Jaguar X-Type Sedan and Estate (Wagon). Manual - part 525

1
2

Is the voltage less than 10 volts?
Yes

REPAIR the circuit between the passenger compartment fuse box and the ignition relay. TEST the system for normal
operation.

REPAIR the circuit between the passenger compartment fuse box and the generator. TEST the system for normal
operation.

F10: CHECK THE CONTINUITY OF THE GENERATOR CHARGE WARNING INDICATOR LAMP SIGNAL WIRE

Disconnect the ECM electrical connector EN16 and the generator electrical connector EN49.
Measure the resistance between EN49-4 and EN1-79.

Is the resistance less than 5 ohms?
Yes

Refer to the approved Jaguar diagnostic system.

REPAIR the circuit from the ECM to the generator. TEST the system for normal operation.

PINPOINT TEST G : GENERATOR NOISY

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

G1: CHECK GENERATOR FOR SECURITY

INSPECT the generator fixings.

Is the generator loose?
Yes

TIGHTEN generator fixings. TEST the system for normal operation.

GO to G2

. .

G2: CHECK THE ACCESSORY DRIVE BELT

REMOVE and INSPECT the accessory drive belt. For additional information, refer to Section

303-05 Accessory Drive

Is the accessory drive belt OK?
Yes

GO to G3

. .

INSTALL a new accessory drive belt. TEST the system for normal operation.

G3: CHECK THE ACCESSORY DRIVE BELT TENSIONER

REMOVE and INSPECT the accessory drive belt tensioner. For additional information, refer to Section

303-05 Accessory

Drive

Is the accessory drive belt tensioner OK?
Yes

GO to G4

. .

INSTALL a new accessory drive belt tensioner. For additional information, refer to Section

303-05 Accessory Drive

TEST the system for normal operation.

G4: CHECK GENERATOR FOR MECHANICAL NOISE

ROTATE the generator pulley by hand.

Does the generator rotor shaft rotate smoothly?
Yes

For vehicles fitted with manual transmission

GO to G5

. . For vehicles fitted with automatic transmission

GO to G6

. .

INSTALL a new generator. TEST the system for normal operation.

G5: CHECK GENERATOR DRIVE PULLEY (VEHICLES FITTED WITH MANUAL TRANSMISSION)

ROTATE the generator pulley quickly by hand.
Stop the generator pulley from spinning by holding the pulley.

Does the generator rotor shaft continue to rotate?
Yes

GO to G6

. .

INSTALL a new generator. TEST the system for normal operation.

G6: CHECK THE ACCESSORY DRIVE BELT IDLER PULLEYS

ROTATE the accessory drive belt idler pulleys by hand.

Do the accessory drive belt idler pulleys rotate smoothly?
Yes

GO to G7

. .

INSTALL new accessory drive belt pulleys as necessary. TEST the system for normal operation.

G7: CHECK GENERATOR FOR ELECTRICAL NOISE

INSTALL the accessory drive belt. For additional information, refer to Section

303-05 Accessory Drive

START and RUN the engine at 1500 RPM. APPLY a high electrical load to the battery.

Is the noise only heard with the high electrical load applied?
Yes

GO to G8

. .

CHECK the air conditioning compressor. For additional information, refer to Section

412-03 Air Conditioning

. CHECK

the power steering pump. For additional information, refer to Section

211-02 Power Steering

. TEST the system for

normal operation.

G8: ELIMINATE THE GENERATOR AS THE CAUSE OF ELECTRICAL NOISE

REMOVE fuse 82 from the passenger compartment fuse box.
START and RUN the engine at 1500 RPM.

Is the noise still present?
Yes

CHECK the air conditioning compressor. For additional information, refer to Section

412-03 Air Conditioning

. CHECK

the power steering pump. For additional information, refer to Section

211-02 Power Steering

. TEST the system for

normal operation.

INSTALL a new generator. TEST the system for normal operation.

PINPOINT TEST H : RADIO INTERFERENCE

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2

1
2
3

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

H1: CHECK THE GENERATOR FOR THE CAUSE OF RADIO INTERFERENCE

START and RUN the engine at 1500 RPM.
TURN the radio switch to the ON position.

Is radio interference present?
Yes

GO to H3

. .

GO to H2

. .

H2: CHECK THE GENERATOR FOR THE CAUSE OF RADIO INTERFERENCE WITH A HIGH ELECTRICAL LOAD APPLIED TO THE
BATTERY

START and RUN the engine at 1500 RPM
APPLY a high electrical load to the battery.
TURN the radio switch to the ON position.

Is radio interference present?
Yes

GO to H3

. .

