
request to 0 until vehicle speed decreases to less than 70 km/h (44 mph) again.

If battery voltage increases to more than 16 V for 5 seconds the ATC module changes the fan speed to 0 until the voltage
decreases to less than 15.8 V.

Temperature Control

To determine the amount of heat required, in the form of coolant flow through the heater, the ATC module compares the
reference value with the heater temperature and incorporates a correction factor to compensate for changes of coolant flow
rate with engine speed. From the resultant value the ATC module determines the open duration of the coolant valve and
outputs the appropriate control signal. On the automatic system, separate values and output signals are generated for each
coolant valve to produce the individual temperature control for the LH and RH sides of the passenger compartment.

When the temperature setting on the control panel is set to maximum, the ATC module signals the coolant valve to remain
open. When the temperature setting on the control panel is set to minimum, the ATC module signals the coolant valve to
remain closed.

On the automatic system, the minimum setting is over-ridden when the defrost program, maximum A/C, rest heating or FFBH
(fuel fired booster heater) functions are selected.

Heater Coolant Circuit

Item Description
1 Coolant valve (manual system)
2 Heater core
3 Coolant valves (automatic system)
4 Auxiliary coolant pump
5 Engine cooling system
6 ATC module
7 Changeover valve (where fitted)
 8 FFBH unit (where fitted)
Door Control - Manual System

While the ignition is on, the position of the recirculation doors is manually controlled by selection of the recirculation switch on
the control panel and the steering wheel recirculation switch (where fitted). If the recirculation doors are in the recirculation
position when the ignition is switched off, the ATC module automatically sets them to the fresh air position, to ensure that
fresh air is available if a fault occurs with the recirculation door drive circuit at the next ignition on.

The positions of the distribution doors are manually controlled by selection of the distribution rotary switch on the control
panel. The doors are also automatically positioned by the ATC module to open the:

Windshield and footwell outlets, when parked heating is initiated by the FFBH.
Face and footwell outlets, when parked ventilation is initiated.
Windshield outlets, when the ignition is switched off and the ambient temperature is less than 0°C, or windshield and
footwell outlets when the ignition is switched off and the ambient temperature is 0°C and above.

Door Control - Automatic System

The position of the ram air doors is automatically controlled by the ATC module. The positions of the recirculation doors and
the distribution doors are either automatically controlled by the ATC module or manually controlled by the related switches.

Ram Air Doors

The ATC module progressively closes the ram air doors, in four steps, as vehicle speed increases, and opens them again as
vehicle speed decreases. At the maximum closed position, 90% of the fresh air inlet area is closed off. A hysteresis of 15
km/h (9 mph) prevents the ram air doors from hunting at a constant vehicle speed.

Ram Air Door Positions

NOTE: A = Door position, % open; B = Opening speeds, mph (km/h); C = Closing speeds, mph (km/h)

Recirculation Doors

Unless the recirculation doors are manually selected closed, using the recirculation switch on the control panel or the steering
wheel recirculation switch (where fitted), they are normally open, but automatically closed by the ATC module under certain
conditions:

Rapid Cooling: For rapid cooling of the passenger compartment, when the A/C system is selected on, if the driver's side
reference value is less than -20% and the ambient temperature is more than 6 °C (43 °F), the ATC module closes the
recirculation doors. The ATC module opens the recirculation doors after 12 minutes (temperate climates) or 20 minutes (hot
climates), if the driver's side reference value increases to more than -5% or if the ambient temperature decreases to 6 °C (43
°F).
Pollution: When the ATC module detects a high level of pollutants, it sets the recirculation doors to the recirculation position
for:

3 minutes if the A/C system is in the heating mode.

10 minutes if the A/C system is in the cooling mode.

After the recirculation time period, the ATC module returns the recirculation doors to the fresh air position. After 1 minute, if
the pollutants are still present, the ATC module repeats the recirculation cycle.

