Estimated Execution Times
Realistic estimates for an experienced general mechanic working on an I-PACE for the first time. Includes reading this guide, setup, and tea breaks.
Recommended split: Day 1 = Sections 1-4 (drain test, HV isolation, compressor swap). Day 2 = Sections 5-9 (recharge, park lock, final test). Sections 7 & 8 done while subframe is dropped — no extra time.
Diagnostic Status Current
What We Know
Vehicle arrived non-driveable. BPS charged the 12V battery and 8 of 13 DTCs cleared immediately. This confirms the HV battery (90 kWh) is healthy — the original fault codes were caused by the 12V going flat. The 5 remaining codes are the real issues.
JLR Manual p.1258 — I-PACE HV component layout. 1=Front/rear inverters, 2=Junction box, 3=HV heater, 4=AC compressor, 5=Onboard charger, 6/7=EDU labels, 8=NVH material. Table below image gives full key.
Remaining DTCs — 5 Active Faults
P272C-13
Park Lock Actuator — Stuck or not engaging. Check wiring first before replacing. p.755-756
P303F-15
Park Lock Position Sensor — Can't determine gear position. Linked to P272C. BPS reconnected cable — clear and re-test.
P303F-29
Park Lock — Signal Comparison — Mismatch between expected and actual position. If P272C clears, this will likely clear too.
U0080-87
ABS Module Bus Fault — CAN bus communication. May resolve once other faults clear.
B1479-08
GWM (Gateway Module) — Bus signal performance. Possibly cascade from 12V issue. Clear and re-test.
BECM Faults (×8)
All battery/energy control module faults cleared on 12V charge. HV battery confirmed healthy.
Tools Required Full List
Essential Tools — Every Job
- Autel MaxiSys / iCarsoft i930 — Jaguar-capable diagnostic scanner. For DTCs, AC Service Mode, park lock calibration
- Torque wrench (small) — 5-50 Nm, 3/8" drive. AC pipes, terminals, small fasteners
- Torque wrench (large) — 40-200 Nm, 1/2" drive. Subframe, wheels, suspension
- Socket set — metric — 8, 10, 12, 13, 14, 15, 17, 18, 19, 21, 24mm. Both 3/8" and 1/2"
- Allen key / hex bit set — 4, 5, 6, 8, 10mm
- Torx bit set — T20, T25, T27, T30, T40, T45, T50, T55
- Combination spanners — 10-24mm metric
- Breaker bar — 1/2", 600mm. For stuck subframe bolts
- Multimeter — DC Amps (mA/A range) for drain test, voltage, continuity
- Trim removal kit — Plastic pry tools for interior panels
- Transmission jack / hydraulic table — Min 200kg rated. For subframe drop
- Axle stands (×4) — 3-tonne minimum
- Trolley jack — 3-tonne
- LED inspection light / headtorch — Magnetic LED bar ideal for underbody
HV Safety Equipment — Mandatory
JLR Manual p.3575 — HV warning sign (must be displayed on steering wheel) and initial power-down steps 9-12. Shows sign placement requirement and 12V disconnection prerequisites.
- Class 0 insulated gloves — 1000V rated. MUST wear for any HV work. Not optional
- Leather outer gloves — Over the rubber gloves for puncture protection
- Safety glasses — Impact rated, arc flash protection
- HV warning sign — "VEHICLE ELECTRICALLY ACTIVE" for steering wheel
- Insulated tools — 1000V rated if working near HV connections directly
- Lockout/tagout kit — For SDU key. Tag with name and date
The I-PACE runs a 400V system. Contact with HV components can be FATAL. Full power-down is mandatory before AC compressor work.
AC System Tools
- R1234yf recovery/recharge station — Must be R1234yf specific (NOT R134a)
- Electronic leak detector — R1234yf compatible
- New O-rings — R1234yf compatible for all AC connections
- PAO 68 compressor oil (SP-A2) — Only approved oil. 100ml total system capacity
- Measuring cylinder — For old compressor oil measurement
1. Moving the Vehicle Safety Critical ~30 min
Emergency Park Release (EPR) — Getting into Neutral
Vehicle cannot be driven. To roll it onto a ramp, release the parking pawl via the EPR lever in the frunk.
JLR Manual p.1257 — Jacking points, towing eye locations, and axle stand positions. Use these positions ONLY when supporting the vehicle.
