Heater hose JAGUAR X308 1998 2.G User Guide

Engine Cooling - Coolant Outlet Pipe
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Drain the radiator. Refer to Ge neral Procedures. Retain the
coolant drain tray in position to catch any spillage when
removing the outlet pipe.

3. Disc onne
ct the top hose and br
eather pipe from the coolant
outlet pipe.
1. Release and reposition th e hose clip, and disconnect
the top hose.
2. Release and disconnect the breather pipe quick fit connector.
3. Disconnect the multi-plug from the temperature sensor and unscrew the sens or from the outlet pipe.
4. Release and reposition the hose clip along the bypass
hose.

4. Disc
onnect the bottom hose
from the thermostat housing.
1. Release and reposition th e hose clip along the hose.
2. Disconnect the bottom hose.

5. Disc
onnect the coolant outlet pipe from the cylinder heads.
1. Remove the four bolts which secure the outlet pipe.
2. Remove the outlet pipe from the bypass hose and
from the cylinder heads (still connected to the
heater hose).
6. Release and reposition the clip which secures the heater hose
to the outlet pipe and disconnect the hose. Remove the outlet
pipe.
7. Remove the thermostat from the outlet pipe.
1. Remove the three bolts which secure the thermostat cover to the outlet pipe.
2. Remove the thermostat cover, the thermostat and
the seal from the outlet pipe. Discard the seal.

KS fail
ure
P0335Cranksh
a
ft positi
on (CKP) sensor
circuit malfunction
CK P
sensor disconnected
CKP sensor air gap
i
n
correct/foreign matter on face
CKP sensor sen
s
ing circuit open
circuit, short circuit to ground,
short circuit to high voltage
CKP s e
nsor failure
F
or CKP sensor circ ui
t tests,GO to
Pinpoint Test N.
.
P0340Camshaft position
(CMP) sensor
circuit malfunction
CM P
sensor disconnected
CMP sensor air gap
i
n
correct/foreign matter on face
CMP sensor sen
s
ing circuit open
circuit, short circuit to ground,
short circuit to high voltage
CMP s e
nsor failure
F
or CMP sensor circ ui
t tests,GO to
Pinpoint Test O.
.
P0351Igniti
on coil primary/secondary
circuit malfunction, cyl 1
ECM to ignit
ion module primary
circuit open circuit, short circuit to
ground, high resistance
Igniti
on module to ignition coil
primary circuit open circuit, short
circuit to ground, high resistance
Ignition modu le
ground circuit
open circuit, hi gh resistance
Ignition coil fail
ure
Ignition modul
e
failure
F
o
r ignition circuit tests,
REFER to Section 303
-07 En
gine
Ignition. P0352Ignit
i
on coil primary/secondary
circuit malfunction, cyl 3
P0353Ignit i
on coil primary/secondary
circuit malfunction, cyl 5
P0354Ignit i
on coil primary/secondary
circuit malfunction, cyl 7
P0355Ignit i
on coil primary/secondary
circuit malfunction, cyl 2
P0356Ignit i
on coil primary/secondary
circuit malfunction, cyl 4
P0357Ignit i
on coil primary/secondary
circuit malfunction, cyl 6
P0358Ignit i
on coil primary/secondary
circuit malfunction, cyl 8
P0400Exhaus t gas
recirculation (EGR)
flow malfunction
EGR valve c
onnector pins high
resistance
EGR pipe/exhaust manifol
d leak
EGR pipe blocke

d
EGR valve st

uck open/closed,
blocked
EGR valve fai
lure
For EGR
pinpoint t
ests,
REFER to Section 303
-08 En
gine
Emission Control.
P0405Exhaus
t gas
recirculation (EGR)
drive circuits open circuit
EGR valve power supply circuit
o p
en circuit
EGR valve t
o
ECM drive circuit pair
- EGR pins 1/3, 4/6 open circuit,
high resistance
EGR val v
e failure (stepper motor
open circuit)
For EGR pinpoint t
ests,
REFER to Section 303
-08 En
gine
Emissi
on Control.
P0406Exhaus t gas
recirculation (EGR)
drive circuits short circuit
EGR valve t o
ECM drive circuit pair
- EGR pins 1/3, 4/6 short circuit to
ground or high voltage
EGR val v
e failure (stepper motor
short circuit)
For EGR pinpoint t
ests,
REFER to Section 303
-08 En
gine
Emissi
on Control.
P0420Right-
hand catalytic converter
efficiency below threshold
HO2S di
sconnected.
HO2
S
to ECM wiring fault.
HO2
S
heater to ECM wiring fault.
HO2
S
heater failure.
HO2
S
failure.
Cat
a
lyst monitor sensor failure.
Catal
y
tic converter failure.
R
e
fer to pinpoint tests for components

listed. Visually inspect catalytic
converters.
P0442Evaporati v
e emissions system
(EVAP) leak detected
Fue l
filler cap missing
Fu

el filler cap seal faulty
EVAP system
leak (can
ister
damage, pipework damage)
EVAP v a
lve to ECM drive circuit
open circuit, short circuit, high
resistance
EVAP valve to engine pu rge pipe
damaged/blocked/leaking
EVAP ope r
ating vacuum hose
F
or evaporati
ve emissions pinpoint
tests,
REFER to Section 303
-1 3
Evaporative

Emissi
ons
.