Ignition Off: If the recirculation doors are in the recirculation position when the ignition is switched off, the ATC module
automatically sets them to the fresh air position, to ensure that fresh air is available if a fault occurs with the recirculation
door drive circuit at the next ignition on. When the ignition is switched on, the ATC module sets the recirculation doors to the
position they were in at ignition off.

Distribution Doors

When a manual distribution selection is made on the control panel, the ATC module moves the distribution doors to preset
positions. When the system is in the automatic mode, the ATC module uses maps of the driver's side reference value to
determine the position of the distribution doors. Each distribution door has a separate map, and there are separate maps for
temperate and hot climates. The mapped positions of the face level distribution doors are given a correction factor from the
sunlight sensor inputs. The mapped positions of the distribution doors are overridden by special programs, as follows:

Condensation Prevention: To prevent condensation on the windshield, the ATC module closes the windshield doors for 12
seconds each time the engine starts. If a manual distribution selection is made during the 12 seconds, the windshield doors
revert to normal control.

The ATC module also closes the windshield doors when the reference value is less than 90% with the recirculation doors
closed and the A/C compressor disengaged.

Cold Start: When the engine starts, if the system is in the automatic mode, the driver's side reference value is 100% and the
heater core temperatures is less than 30 °C (86 °F), the ATC module closes the face level and footwell doors and opens the
windshield doors.

Duct Purging: After a cold start, if the system is in the automatic mode and the reference value is 100%, the ATC module
keeps the face level doors closed until one of the heater core temperatures exceeds 60 °C (140 °F). The ATC module then
fully opens the face level doors for 25 seconds to purge the ducts of cold air. After the purge the face level doors revert to
normal automatic control. If, before or during the purge process, the reference value decreases below 100%, the ignition has
been on for 15 minutes, or a manual distribution selection is made, then the purge process is cancelled.

Blower Control

In the automatic mode, blower speed is determined from reference temperature maps. In general terms, the more heating or
cooling required to achieve the temperature selected on the control panel with the driver's side temperature switch, the faster
the blower speed.

When maximum cooling is first required in the automatic mode, the ATC module runs the blower at full speed for a fixed
period regardless of any drop in passenger compartment temperature. Different time periods are incorporated for the
following markets:

NAS and Gulf States

Europe and ROW
Japan.

NAS and Gulf States have the longest time period with the blower at full speed and Japan the shortest. T4 can be used to
change the market setting so, in some cases, if a customer complains of the duration the blower runs at full speed, changing
the market setting could resolve the complaint.

When heating is required, blower speed is reduced if the engine is cold and then progressively increased to the nominal
setting as the engine coolant temperature increases from 20 to 50 °C (68 to 122 °F).

On the automatic system, blower speed is also influenced by the sunlight sensor. At high light levels blower speed will
increase to increase the cooling effect.

When the blower is selected off temperature regulation is no longer possible so the ATC module disengages the A/C
compressor, de-energizes the auxiliary water pump and closes the coolant valves. Pressing any of the A/C system switches
restores blower operation and activates the required function. If the blower is selected off when the ignition is switched off,
the blower remains off if the ignition is switched on again within 15 minutes. If more than 15 minutes elapses between the
ignition being switched off and back on again, the ATC module switches the blower on at speed 1.

If battery voltage is low the ATC module reduces blower speed to conserve power. If battery voltage decreases to less than 12
V, the ATC module decreases the blower signal voltage, and thus the voltage to the blower motor, in direct proportion to the
reduction in battery voltage.

Defrost Program (Automatic System Only)

When the defrost program is selected the ATC module:

Opens the windshield distribution doors and closes the face and footwell doors.
 Sets the recirculation doors to the fresh air position.
Runs the blower at speed 7.
Activates the A/C compressor.
Activates the HRW.
Activates the heated windshield (where fitted).

When the ambient temperature is 10 °C (50 °F) and below, the ATC module signals the coolant valves to remain open. When
the ambient temperature is more than 10 °C (50 °F), the ATC module checks the existing heater core temperature and, if
necessary, increases the open time of the coolant valves to produce a minimum heater core temperature of 30 °C (86 °F).

