heater JAGUAR XJ6 1997 2.G Workshop Manual

3261 Jaguar XJ6
Roadside repairs0•7
When jump-starting a car using a
booster battery, observe the following
precautions:
4Before connecting the booster
battery, make sure that the ignition
is switched off.
4Ensure that all electrical equipment
(lights, heater, wipers, etc) is
switched off.
4Take note of any special precautions
printed on the battery case.4Make sure that the booster battery
is the same voltage as the
discharged one in the vehicle.
4If the battery is being jump-started
from the battery in another vehicle,
the two vehicles MUST NOT TOUCH
each other.
4Make sure that the transmission is in
neutral (or PARK, in the case of
automatic transmission).
Jump starting will get you
out of trouble, but you must
correct whatever made the
battery go flat in the first
place. There are three possibilities:
1) The battery has been drained by
repeated attempts to start, or by
leaving the lights on.
2) The charging system is not working
properly (alternator drivebelt slack or
broken, alternator wiring fault or
alternator itself faulty).
3) The battery itself is at fault (electrolyte
low, or battery worn out).
Connect one end of the red jump lead
to the positive (+) terminal of the flat
batteryConnect the other end of the red lead
to the positive (+) terminal of the
booster batteryConnect one end of the black jump lead
to the negative (-) terminal of the
booster battery
Connect the other end of the black
jump lead to a bolt or bracket on the
engine block, well away from the
battery, on the vehicle to be started
123
4
Make sure that the jump leads will not
come into contact with the fan,
drivebelts or other moving parts of the
engine5
Start the engine using the booster
battery, then with the engine running at
idle speed, disconnect the jump leads
in the reverse order of connection6
Jump starting

leak be found, renew the offending gasket or
oil seal by referring to the appropriate
Chapters in this manual.
2Also check the security and condition of all
the engine-related pipes and hoses. Ensure
that all cable ties or securing clips are in place
and in good condition. Clips which are broken
or missing can lead to chafing of the hoses,
pipes or wiring, which could cause more
serious problems in the future.
3Carefully check the radiator hoses and
heater hoses along their entire length. Renew
any hose which is cracked, swollen or
deteriorated. Cracks will show up better if
the hose is squeezed. Pay close attention
to the hose clips that secure the hoses to the
cooling system components. Hose clips can
pinch and puncture hoses, resulting in cooling
system leaks.
4Inspect all the cooling system components
(hoses, joint faces etc.) for leaks. A leak in the
cooling system will usually show up as white-
or rust-coloured deposits on the area
adjoining the leak. Where any problems of this
nature are found on system components,
renew the component or gasket with
reference to Chapter 3.
5From within the engine compartment,
check the security of all fuel hose attachments
and pipe unions, and inspect the fuel hoses
and vacuum hoses for kinks, chafing and
deterioration.
6Also check the condition of the power
steering fluid hoses and pipes.
8 Automatic transmission
fluid level check
1
1The level of the automatic transmission fluid
should be carefully maintained. Low fluid level
can lead to slipping or loss of drive, while
overfilling can cause foaming, loss of fluid and
transmission damage.
2The transmission fluid level should only be
checked when the transmission is at its
normal operating temperature.
Caution: If the vehicle has just been driven
for a long time at high speed or in city
traffic in hot weather, or if it has been
pulling a trailer, an accurate fluid level
reading cannot be obtained. Allow the fluid
to cool down for about 30 minutes.
3If the vehicle has not been driven, park the
vehicle on level ground, set the handbrake,
then start the engine and bring it to operating
temperature. While the engine is idling,
depress the brake pedal and move the
selector lever through all the gear ranges,
beginning and ending in Park.
4With the engine still idling, remove the
dipstick from its tube (see illustration). Check
the level of the fluid on the dipstick (see
illustration)and note its condition.
5Wipe the fluid from the dipstick with a clean
rag and reinsert it back into the filler tube until
the cap seats.6Pull the dipstick out again and note the fluid
level. If the transmission is cold, the level
should be in the COLD or COOL range on the
dipstick. If it is hot, the fluid level should be in
the HOT range. If the level is at the low side of
either range, add the specified transmission
fluid through the dipstick tube with a funnel.