EPR Procedure
1
Open the frunk. EPR lever is under a cover panel on the left-hand side.
2
Pull the EPR lever upward through 90 degrees. Vehicle is now in Neutral.
3
Chock the wheels immediately — car will roll freely.
4
Push into position. Steering will be heavy (no power assist) — two people recommended.
With EPR engaged, there is NO parking pawl. Car will roll on any gradient.
Electric Parking Brake (EPB) — Manual Release
If EPB is also locked on, manually release the rear calipers. Requires removing BOTH rear wheels.
JLR Manual p.1261 — EPB motor connector (purple), caliper carrier (blue), and manual release mechanism. Three detailed views showing connector, caliper pivot, and adjuster access.
Manual EPB Release
1
Jack up rear, support on axle stands, remove both rear wheels. Wheel nuts: 140 Nm on refit (3-stage: hand → 100 → 140 Nm, star pattern).
2
Disconnect EPB motor connector (purple) on each rear caliper.
3
Remove caliper top bolt to allow caliper to pivot open.
4
Rotate EPB adjuster: RIGHT side = counter-clockwise, LEFT side = clockwise. Turn until pads retract and disc spins freely.
5
Reassemble — pivot caliper back, refit bolt, reconnect connector. Repeat other side. Refit wheels.
Once EPB is released + EPR engaged, the car has NOTHING holding it. Chock all four wheels.
2. 12V Parasitic Drain Investigation Priority ~45 min
Background
12V went flat causing all initial DTCs. Confirm whether there's a parasitic drain before doing anything else.
JLR Manual p.3309 — 12V battery location in the frunk. Cross-member, harness routing, and terminal positions shown. Full removal/refit procedure text included.
Drain Test Procedure
1
Everything off — all doors closed, no keys nearby. Wait 30 min for module sleep (I-PACE modules take longer than ICE cars).
2
Disconnect negative terminal — 10mm. 5 Nm on refit.
JLR Manual p.3310 — Battery terminal detail, cable routing, and connection procedure steps.
3
Connect multimeter in series — Red to negative cable, black to battery terminal. Set to 10A range.
4
Read current: Normal = 20-50 mA. Suspect = 80-150 mA. Problem = 200+ mA.
5
If drain found — Pull fuses one at a time watching the meter. When drain drops, that circuit is the culprit.
6
Reconnect — 5 Nm. Petroleum jelly on terminal.
Known issue: telematics module can stay awake and drain 12V. If drain is on telematics fuse, may need software update via JLR SDD/PATHFINDER.
3. HV Safety — Full Power Down Must Do Before AC Work ~30 min
HV Isolation Procedure p.3570-3616
The HV battery stores 90 kWh at 388V. Contact with live HV components can be FATAL. This is not optional.
1
Ignition OFF, key fob 5+ metres away.
2
Display HV warning sign on steering wheel.
JLR Manual p.3576 — Frunk interior trim panel (blue) removal for 12V battery access. Quarter-turn fastener detail and clip locations shown in insets.
3
Open frunk, remove trim cover over 12V battery.
4
Disconnect 12V negative — 10mm. 5 Nm refit. Insulate terminal with tape.
JLR Manual p.3577 — 12V negative terminal location and bracket detail. Disconnect this FIRST before proceeding to SDU.
5
WAIT 10 MINUTES — HV capacitor discharge time. Set a timer.
6
Access SDU (Service Disconnect Unit) — under rear seat.
JLR Manual p.3581 — Rear seat cushion removal. Lift front edge, slide forward, remove. SDU is under the carpet beneath.
7
Remove rear seat base — lift front edge up, slide forward, lift clear. Peel back carpet.
8
Remove SDU access panel — Torx T30 fasteners.
JLR Manual p.3583 — SDU visible after access panel removal. The orange/yellow key handle (bottom image) is what you remove to isolate HV.
9
PUT ON INSULATED GLOVES NOW. Check for holes first (inflate and squeeze test).
10
Remove SDU key — rotate 90° counter-clockwise, pull straight out. This physically breaks the HV circuit. LOCK KEY AWAY, tag with name and date.
JLR Manual p.3584 — SDU key removal sequence. Rotate counter-clockwise then pull straight out. Right image shows SDU with key removed — HV now isolated.