Air Distribution and Filtering - Air Distri
bution and Filtering
Description an
d Operation
Air Distribution


Ou
tside air enters the plen
um via four inlets in the lower windshield panel.
If the air conditioning system is operating in FRESH mode (not recirculation mode), then air is drawn through the four
plenum apertures (and particle filters where fitted) and into the air conditioni ng unit via the blower interconnecting ducts in
the LH and RH blower assemblies. Air is c ooled and dehumidified as it passes through the evaporator and is then 'reheated'
to the required temperature as it passes through the heater matrix.
In RECIRCULATION mode, the air in the pass enger compartment is drawn into the air conditioning unit via the recirculation
air inlets on the blower assemblies.
In FRESH mode, air flows from the cabin into the trunk through a gap between the backlight and the parcel shelf. The air is
exhausted from the vehicle through extraction vent assemblies (incorporating one way flaps) whose outlets are above the
rear mufflers.
Air Flow Path

Air Distribution Modes
Bi
-level mode

Parts List
The heater circuit 'scavenges' coolant from the engine cooling system by mean s of an electric water pump. The water pump
has a protection circuit to inhibit operation when the coolant temperature is <16°C; this is to prevent possible damage to
the impeller due to the presence of coolant borne ice particles. Coolant is drawn from the en gine system through the water
valve inlet port into the heater matrix. The coolant passes thro ugh the bottom section of the heater matrix from left to right
filling the end tank of the matrix before returning through the top half of the ma trix and through the outlet ports of the
water valve and back into the engine cooling system.
Non return valves are located in the heat er bypass hose and the hose between the water pump and valve. These valves are
required to prevent coolant flowing in th e wrong direction at low engine speeds and restrict convected flow through the
heater after the engine is switched off.
When the exterior ambient temperature is > 0°C the refrigerat ion system automatically operates cooling and dehumidifying
incoming air before it is re -heated by the heater matrix.
Water Valve Assembly
Location
The water valve assembly is located above the water pump, in the engine compartmen t and is secured to the firewall by a
bracket. The valve operates by means of an electrical solenoid which oscillates the valve stem between the inlet and outlet
ports.
When in automatic mode, the water valve duty cycle is influenced by the following inputs to the A/CCM:
Outlet air temperature 'Air off' heater matrix temperature External ambient Coolant temperature
ItemPart NumberDescription
1—Assembly pump - water
2—Hose - from header tank
3—Hose / connector - return to engine
4—Hose - heater feed to matrix
5—Valve - non return (by-pass)
6—Hose / connector - feed from engine
7—Hose - heater return from matrix
8—Assembly valve - water
9—Valve - non return

Engine speed (valve closed with the engine not running) Demand (set) temperature In-car temperature sensor Solar sensor
Re-heating of the refrigerated air is contro lled by the time that the water valve is open (i.e. not energised) over a six secon d
interval. The duty cycle of the water valve, the time open / time closed, is controlled by the A/CCM.
Maximum heating demand will cause the water valve to be fu lly open (not energised) to allow maximum coolant flow
through the heater matrix.
At Maximum cooling, the water va lve will be fully closed (energised) to prevent hot (engine temperature) coolant entering
the heater circuit; the pump however will continue to circulate coolant through both the heater matrix and water valve
bypass.
The water valve defaults open when the ignition is OFF.
Under engine stall conditions, when ignition is ON, the water valve will be open.
Water Pump Assembly
Located in the same area as the water valve, the water pump continually circulates coolant through the heater matrix
except when the conditions below apply:
The engine coolant is below 16°C. The ignition is OFF. Under engine stall conditions, when ignition is ON. Control panel OFF
Non return valves
The heater bypass hose has a non-return valve, located between the engine feed and return hoses. The valve prevents the
water pump from recirculating coolant fro m the heater at low engine speeds.
The flow indicator arrow embossed on the valve bo dy MUST point towards the coolant header tank.
CAUTION: Coolant flow will be compromi sed if either valve is fitted incorrectly. Observe the correct direction.
A second non-return valve is located betw een the water pump and water valve. This valve prevents hot coolant from flowing
into the heater with the engine switched off. The flow indicator arrow MUST point towards the water pump.
Heater feed and return hoses
The heater feed and return hoses are connected to the engine feed and return hoses by 'Quick-Fit' connection unions. The
feed hose has a Norma R20 connector and the return hose a Norma push and seal connector. The coolant system bleed
joints have Cobra clamps. All remaining hose connections have spring band hose clamps.
The engine feed hose is connected to the engine bypass hous ing and the engine return hose is connected to the engine
water pump.
Clamp Identification

Heating and Ventilation - Heater Core and Evaporator Core Housing
Removal and Installation
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Recover refrigerant from air co nditioning system; refer to
82.30.30.
3. Drain radiator coolant only; refer to 26.10.01 or (SC)
26.10.01.
4. Remove instrument panel for access, refer to 76.46.01.