7Add just enough of the recommended fluid
to fill the transmission to the proper level. It
takes about one pint to raise the level from the
low mark to the high mark when the fluid is
hot, so add the fluid a little at a time and keep
checking the level until it is correct.
8The condition of the fluid should also be
checked along with the level. If the fluid at the
end of the dipstick is black or a dark reddish
brown colour, or if it emits a burned smell, the
fluid should be changed (see Section 26). If
you are in doubt about the condition of the
fluid, purchase some new fluid and compare
the two for colour and smell.9 Differential oil level check
1
1The differential has a check/fill plug which
must be removed to check the lubricant level.
If the vehicle is raised to gain access to the
plug, be sure to support it safely on axle
stands - DO NOT crawl under the vehicle
when it’s supported only by the jack!2Remove the lubricant check/fill plug from
the differential (see illustration).Use a
3/8-inch drive ratchet and a short extension to
unscrew the plug.
3Use your little finger as a dipstick to make
sure the lubricant level is even with the
bottom of the plug hole. If not, use a syringe
or squeeze bottle to add the recommended
lubricant until it just starts to run out of the
opening.
4Refit the plug and tighten it securely.
10 Exhaust system check
1
1With the engine cold (at least three hours
after the vehicle has been driven), check the
complete exhaust system from its starting
point at the engine to the end of the tailpipe.
This should be done on a hoist where
unrestricted access is available.
2Check the pipes and connections for
evidence of leaks, severe corrosion or
damage. Make sure that all brackets and
hangers are in good condition and tight (see
illustration).
3At the same time, inspect the underside of
the body for holes, corrosion, open seams,
etc. which may allow exhaust gases to enter
the passenger compartment. Seal all body
openings with silicone or body putty.
4Rattles and other noises can often be
traced to the exhaust system, especially the
mounts and hangers. Try to move the pipes,
Every 7500 miles or 6 months 1•11
1
9.2 The differential check/fill plug is
located on the rear of the differential
housing - place your finger in the filler plug
hole to make sure the lubricant level is
even with the bottom of the hole
10.2 Check the exhaust system hangers
(arrowed) for damage and cracks
3261 Jaguar XJ6
8.4a The automatic transmission dipstick
(arrowed) is located in a tube which
extends forward from the transmission
8.4b Check the automatic transmission
fluid with the engine idling at operating
temperature and the gear selector in Park,
then add fluid to bring the level to the
upper mark

16 Spark plug renewal
2
Refer to Section 4, renewing the plugs
regardless of their apparent condition.
17 Air cleaner element renewal
1
1The air filter is located inside a housing at
the left side of the engine compartment. To
remove the air filter, release the four spring
clips that secure the two halves of the air
cleaner housing together, then lift the cover
up and remove the air filter element (see
illustration).
Caution: Never drive the car with the air
cleaner removed. Excessive engine wear
could result and backfiring could even
cause a fire under the bonnet.
2Wipe out the inside of the air cleaner
housing.
3Place the new filter into the air cleaner
housing, making sure it seats properly.
4Refitting the cover is the reverse of removal.
18 Fuel filter renewal
2
Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system.
Don’t smoke or allow open flames or bare
light bulbs near the work area, and don’t
work in a garage where a natural gas-typeappliance (such as a water heater or
clothes dryer) with a pilot light is present.
Since petrol is carcinogenic, wear latex
gloves when there’s a possibility of being
exposed to fuel, and, if you spill any fuel on
your skin, rinse it off immediately with soap
and water. Mop up any spills immediately
and do not store fuel-soaked rags where
they could ignite. The fuel system is under
constant pressure, so, if any fuel lines are
to be disconnected, the fuel pressure in
the system must be relieved first (see
Chapter 4 for more information). When you
perform any kind of work on the fuel
system, wear safety glasses and have a
Class B type fire extinguisher on hand.