DIAGNOSE the entertainment system. For additional information, refer to Section

415-00 Information and

Entertainment System - General Information

H3: ELIMINATE THE GENERATOR AS THE CAUSE OF RADIO INTERFERENCE

REMOVE fuse 82 from the passenger compartment fuse box.
START and RUN the engine at 1500 RPM.
TURN the radio switch to the ON position.

Is radio interference still present?
Yes

Diagnose the Entertainment System. For additional information, refer to Section

415-00 Information and

Entertainment System - General Information

CLEAN and TIGHTEN all mounting points, positive and ground cable connections. INSTALL fuse 82 in the passenger
compartment fuse box. TEST the system for normal operation. If interference is still present, INSTALL a new
generator.

Base Voltage Test

• NOTE: Prior to running this test, turn the headlamps on for 30 seconds to remove any surface charge from the battery. Wait until the
voltage stabilizes before carrying out the base voltage test.

1. With the ignition switch in the OFF position and no electrical loads applied to the battery, connect the negative lead of a digital

multimeter to the battery ground cable clamp.

2. Connect the positive lead of the digital multimeter to the battery positive terminal cable clamp.

3. Read and record the battery voltage shown on the digital multimeter. This is called base voltage and will be used in later tests.

No-Load Test

1. Connect the digital multimeter leads across the battery terminals.

2. Read the voltage (base voltage). If the battery voltage is less than 12 volts. Charge the battery before test.

3. Start the engine.

4. Run the engine to 1500 RPM with no electrical load applied to the battery.

5. Read the voltage. If the voltage increase is less than 0.5 volts above the base voltage, carry out the Battery Condition Test. If

there is no voltage increase, diagnose the charging system. For additional information refer to the symptom chart.

Battery Condition Test

• W ARNINGS:

Batteries contain sulphuric acid and explosive mixtures of Hydrogen and Oxygen gasses; protective clothing should be worn to avoid

the risk of personal injury.

Avoid sparks and all sources of ignition when working on the battery.

• CAUTIONS:

Do not carry out this test if the battery voltage is below 12.5 volts.

Do not carry out this test for longer than 15 seconds or damage to the battery may occur.

• NOTE: Make sure that the high rate discharge tester is capable of applying a load of 300 Amps to the battery.

1. Connect the high rate discharge tester to the battery.

2. Observe and record the voltage reading of the battery.

3. Turn the switch to the ON position for 15 seconds.

4. Observe and record the minimum voltage reading of the battery.

5. Turn the switch to the OFF position.

6. Observe the voltage reading of the battery.

The battery should recover to the original voltage when the test is complete.

The battery voltage should not fall below 9.6 volts at a temperature of 21°C (70°F) when carrying out the test.

Published: 11-May-2011

Battery and Charging System - General Information - Charging System2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma

Diagnosis and Testing

Principle of operation

The diesel charging system differs from that used in petrol-engined variants in that it incorporates a 'smartcharge' function.

This function is capable of supplying infinitely variable voltages to the battery, depending on the temperature and on the current
requirements of the battery.

The system continuously monitors the battery voltage and temperature (via the ambient air temperature sensor), and uses a map of both to
deliver the optimum charge to the battery.

Another feature of this system is that it uses a 'wake-up' and 'sleep' strategy, initiated by the ignition switch position and engine control
module (ECM) to avoid current drain.

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

3. Check the vehicle battery condition and state of charge before condemning any of the charging system components. For additional

information, refer to the battery care manual.

Visual Inspection Chart

Mechanical

Electrical

Generator
Drive belt
Drive belt tensioner
Generator pulley
Check the security of the generator fittings

Generator
Battery
Charging system warning light function (ignition ON, engine OFF)
Fuse 36 (7.5A) front power distribution box (battery voltage sense)
Engine/Generator ground connection
Circuit(s)
Electrical connector(s)
Engine control module (ECM)

4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next

step.

5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan tool to retrieve the

fault codes before proceeding to the symptom chart.

CAUTION: W hen probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number

3548-1358-00.

• NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and
with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.

• NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

Symptom Chart

• NOTE: For a full list of DTCs,
REFER to:

Electronic Engine Controls

(303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,

Diagnosis and Testing).

DTC

Condition

Possible Source

Action

P0622 Generator monitor circuit fault

Generator monitor circuit: open
circuit, high resistance, short circuit
to B+, short circuit to ground
Generator regulator failure
ECM fault

For generator monitor circuit tests, GO to Pinpoint Test

P0623 Generator warning light circuit

fault

Generator warning light circuit: open
circuit, short circuit

For generator warning light circuit tests,
REFER to:

Electronic Engine Controls

(303-14B Electronic

Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW /150PS) - Puma, Diagnosis and Testing).