11
WAIT 5 MORE MINUTES — additional capacitor discharge.
12
Verify isolation — CAT III multimeter, check for 0V between HV+ and HV- at front motor junction box.
HV system fully isolated. Proceed with AC compressor work.
4. AC Compressor Removal & Installation Main Job 5-7 hours
Overview p.2904-2918
AC compressor sits on the front motor/drive unit. Access requires lowering front subframe by 80mm. New compressor already purchased (~£300 eBay).
Pre-Requisites
- HV system fully powered down (Section 3 — SDU key removed, verified 0V)
- AC refrigerant fully recovered (Section 5 — service mode required)
- 12V disconnected
- Vehicle on ramp or stands, wheels removed
Removal Procedure
Stage 1 — PPE & Access
JLR Manual p.2905 — Required PPE symbols and safety prerequisites. Eye protection, HV gloves, and EV-specific precautions mandatory throughout.
1
Remove front undertray — Torx T30 + push clips. Penetrating fluid for corroded fasteners.
2
Remove front wheel arch liners (front sections) for subframe access.
Stage 2 — AC Pipe Disconnection
JLR Manual p.2909 — AC compressor HV connector location (purple, top image). Bottom image shows under-tray access view from below.
3
Confirm refrigerant fully recovered — 0 pressure both sides.
4
Disconnect suction (LP) pipe — 9 Nm refit. Cap both ends immediately. Discard old O-rings.
5
Disconnect discharge (HP) pipe — 9 Nm refit. Cap and plug.
JLR Manual p.2914 — AC compressor pipe connections close-up. Suction line (left), discharge line (bottom), mounting bolts (right). Note O-ring positions at each joint.
Stage 3 — HV Connector
6
Disconnect HV electrical connector — Orange cable. Push locking tab, pull straight off.
Stage 4 — Lower Subframe 80mm
JLR Manual p.2912 — Steps 18-19. Top: Front subframe (yellow) bolt positions — 1=rear mounts, 2=mid mounts, 3=front mounts. Loosen position 1 bolts, remove positions 2+3. Bottom: 80mm gap shown with transmission jack. The 80mm measurement is clearly marked.
7
Support subframe — transmission jack centrally underneath, take the weight.
8
Loosen the 6 subframe bolts (do NOT fully remove position 1 bolts):
2× rear mount (Position 1) — LOOSEN ONLY
4× mid + front (Positions 2 & 3) — REMOVE
All bolts on refit: 175 Nm + 90° angle
9
Disconnect any harnesses/pipes that would strain during 80mm drop.
10
Lower jack by exactly 80mm — slowly, evenly. Watch for snagging cables/pipes.
Do NOT lower more than 80mm. Steering UJs, CV joints, and brake hoses have limited travel.
Stage 5 — Compressor Out
JLR Manual p.2915 — Step 25: AC compressor (blue) with 3× mounting bolts (purple, ×3). Step 26: Compressor being removed from front EDU (yellow). Second technician recommended to reposition EDU and steering gear.
11
Remove 3 compressor mounting bolts — 25 Nm refit.
12
Slide compressor out through the gap. ~8-10kg. Second pair of hands useful.
13
Drain and measure old compressor oil:
Tip old compressor, drain ALL oil into measuring cylinder
Record amount (e.g. 45ml)
New compressor oil = 100ml minus drained amount (e.g. 100-45 = 55ml)
Oil: PAO 68 (SP-A2 ONLY)
Installation Procedure
JLR Manual p.2916 — Complete front subframe assembly reference for reassembly. All bolt positions, suspension arms, and steering rack mounting points visible. Use this as your refit reference.
14
Add calculated oil to new compressor through suction port. PAO 68 only.
15
Rotate shaft 10 full turns by hand to distribute oil.
16
Fit new O-rings — lubricate with thin film of PAO 68.
17
Slide compressor in, align 3 mounting holes.
18
Torque 3 mounting bolts — 25 Nm star pattern.
19
Reconnect HV connector — click locking tab. Route cable clear of moving parts.
20
Reconnect HP pipe — new O-ring. 9 Nm.
21
Reconnect LP pipe — new O-ring. 9 Nm.
22
Raise subframe — jack up slowly, align bolts.
23
Torque all 6 subframe bolts — 175 Nm + 90° cross pattern.