1The canister type filter is mounted
underneath the car on the passenger’s side
frame rail just in front of the left rear tyre.
2Depressurise the fuel system (refer to
Chapter 4), then disconnect the cable from
the negative terminal of the battery.
3On 1988 to 1990 models, detach the banjo
bolt from the outlet side of the filter then
remove the union from the inlet side of the
filter. Unscrew the filter mounting bolt and
remove the filter (see illustration).
4On 1991 to 1994 models, the fuel filter has
quick-disconnect fittings that do not require 8Clean and lubricate the handbrake cable,
along with the cable guides and levers. This
can be done by smearing some of the chassis
grease onto the cable and its related parts
with your fingers.
9Open the bonnet and smear a little chassis
grease on the bonnet latch mechanism. Have
an assistant pull the bonnet release lever from
inside the car as you lubricate the cable at the
latch.
10Lubricate all the hinges (door, bonnet,
etc.) with engine oil to keep them in proper
working order.
11The key lock cylinders can be lubricated
with spray graphite or silicone lubricant, which
is available at motor factors.12Lubricate the door weather-stripping with
silicone spray. This will reduce chafing and
retard wear.
15 Road test
1
Instruments and electrical
equipment
1Check the operation of all instruments and
electrical equipment.
2Make sure that all instruments read
correctly, and switch on all electrical
equipment in turn, to check that it functions
properly.
Steering and suspension
3Check for any abnormalities in the steering,
suspension, handling or road “feel”.
4Drive the car, and check that there are no
unusual vibrations or noises.
5Check that the steering feels positive, with
no excessive “sloppiness”, or roughness, and
check for any suspension noises when
cornering and driving over bumps.
Drivetrain
6Check the performance of the engine and
transmission, listening for any unusual noises.7Make sure that the engine runs smoothly
when idling, and that there is no hesitation
when accelerating.
8Check that the gear changing action of the
transmission is smooth and progressive and
that the drive is taken up smoothly from a
standing start.
Braking system
9Make sure that the car does not pull to one
side when braking, and that the wheels do not
lock prematurely when braking hard.
10Check that there is no vibration through
the steering when braking.
11Check that the handbrake operates
correctly without excessive movement of the
lever, and that it holds the car stationary on a
slope.
12Test the operation of the brake servo unit
as follows. With the engine off, depress the
footbrake four or five times to exhaust the
vacuum. Hold the brake pedal depressed, then
start the engine. As the engine starts, there
should be a noticeable “give” in the brake
pedal as vacuum builds up. Allow the engine to
run for at least two minutes, and then switch it
off. If the brake pedal is depressed now, it
should be possible to detect a hiss from the
servo as the pedal is depressed. After about
four or five depressions, no further hissing
should be heard, and the pedal should feel
considerably harder.
1•14Every 7500 miles or 6 months
17.1 Detach the clips and separate the
cover, then slide the filter element out of
the housing
3261 Jaguar XJ6
14.6 Grease fittings for the rear
driveshafts are located in the centre
on each U-joint
Every 15 000 miles (24 000 km) or 12 months

5After the coolant stops flowing out of the
radiator, move the container under the engine
block drain plug. Remove the plug and let the
coolant in the block to drain (see illustration).
6While the coolant is draining from the
engine block, check the condition of the
radiator hoses, heater hoses and clamps
(refer to Section 7 if necessary).
7Replace any damaged clamps or hoses
(see Chapter 3).
Flushing
8Once the system is completely drained,
flush the radiator with fresh water from agarden hose until water runs clear at the drain.
The flushing action of the water will remove
sediments from the radiator but will not
remove more serious rust and scale from the
engine and cooling tube surfaces.
9These deposits can be removed by using
proprietary chemical cleaners. It should be
stressed, however, that these should only
need to be used if the system has been
neglected. Follow the procedure outlined in
their manufacturer’s instructions. If the
radiator is severely corroded, damaged or
leaking, it should be removed (see Chapter 3)
and taken to a radiator repair workshop.10On 1988 and 1989 models remove the
overflow hose from the coolant recovery
reservoir. Drain the reservoir and flush it with
clean water, then reconnect the hose (see
Chapter 3).