The defrost program is cancelled by pressing the defrost switch again, or pressing the automatic, A/C or maximum A/C
switches

Maximum A/C (Automatic System Only)

Pressing the maximum A/C switch while the engine is running and the ambient temperature is more than 7 °C (45 °F)
provides the maximum cooling possible from the system to cool the passenger compartment down as rapidly as possible.
When maximum A/C is selected the coolant valves are held closed, the A/C compressor is engaged, the blower speed is set to
maximum and the recirculation doors are set to the recirculation position. After 12 minutes the recirculation doors will be set
to fresh air for 1 minute then returned to the recirculation position.

The maximum A/C function is cancelled when any of the other A/C system switches are pressed.

Rest Heating (Automatic System Only)

When the engine is not running, pressing the maximum A/C switch activates the rest heating function to heat the passenger
compartment with residual heat from the engine. The rest heating function activates provided the following conditions exist:

It is less than 15 minutes since the ignition was selected off.

Ambient temperature is less than 15 °C (59 °F).
On the previous ignition cycle engine temperature exceeded 70 °C (158 °F).
Battery voltage is 11.4 V minimum.

To provide the rest heating function, the ATC module activates the auxiliary coolant pump, coolant valves, control door and
blower. The ATC module regulates the temperature (to the driver setting selected before the ignition was switched off), opens
the face level distribution doors and runs the blower at speed 4.

The rest heating function is cancelled after 15 minutes or when:

The maximum A/C switch is pressed again.

The ignition is selected on.
Battery voltage decreases to less than 11 V.

Rear Passenger Face Level Air (Automatic System Only)

The volume and temperature of the air from the rear passenger face register are adjusted with the thumbwheels at the sides
of the register. Each thumbwheel operates a variable potentiometer connected to the ATC module. The volume thumbwheel
controls stepless changes of rear blower speed between off and full speed. The temperature thumbwheel controls the position
of the rear passenger face level blend door in the heater assembly when the driver's side reference temperature is more than
0%.

Volume Control

The volume potentiometer outputs between 0 and 5 V to the ATC module. The ATC module translates the voltage from the
potentiometer into a signal voltage for the output stage in the rear blower. Potentiometer voltages of less than 1.25 V are
interpreted as a blower off selection and translate into a signal voltages less than 0.1 V. Potentiometer voltages between 1.25
and 5 V are translated into proportional signal voltages between 0.1 and 5 V.

The ATC module automatically switches off the rear blower when:

The defrost program is active.

The main blower is selected off.
The engine cranks.
The ignition is selected off (the rear blower remains off during rest heating, parked heating and parked ventilation).

Temperature Control

The temperature potentiometer outputs between 0 and 5 V to the ATC module. The ATC module translates the voltage from
the potentiometer into a blend door position between 0% (cold) and 100% (hot) and outputs the appropriate control signal on
the M bus to the blend door motor. Potentiometer voltages of less than 1.5 V translate to a blend door position of 0%.
Potentiometer voltages of more than 3.4 V translate to a blend door position of 100%. Potentiometer voltages between 1.5
and 3.4 V translate linearly to blend door positions between 0 and 100%.

Heated Windshield (Where Fitted)

When the engine is running and the heated windshield is selected on, the ATC module illuminates the LED above the switch
and energizes the heated windshield relay attached to the passenger end of the fascia cross tube. If not already active, the
ATC module also activates the A/C compressor and the blower, and sets air distribution to windscreen. After 10 minutes
(when ambient temperature is -15 °C (5 °F) or above) or 17 minutes (when ambient temperature is less than -15 °C (5 °F)),
the ATC module extinguishes the LED and de-energizes the heated windshield relay. After the heater times out or is switched
off, the timer in the ATC module is reset to zero.