24
Reconnect all harnesses/clips. Check brake lines not kinked.
25
Refit arch liners and undertray.
Compressor installed. Next: evacuate and recharge AC system (Section 5).
5. AC System Recovery, Vacuum & Recharge Specialist Equipment ~1.5 hours
Critical — Service Mode Required p.2790-2796
The I-PACE has electronically controlled AC isolation valves. You MUST activate "AC Service Mode" via diagnostic tool BEFORE connecting the AC station. Valves auto-close after 60 minutes — re-activate if needed.
JLR Manual p.2791 — AC system service information including port locations, safety warnings, and service mode requirement.
Service Mode Activation
1
12V reconnected, ignition ON (not start).
2
Connect diagnostic tool to OBD port (driver footwell).
3
Navigate: HVAC → Actuator Tests → AC Service Mode. Confirm valves OPEN. 60-minute timer starts.
Recovery (Before Compressor Removal)
4
Connect AC station, recover all R1234yf. Record amount (should be ~850g if full).
Evacuation & Recharge (After Installation)
JLR Manual p.2793 — AC condenser connections. Check all these joints for leaks after recharge.
5
Re-activate Service Mode if >60 min elapsed.
6
Pull deep vacuum: below 500 microns, hold 30 minutes minimum. If vacuum rises = leak.
7
Charge: 850g R1234yf.
8
Leak test all joints with electronic detector.
9
Run AC (HV must be reconnected first). Max cold, fan high. Vents should reach 5-10°C.
| AC Spec | Value |
|---|---|
| Refrigerant | R1234yf (NOT R134a) |
| Charge | 850g |
| Oil | PAO 68 (SP-A2) |
| Total Oil | 100ml |
| Vacuum | Below 500 microns, 30 min hold |
6. Park Lock Actuator Diagnostics Check & Test ~30 min
DTCs: P272C-13, P303F-15, P303F-29 p.755-756
All three relate to park lock. BPS reconnected the cable — may already be resolved.
1
Clear all 3 codes.
2
Cycle ignition — ON, Drive, Park, OFF. Repeat 3×.
3
Re-scan: Codes clear = fixed. P272C returns = actuator replacement needed. P303F only = calibration via SDD.
4
Check connector — fully seated, no corrosion, no damaged wires.
P272C-13 is common after 12V death. Usually clears permanently after cable reconnection. Don't replace actuator until code returns after clearing.
7. Front Motor Plate Inspection While Subframe is Down ~15 min
Inspect While You're There p.2913
JLR Manual p.2913 — Front motor/drive unit (yellow) with steering rack bolts (purple inset). Inspect mounting plate for cracks around these bolt holes while subframe is dropped.
- Cracks around mounting bolt holes (aluminium fatigue)
- Corrosion / salt damage on lower subframe faces
- Loose or stretched bolts — replace if thread damage
- Rubber mount condition — splitting, cracking, oil contamination
1
Photograph any damage. Cracks may need welding or plate replacement.
2
Steering rack bolts: 100 Nm + 90°
8. LP Pipe Bracket — Known Recall Check While Open ~15 min
Technical Bulletin TB02109 / TB02087 p.3009-3013
Known JLR recall — original plastic LP pipe bracket fails, pipe vibrates and cracks.
JLR Manual p.3011 — LP (low pressure) pipe routing and bracket location. Electronic isolation valve (blue), LP suction line (yellow). Check bracket at this location for cracking.
1
Locate LP pipe bracket — on suction line between evaporator and compressor.
2
Check bracket: Original T4K12780 (plastic, cracks) → Revised T4K19719 (robust). Replace if original fitted and cracked.
JLR Manual p.3013 — Complete LP pipe routing showing all bracket and clip positions. Check each for cracking or looseness.
3
Inspect LP pipe for chafing, vibration damage, hairline cracks.
While AC system is open for compressor swap, this is the ideal time. Part is cheap — saves a future leak.