Refilling
11Close and tighten the radiator drain. Refit
and tighten the engine block drain plugs.
12Make sure the heater temperature control
is in the maximum heat position.
13Slowly refill the expansion tank with a
mixture of antifreeze and water until the
coolant reaches the base of the filler neck.
14Leave the expansion tank pressure cap
off and run the engine in a well-ventilated area
until the thermostat opens (coolant will begin
flowing through the radiator and the upper
radiator hose will become hot). Race the
engine two or three times under no load.
15Turn the engine off and let it cool. Add
more coolant mixture to bring the level back
up to the base of the filler neck.
16Squeeze the upper radiator hose to expel
air, then add more coolant mixture if
necessary. Refit the expansion tank pressure
cap.
17Start the engine, allow it to reach normal
operating temperature and check for leaks.
Every 2 years 1•21
1
3261 Jaguar XJ6
30.4 The radiator drain fitting (arrowed)
located at the bottom of the radiator30.5 The block drain plug (arrowed) is
located on the right side of the block

6Refit the compression gauge in the spark
plug hole (see illustration).
7Crank the engine over at least seven
compression strokes and watch the gauge.
The compression should build up quickly in a
healthy engine. Low compression on the first
stroke, followed by gradually increasing
pressure on successive strokes, indicates
worn piston rings. A low compression reading
on the first stroke, which doesn’t build up
during successive strokes, indicates leaking
valves or a blown cylinder head gasket (a
cracked cylinder head could also be the
cause). Deposits on the undersides of the
valve heads can also cause low compression.
Record the highest gauge reading obtained.
8Repeat the procedure for the remaining
cylinders and compare the results to this
Chapter’s Specifications.
9Add some engine oil (about three squirts
from a plunger-type oil can) to each cylinder,
through the spark plug hole, and repeat the
test.
10If the compression increases after the oil
is added, the piston rings are definitely worn.
If the compression doesn’t increase
significantly, the leakage is occurring at the
valves or cylinder head gasket. Leakage past
the valves may be caused by burned valve
seats and/or faces or warped, cracked or bent
valves.
11If two adjacent cylinders have equally low
compression, there’s a strong possibility that
the cylinder head gasket between them is
blown. The appearance of coolant in the
combustion chambers or the crankcase
would verify this condition.
12If one cylinder is 20 percent lower than the
others, and the engine has a slightly rough
idle, a worn exhaust lobe on the camshaft
could be the cause.
13If the compression is unusually high, the
combustion chambers are probably coated
with carbon deposits. If that’s the case, the
cylinder head(s) should be removed and
decarbonised.
14If compression is way down or varies
greatly between cylinders, it would be a goodidea to have a leak-down test performed by
an automotive repair workshop. This test will
pinpoint exactly where the leakage is
occurring and how severe it is.
5 Engine removal-
methods and precautions
If you’ve decided that an engine must be
removed for overhaul or major repair work,
several preliminary steps should be taken.
Locating a suitable place to work is
extremely important. Adequate work space,
along with storage space for the vehicle, will
be needed. If a workshop or garage isn’t
available, at the very least a flat, level, clean
work surface made of concrete or asphalt is
required.
Cleaning the engine compartment and
engine before beginning the removal
procedure will help keep tools clean and
organised.
An engine hoist or A-frame will also be
necessary. Make sure the equipment is rated
in excess of the combined weight of the
engine and transmission. Safety is of primary
importance, considering the potential hazards
involved in lifting the engine out of the vehicle.
If the engine is being removed by a novice,
a helper should be available. Advice and aid
from someone more experienced would also
be helpful. There are many instances when
one person cannot simultaneously perform all
of the operations required when lifting the
engine out of the vehicle.