HRW

When the engine is running and the HRW is selected on, the ATC module illuminates the LED above the switch and energizes
the HRW relay in the AJB (auxiliary junction box). After 10 minutes (when ambient temperature is -15 °C (5 °F) or above) or
17 minutes (when ambient temperature is less than -15 °C (5 °F)), the ATC module extinguishes the LED and operates the
HRW at low power for 60 minutes. During the 60 minutes, the ATC module cycles the HRW relay off for 80 seconds and on for
40 seconds. If the HRW switch is pressed again during the low power phase, the ATC module illuminates the LED again and
returns the HRW to full power by keeping the HRW relay energized for 5 minutes. At the end of the 5 minutes the LED is
extinguished and the 60 minutes low power phase is repeated.

The ATC module outputs a K bus message when the HRW is active. The message allows the navigation computer to
compensate for the effect of the magnetic field generated when the HRW is active. In addition, the generic electronic module
(GEM) transfers the message onto the P bus for the door modules, which activate the door mirror heaters together with the
HRW.

Washer Jet Heaters

The ATC module automatically energizes the washer jets relay, on the central junction box (CJB), when the ignition is on and
the ambient temperature is less than 3 °C (37 °F). If the ambient temperature increases to more than 6 °C (43 °F), the ATC
module de-energizes the washer jets relay.

Parked Ventilation

Parked ventilation allows the vehicle interior to be ventilated with ambient air while parked with the engine stopped. Vehicles
without a FFBH have parked ventilation only. On vehicles with a FFBH, parked ventilation operates in conjunction with parked
heating.
For additional information, refer to: Auxiliary Heater (412-02B Auxiliary Heating, Description and Operation).

Parked ventilation is controlled by direct selection on the TSD (touch screen display), or by using the TSD to program one or
two on/off cycle times in the following 24 hour period. Both the direct selection and programmed time modes of operation are
selected when the engine is stopped and the ignition switch is in position I; if required, the key can then be removed from the
ignition switch and the vehicle locked. Parked ventilation only operates if the ambient temperature is 16 °C (61 °F) or more,
and is automatically de-activated after 30 minutes, regardless of any programmed 'off' time, to prevent excessive drain on the
battery. Parked ventilation is automatically de-activated when the ignition is switched on.

When programmed times for parked ventilation are entered on the TSD, the times are stored in the memory of the instrument
cluster and the climate set indicator in the top left corner of the TSD is permanently illuminated.

At a programmed parked ventilation start time, or when parked ventilation is selected on using the TSD, the instrument
cluster outputs:

A parked ventilation request to the TSD on the I bus

A parked ventilation request to the ATC module on the K bus
The ambient temperature to the ATC module and GEM on the K bus.

On receipt of the messages:

The climate set indicator flashes at 2 Hz, to indicate that parked ventilation is active.
The ATC module operates the blower at speed 1, opens the face level distribution doors in the heater assembly and
closes the windshield and footwell doors.

The ATC module disables parked ventilation if battery voltage is less than 11.4 V.

CONTROL DIAGRAM - MANUAL SYSTEM, SHEET 1 OF 2

NOTE: A = Hardwired connection; B = K bus; L = M bus

Item Description
1 Ignition switch
2 Fuse 34, CJB
3 Fuse 12, CJB
4 HRW
5 Fuse 64, CJB
6 Blower output stage
7 HRW relay
 8 Blower
9 Coolant valve
10 Compressor clutch
11 Auxiliary coolant pump
12 Fresh/Recirculated air doors motor
13 Air distribution motor
14 LH washer jet
15 RH washer jet
16 Washer jet heater relay
17 Heated windshield, wiper park heater element
18 Heated windshield, LH heater element
19 Heated windshield, RH heater element
20 Heated windshield relay
21 Heater temperature sensor
22 ATC module
23 Evaporator temperature sensor
24 Refrigerant pressure sensor

CONTROL DIAGRAM - MANUAL SYSTEM, SHEET 2 OF 2

NOTE: A = Hardwired connection; B = K bus; C = Diagnostic DS2 bus; D = High speed CAN bus; K = I bus; M = P bus
Item Description
1 GEM
2 Passenger door module
3 Passenger door mirror
4 Driver door module
5 Driver door mirror
6 FFBH unit
 7 Steering wheel recirculation switch (where fitted)
8 Clockspring
9 Diagnostic socket
10 Instrument cluster
11 ECM