9. Final Test Checklist Before Handback ~1 hour
Complete All Before Returning Vehicle
- HV re-enabled — SDU key refitted (clockwise to lock), rear seat reassembled
- 12V connected — 5 Nm, battery fully charged
- Powers on normally — correct dashboard sequence, no warning lights
- Full DTC scan — ALL modules — all 5 codes should be clear
- AC blows cold — max cold, fan high, vents reach 5-10°C
- No compressor noise — no grinding, rattling, or whine
- No AC leaks — detector on all joints, visual check for oil
- Park lock works — holds on slope, no DTC returns
- Test drive — brakes, steering, suspension, no vibrations
- All wheels torqued — 140 Nm (3-stage, star pattern)
- Undertray and liners refitted — all fasteners present
- 12V drain test passed — under 50mA after 30 min sleep
10. Specialist Parts to Source Prices March 2026
Standard consumables (brake cleaner, cable ties, copper grease, penetrating fluid, Loctite, etc.) — source from your normal motor factor. This list covers only the specialist/EV-specific items you won't have in stock.
AC Compressor
ALREADY PURCHASED (~£300 from eBay). Ensure it came with sealing gasket.
O-Ring Kit — HNBR Green (R1234yf Compatible)
Must be HNBR material, NOT standard NBR. HNBR is R1234yf safe; NBR degrades and causes leaks. Green colour = correct material.
| Option | Price | Link |
|---|---|---|
| Polymax 270pc HNBR Kit — 18 sizes, free UK shipping. Best value | £16.20 | Polymax Direct |
| Amazon UK 270pc HNBR Green Kit — check listing says "HNBR" not "NBR" | £8-15 | Amazon UK |
| eBay UK — various HNBR kits | £8-18 | eBay UK |
PAO 68 Compressor Oil (SP-A2 Rated)
Must be PAO 68, NOT PAG oil. PAG is electrically conductive — dangerous in HV EV systems. Total system capacity 100ml, but buy 250ml to have spare.
| Option | Price | Link |
|---|---|---|
| Auto Air Con Parts — SP-A2 Oil 250ml — Cheapest. Specialist AC supplier | £6.00 | AutoAirConParts |
| Arcomax PAO68 Universal 250ml — Dutch-made, R1234yf compatible | £6.50 | Arcomax |
| Arcomax PAO68 + UV Dye 250ml — same oil with leak detection dye. Worth the premium | £8-10 | eBay UK |
The UV dye version is worth the extra couple of quid — if a seal weeps later, you can spot it with a UV torch without pulling everything apart again.
R1234yf Refrigerant — 850g Needed
R1234yf is regulated under UK F-Gas regs. 1kg retail cans don't exist in the UK — you get small DIY cans (170-500g) or trade cylinders (5kg+, needs F-Gas cert). You'll need ~850g total.
| Option | Price | Link |
|---|---|---|
| AC Pro R1234yf can — ~280-340g each. Need 3 cans. Made in Italy. Genuine product | £86-102/can | eBay UK |
| FreezeECO R1234YF 2-in-1 (gas + oil) 400ml — includes oil, up to 40% more gas | £45-55 | Amazon UK |
| Trade cylinder 5kg (if F-Gas certified) — by far cheapest per gram | £250-300 + £50 deposit | Sevac/AirConGas |
Avoid cans with "leak stop" additives for a fresh system rebuild — leak stop can clog the TXV/expansion valve. Use pure R1234yf only. Check the label says HFO-1234yf.
If anyone at the garage has F-Gas certification, the trade cylinder route is massively cheaper. One 5kg cylinder does 5-6 I-PACE recharges.
LP Pipe — T4K19719
Note: T4K19719 is the complete LP suction hose assembly (not just the bracket). If only the bracket clip is damaged, search separately for "I-PACE AC pipe clip bracket" (£5-15). Full hose only if pipe itself is cracked.
| Option | Price | Link |
|---|---|---|
| Genuine OEM T4K19719 (new) — eBay seller OEM_GENUINE_PARTS, 99.4% positive, Lithuania. Free tracked delivery. 60-day returns | £175.22 | eBay UK |
| Autodoc UK — range of I-PACE AC pipe parts | £4-137 | Autodoc |
| Jaguar dealer OEM | £200-350 | Phone local dealer with part number |
Inspect the pipe first. If there's no cracking and only the bracket has failed, a £5-15 clip replacement is all you need. Don't buy the full £175 hose unless the pipe is damaged.
Park Lock Actuator — T4K18381 — IF NEEDED (Test First!)