Plan the operation ahead of time. Arrange
for or obtain all of the tools and equipment
you’ll need prior to beginning the job. Some of
the equipment necessary to perform engine
removal and refitting safely and with relative
ease are (in addition to an engine hoist) a
heavy duty trolley jack, complete sets of
spanners and sockets as described in the
front of this manual, wooden blocks and
plenty of rags and cleaning solvent for
mopping up spilled oil, coolant and petrol. If
the hoist must be rented, make sure that you
arrange for it in advance and perform all of the
operations possible without it beforehand.
This will save you money and time.
Plan for the vehicle to be out of use for
quite a while. A machine workshop will be
required to perform some of the work which
the do-it-yourselfer can’t accomplish without
special equipment. These shops often have a
busy schedule, so it would be a good idea to
consult them before removing the engine in
order to accurately estimate the amount of
time required to rebuild or repair components
that may need work.
Always be extremely careful when removing
and refitting the engine. Serious injury can
result from careless actions. Plan ahead, take
your time and a job of this nature, although
major, can be accomplished successfully.
6 Engine- removal and refitting
3
Note:Read through the entire Section before
beginning this procedure. It is recommended
to remove the engine and transmission from
the top as a unit, then separate the engine
from the transmission on the workshop floor. If
the transmission is not being serviced, it is
possible to leave the transmission in the
vehicle and remove the engine from the top by
itself, by removing the crankshaft damper and
tilting up the front end of the engine for
clearance,but access to the upper
bellhousing bolts is only practical when the
rear transmission mount and driveshaft have
been removed and the transmission is angled
down with a trolley jack.
Removal
1Relieve the fuel system pressure (see
Chapter 4).
2Disconnect the battery negative cable.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
3Place protective covers on the wings and
cowl and remove the bonnet (see Chapter 11).
4Remove the battery and battery tray.
5Remove the air cleaner assembly (see
Chapter 4).
6Raise the vehicle and support it securely on
axle stands. Drain the cooling system and
engine oil and remove the drivebelts (see
Chapter 1).
7Clearly label, then disconnect all vacuum
lines, coolant and emissions hoses, wiring
harness connectors and earth straps.
Masking tape and/or a touch up paint
applicator work well for marking items (see
illustration). Take instant photos or sketch
the locations of components and brackets.
8Remove the cooling fan(s) and radiator (see
Chapter 3).
9Disconnect the heater hoses.
10Release the residual fuel pressure in the
tank by removing the petrol cap, then detach
the fuel lines connecting the engine to the
chassis (see Chapter 4). Plug or cap all open
fittings.
2B•4 Engine removal and overhaul procedures
4.6 A compression gauge with a threaded
fitting for the spark plug hole is preferred
over the type that requires hand pressure
to maintain the seal - be sure to block
open the throttle valve as far as possible
during the compression check!
6.7 Label both ends of each wire and hose
before disconnecting it
3261 Jaguar XJ6

3261 Jaguar XJ6
3
Chapter 3
Cooling, heating and air conditioning systems
General
Radiator cap pressure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 to 117.5 psi
Thermostat rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 to 207° F
Torque wrench settingsNm lbf ft
Coolant pipe to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Fan assembly-to-drive hub nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Fan clutch-to-fan blade bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Thermostat cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Thermostat housing-to-block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21
Water pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21 Air conditioning and heating system - check and maintenance . . . . 13
Air conditioning compressor - removal and refitting . . . . . . . . . . . . . 15
Air conditioning condenser - removal and refitting . . . . . . . . . . . . . . 16
Air conditioning evaporator and expansion valve - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning receiver/drier - removal and refitting . . . . . . . . . . . . 14
Antifreeze/coolant - general information . . . . . . . . . . . . . . . . . . . . . . 2
Coolant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Coolant temperature sender unit - check and renewal . . . . . . . . . . . .9
Cooling system check . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Cooling system draining, flushing and refilling . . . . . . . . See Chapter 1
Drivebelt check, adjustment and renewal . . . . . . . . . . . See Chapter 1
Engine cooling fans - check and renewal . . . . . . . . . . . . . . . . . . . . . 4Engine oil cooler - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Heater and air conditioning blower motors -circuit check
and component renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heater and air conditioning control assembly -
check, removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heater core - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator, expansion tank and coolant reservoir -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermostat - check and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Underbonnet hose check and renewal . . . . . . . . . . . . . . See Chapter 1
Water pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump and pipes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
1 General information
Engine cooling system
All vehicles covered by this manual employ a
pressurised engine cooling system with
thermostatically-controlled coolant circulation.