5. From under the hood: Disconnect air conditioning pipes at the
evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.

6. Disconnect heater hoses from heater matrix pipes.
1. Release spring band clips and disconnect heater hoses.
2. Install suitable blanking plugs.

7. From inside the vehicle: re move driver footwell duct.
Remove screw.
Remove duct.
8. Remove upper steering column lower fixings.
1. Remove nut.
2. Remove bolt.

15. Position upper steering column and install upper fixings.
1. Install bolts, do not tighten.

16. Install upper steering column lower fixings.
Tighten fixings.

17. Tighten upper fi xing bolts.
18. Under hood: reconnect heater ho ses to heater matrix pipes.
Remove blanking plugs.
Reconnect heater hoses and secure with spring band clips.

Compressor:
Features
Engine mounted, driven by the accessory drive belt. Fixed displacement type. High-pressure relief valve, to avoid system over-pressure. ECM controlled clutch energized via a relay.
Receiver drier:
Vertically mounted on the ri ght-hand side of the engine compartment next to the engine coolant radiator. Fitted with the high-side charge port. Includes a fluorescent tracer dye me chanism to aid leak detection.
ItemPart NumberDescription
1—Compressor assembly
2—Condenser
3—Evaporator and heater matrix (internal)
4—Receiver drier
5—4-level pressure switch
6—Expansion valve (internal)
7—High-side charge port
8—Low-side charge port
9—Suction muffler
10—Discharge hose
11—Discharge pipe
12—Suction hose
13—Suction pipe
14—Liquid line
15—Jumper hose (condenser hose)

Generally, resistance spot welding equipment used in the motor vehicle repair industry does not produce welds of equivalent strength to those achieved during manufactu re. The expression 'single row of resistance spot welds' indicates that the spots
should be spaced on a pitch of 19mm to 25mm, which normally results in mo re spot welds than those produced in the
original factory joint.
Resistance spot welds should be removed using a resistance spot weld cutter. If the new joint is to be MIG plug welded, old
resistance spot welds should be cut from the panel to be reta ined and the resulting holes used for plug welding. Suitable
holes may also be drilled or punched; 8,0 mm dia for sect ions up to 1,6 mm, and 10,0 mm dia for thicker sections.
PLASTICS-EXPLANATORY NOTES
Plastic component and trim materials
This table, in conjunction with the illu strations on the following pages will enable rapid identification of the particular
material of any major plastic part.
• NOTE: Only those components suitable for economic reclamation are identified.
Plastics - Handling Notes
The exterior panel temperature of a vehicle must not exceed 95°C at any time and may only be held at this level for a
maximum of two hours. Similarly, interior vehicle temperatur e must be limited to 86°C for a maximum duration of two
hours. Exposure to temperatures above those specified may result in distorted or permanently damaged components. If
there is doubt concerning temperature limitations, components that may be adversel y affected by exposure to heat should
be removed from the vehicle.
Plastic components that become greasy may be clea ned with an 'SBP 3' spirit wipe, or equivalent.
Recycled Materials
Any of the materials listed in this section, may be recycled provided that they ar e not contaminated by other incompatible
plastics or metals. For instan ce, the air conditioning unit case, manufactur ed from PP (polypropylene), must be separated
from the heater matrix, evaporator, contro l devices (electronic and mechanical) and all fixings before it can be considered
for recycling. After removal, the case mu st only be placed for disposal with materials of the same generic type. Bumper
cover assemblies similarly have side arma tures of dissimilar materials rivetted to them, these together with their fixings
must be removed prior to recy cling. Components manufactured from 'blended' materials must not be recycled with pure
materials. For example do not mix PC/ABS (wheel trim) with ABS ('B' pillar upper trim).
Plastics, Component Location and Type - External
TermMaterial Name
absAcrylonitrile Butadiene Styrene
abs / paAcrylonitrile Butadiene Styrene and Polyamide (nylon) blend
abs / pcAcrylonitrile Butadiene Styrene and Polycarbonate blend
ABS / PBTAcrylonitrile Styrene Acrylate and Polybutylene Terephthalate
paPolyamide (nylon)
pcPolycarbonate
pePolyethylene
pmmaPolymethyl Methacrylate
pomPolyoxymethylene (acetal)
ppPolypropylene
ppoModified Polyphenylene Oxide
purPolyurethane
pvcPolyvinylchloride
SMAStyrene Maleic Anhydride