P1632 Generator communications

circuit fault

Generator communications circuit:
open circuit, high resistance, short
circuit to B+, short circuit to ground
Generator regulator failure
ECM fault

For generator communications circuit tests, GO to
Pinpoint Test

None The battery warning light is

on, intermittent, or flickers
with the engine running

Battery, low voltage
Accessory drive belt tension
Generator failure
ECM
Instrument cluster (IC) fault

Check the battery condition and state of charge. Refer to
the battery care manual. Check the accessory drive belt
tension,
REFER to:

Accessory Drive Belt Tensioner - 2.0L Duratorq-

TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma

(303-05

Accessory Drive, Removal and Installation).
Check the generator output, GO to Pinpoint Test

and

GO to Pinpoint Test

. For CAN circuit tests,

REFER to:

Communications Network - VIN Range:

E96603->J28492

(418-00 Module Communications

Network, Diagnosis and Testing).

1
2
3

1
2

DTC

Condition

Possible Source

Action

None The battery keeps discharging

Battery fault
Battery cables
Battery quiescent drain
Accessory drive belt tension
Generator failure
Generator pulley fault

Check the battery condition and state of charge. Refer to
the battery care manual. Check the volt drop across the
charging circuit, GO to Pinpoint Test

Check the

accessory drive belt tension,
REFER to:

Accessory Drive Belt Tensioner - 2.0L Duratorq-

TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma

(303-05

Accessory Drive, Removal and Installation).
Check the generator output, GO to Pinpoint Test

and

GO to Pinpoint Test

Check that the generator pulley

does not turn independently of the generator.

None Generator noisy

Generator failure
Accessory drive belt tension
Accessory drive belt
Accessory drive belt tensioner

For generator mechanical tests, GO to Pinpoint Test

Check the accessory drive belt and tensioners,
REFER to:

Accessory Drive Belt Tensioner - 2.0L Duratorq-

TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma

(303-05

Accessory Drive, Removal and Installation).

None Radio interference

Generator
W iring harness

For interference tests, GO to Pinpoint Test

Pinpoint tests

PINPOINT TEST A : CHECK THE GENERATOR OUTPUT UNDER LOAD AT IDLE

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: CHECK THE GENERATOR OUTPUT AT IDLE

Start the engine and allow to idle.
Turn the headlights ON.
W ith the engine idling, measure the voltage between the battery positive terminal and GROUND over ten seconds.

Was the average voltage greater than 12.85 volts?
Yes

GO to A2

Check the volt drop across the charging circuit, GO to Pinpoint Test

. If the volt drop is within limits, install a

new generator.
REFER to: Generator.

A2: CHECK THE GENERATOR OUTPUT AT IDLE FOR OVERCHARGE

W ith the engine idling and headlights still ON, measure the voltage between the battery positive terminal and
GROUND over ten seconds.

Was the average voltage greater than 15.25 volts?
Yes

The generator is overcharging. INSTALL a new generator.
REFER to: Generator.

Charging system is within limits.

PINPOINT TEST B : CHECK THE GENERATOR OUTPUT UNDER LOAD

• NOTE: Before beginning this test, make sure the warning light function is normal without the engine running (see visual inspection table).

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: CHECK THE FUNCTION OF THE CHARGING SYSTEM WARNING LIGHT

Start the engine and allow to idle.

Is the charging system warning light illuminated?
Yes

Check for DTC P0623.
REFER to:

Electronic Engine Controls

(303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi

(110kW/150PS) - Puma, Diagnosis and Testing).

GO to B2

B2: CHECK THE CHARGING SYSTEM OUTPUT UNDER LOAD (LOW VOLTAGE)

Turn the headlights and heated rear window to the ON position.
Raise the engine speed to between 2,800 rpm and 3,200 rpm and hold for ten seconds.
W hilst holding the engine rpm in the above range, measure the voltage between the battery positive terminal and
GROUND.
Allow the engine to idle.

Was the average battery voltage less than 12.85 volts?
Yes

GO to B4

GO to B3

B3: CHECK THE CHARGING SYSTEM OUTPUT UNDER LOAD (HIGH VOLTAGE)

Raise the engine speed to between 2,800 rpm and 3,200 rpm and hold for ten seconds.
W hilst holding the engine rpm in the above range, measure the voltage between the battery positive terminal and
GROUND.
Allow the engine to idle.

Was the average battery voltage greater than 15.25 volts?
Yes

INSTALL a new generator.
REFER to: Generator.
CLEAR the DTC. TEST the system for normal operation.

Charging system output is within limits.

B4: CHECK THE CHARGING SYSTEM VOLTAGE AT THE GENERATOR CONNECTOR, PIN 01

WARNING: The following test may involve working in close proximity to hot components. Observe caution when working in this area.

Failure to follow this instruction may result in personal injury.

Turn the headlights and heated rear window to the OFF position.

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