Clear codes first (Section 6). Only buy if P272C returns after clearing. Also check Jaguar recall Campaign H288 — if your VIN is covered, the dealer replaces it FREE including the wiring loom.
| Option | Price | Link |
|---|---|---|
| Genuine New T4K18381 — JLR Parts UK Ltd, Bromsgrove. 10 in stock. FedEx delivery. Collection available | £340.65 | eBay UK |
| Used/breaker — rare, I-PACEs not commonly scrapped yet | £150-250 est. | 1st Choice |
| Jaguar dealer | £350-500 | Phone dealer — quote VIN for H288 recall check first |
Before spending £340+ — phone your local Jaguar dealer with VIN SADHA2A19L1F82690 and ask if Campaign H288 applies. If it does, the actuator, wiring loom, and labour are all covered FREE. The H288 recall addresses corroded connector pins on the park lock actuator.
HV Safety Gear (if not already owned)
| Option | Price | Link |
|---|---|---|
| CATU Presel GP-0 Class 0 Gloves — cheapest genuine option | £27.30 | SafetyGloves.co.uk |
| Polyco SuperGlove Volt Class 0 — well-known UK brand | £29.16 | SafetyGloves.co.uk |
| Warwick Test Supplies — Class 0, EV-specific | £38.76 | Warwick TS |
| Leather outer gloves (protectors) | £10-20 | Amazon UK |
Must be Class 0 (1000V AC). Class 00 is only 500V — not enough for EV work. Check for EN 60903 certification. Inspect for holes before every use (inflate and squeeze test).
Cost Summary
| Item | Budget | Mid-Range |
|---|---|---|
| AC Compressor | ALREADY BOUGHT — £300 | |
| HNBR O-Ring Kit | £8 (Amazon) | £16 (Polymax) |
| PAO 68 Oil 250ml | £6 (AutoAirConParts) | £6.50 (Arcomax) |
| R1234yf Refrigerant | £45-55 (DIY can) | £86-102 (AC Pro) |
| HV Gloves + Outers | £37 (CATU + leather) | £49 (Polyco + leather) |
| TOTAL (excl. compressor) | £96-114 | £158-174 |
LP pipe only if cracked (£175). Park lock actuator only if codes return (£340) — check H288 recall first (potentially FREE). These are worst-case additions.
11. Complete Torque Reference All Values
| Fastener | Torque | Notes |
|---|---|---|
| Front subframe bolts (×6) | 175 Nm + 90° | Angle-tighten. Cross pattern. p.2912 |
| Wheel nuts | 140 Nm | 3-stage: hand → 100 → 140 Nm. Star pattern. p.2046 |
| Steering rack bolts | 100 Nm + 90° | Angle-tighten. p.2913 |
| AC compressor mounting (×3) | 25 Nm | p.2915 |
| AC pipe connections | 9 Nm | New O-rings. Don't over-tighten. p.2793 |
| 12V battery terminals | 5 Nm | Petroleum jelly after. p.3309 |
| 12V battery clamp | 10 Nm | p.3311 |
| Brake caliper bolt (EPB) | 35 Nm | p.1261 |
| SDU panel (Torx T30) | 3 Nm | Finger-tight + snug |
| Undertray (Torx T30) | 5 Nm | Plastic — don't overtighten |
| Condenser connections | 9 Nm | If disturbed. New O-rings. p.2793 |
"+ 90°" bolts: Torque to initial value, then turn an additional 90° with angle gauge. These are torque-to-yield — replace if stretched.
Workshop Manual Page Index Quick Reference
Where to Find It in the Manual
| Topic | Pages |
|---|---|
| Emergency Park Release (EPR) | p.1256-1258 |
| Electric Parking Brake manual release | p.1259-1263 |
| Park Lock DTC diagnosis (P272C) | p.755-756 |
| Wheel nut torque specs | p.2046 |
| AC system recovery & recharge | p.2790-2792 |
| AC system specs & torques | p.2793-2796 |
| AC compressor removal & installation | p.2904-2918 |
| LP pipe & bracket (TB02109) | p.3009-3013 |
| 12V battery disconnect/reconnect | p.3309-3312 |
| HV safety — full power down | p.3570-3616 |
All diagrams and procedures from JLR Workshop Manual — Jaguar I-PACE X590 (2018-2024), 8,785 pages.
Guide prepared by Ade Whetton for BPS Garage Services — March 2026