CONTROL DIAGRAM - AUTOMATIC SYSTEM, SHEET 1 OF 2

NOTE: A = Hardwired connection; B = K bus; L = M bus

Item Description
1 HRW
2 HRW relay
3 Fuse 12, CJB
4 Rear passenger face register
5 Fuse 64, CJB
6 Blower
7 Blower output stage
 8 Rear blower relay
9 Rear blower output stage
10 Dual coolant valve
11 Rear blower
12 Compressor clutch
13 Pollution sensor
14 Auxiliary coolant pump
15 Sunlight sensor
16 Fresh/Recirculated air doors motor
17 Washer jet heater relay
18 LH washer jet
19 RH washer jet
20 Heated windshield, LH heater element
21 Heated windshield, wiper park heater element
22 Heated windshield, RH heater element
23 Heated windshield relay
24 RH heater temperature sensor
25 LH heater temperature sensor
26 ATC module
27 Evaporator temperature sensor
28 Refrigerant pressure sensor
29 Ignition switch
30 Fuse 34, CJB

CONTROL DIAGRAM - AUTOMATIC SYSTEM, SHEET 2 OF 2

NOTE: A = Hardwired connection; B = K bus; C = Diagnostic DS2 bus; D = High speed CAN bus; K = I bus; L = M bus;
M = P bus
Item Description
1 ECM
2 Instrument cluster
3 Windshield distribution motor
4 Face level distribution motor
5 Footwell distribution motor
6 Rear face level temperature blend motor
7 Ram air motor
8 Driver door mirror
9 Driver door module
10 FFBH unit
11 GEM
12 Passenger door mirror
13 Passenger door module
14 Steering wheel recirculation switch (where fitted)
15 Diagnostic socket
16 Clockspring
Published: 11-May-2011
Control Components - Ambient Air Temperature Sensor
Removal and Installation

Removal

1. Remove the radiator grille.

For additional information, refer to: Radiator Grille (501-08 Exterior
Trim and Ornamentation, Removal and Installation).

2. Remove the ambient air temperature sensor.

Disconnect the electrical connector.

Installation

1. To install, reverse the removal procedure.

Published: 11-May-2011
Control Components - Driver Side Temperature Blend Door Actuator
Removal and Installation

Removal

1. Remove the instrument panel driver side reinforcement.

For additional information, refer to: Instrument Panel Driver Side
Reinforcement (501-12, Removal and Installation).

2. Remove the driver side footwell duct.

Remove the 2 Torx screws.

3. Remove the temperature blend door actuator.

Disconnect the electrical connector.
Remove the 2 screws.

Installation

1. Install the temperature blend door actuator.

Tighten the screws.
Connect the electrical connector.

2. Install the driver side footwell duct.

Tighten the screws.

3. Install the instrument panel driver side reinforcement.

For additional information, refer to: Instrument Panel Driver Side
Reinforcement (501-12, Removal and Installation).
Published: 11-May-2011
Control Components - Instrument Panel Blend Door Actuator LHD AWD
Removal and Installation

Removal

1. Remove the instrument panel driver side reinforcement.

For additional information, refer to: Instrument Panel Driver Side
Reinforcement (501-12, Removal and Installation).

2.
NOTE: Some variation in the illustrations may
occur, but the essential information is always correct.

Remove the driver side footwell duct.

Remove the 2 Torx screws.

3.
NOTE: Some variation in the illustrations may
occur, but the essential information is always correct.

Remove the instrument panel blend door actuator.

Disconnect the electrical connector.
Remove the 2 screws.

Installation

1. Install the instrument panel blend door actuator.

Tighten the screws to 1 Nm.
Connect the electrical connector.

2. Install the driver side footwell duct.

Tighten the screws.

3. Install the instrument panel driver side reinforcement.

For additional information, refer to: Instrument Panel Driver Side
Reinforcement (501-12, Removal and Installation).