An impeller type water pump mounted on the
front of the block pumps coolant through the
engine. The coolant flows around each cylinder
and toward the rear of the engine. Cast-in
coolant passages direct coolant around the
intake and exhaust ports, near the spark plug
areas and in proximity to the exhaust valve
guides.A wax-pellet type thermostat is located in
the thermostat housing at the front of the
engine. During warm up, the closed
thermostat prevents coolant from circulating
through the radiator. When the engine
reaches normal operating temperature, the
thermostat opens and allows hot coolant to
travel through the radiator, where it is cooled
before returning to the engine.
The cooling system is sealed by a pressure-
type radiator cap. This raises the boiling point
of the coolant, and the higher boiling point of
the coolant increases the cooling efficiency
of the radiator. If the system pressure exceeds
the cap pressure-relief value, the excess
pressure in the system forces the spring-
loaded valve inside the cap off its seat and
allows the coolant to escape through the
overflow tube into a coolant reservoir. Whenthe system cools, the excess coolant is
automatically drawn from the reservoir back
into the radiator. This type of cooling system is
known as a closed design because coolant
that escapes past the pressure cap is saved
and reused.
The Jaguar cooling system on 1988 and
1989 models has both a manifold tank and a
coolant recovery tank. The manifold tank is the
highest point in the cooling system and is the
location of the “radiator” cap (the cap is not on
the radiator). The recovery tank down in the
passenger’s footwell collects heated coolant
as described above. Models from 1990 to
1994 do not have a coolant recovery tank, but
have an enlarged manifold tank. In all models,
the recovery tank has a sensor in it to detect a
low coolant level, and the instrument panel has
a warning light to that effect.

Heating system
The heating system consists of two blower
fans, one under the dash on the right and one
on the left, and a heater core located within
the heater/air conditioning assembly which is
under the dash and behind the console.
Hoses connect the heater core to the engine
cooling system. Heater function is controlled
by the heater/air conditioning control head on
the dashboard. Hot engine coolant is
circulated through the heater core. When the
heater mode is activated, a flap door opens to
expose the heater box to the passenger
compartment. A fan switch on the control
head activates the blower motor, which forces
air through the core, heating the air.
Air conditioning system
The air conditioning system consists of a
condenser mounted in front of the radiator, an
evaporator mounted in the heat/air
conditioning assembly behind the console and
under the centre of the dash, a compressor
mounted on the engine, a filter-drier which
contains a high pressure relief valve and the
plumbing connecting all of the above.
A blower fan forces the warmer air of the
passenger compartment through the
evaporator core (sort of a radiator-in-reverse),
transferring the heat from the air to the
refrigerant. The liquid refrigerant boils off into
low pressure vapour, taking the heat with it
when it leaves the evaporator. The
compressor keeps refrigerant circulating
through the system, pumping the warmed
coolant through the condenser where it is
cooled and then circulated back to the
evaporator.
2 Antifreeze/coolant-
general information
Warning: Do not allow antifreeze
to come in contact with your
skin or painted surfaces of the
vehicle. Rinse off spills immediately withplenty of water. Antifreeze is highly toxic if
ingested. Never leave antifreeze lying
around in an open container or in puddles
on the floor; children and pets are
attracted by it’s sweet smell and may drink
it. Check with local authorities about
disposing of used antifreeze. Many
communities have collection centres which
will see that antifreeze is disposed of
safely. Never dump used antifreeze on the
ground or into drains.
Note:Non-toxic antifreeze is now
manufactured and available at local car
accessory outlets, but even these types
should be disposed of properly.
The cooling system should be filled with a
water/ethylene-glycol based antifreeze
solution, which will prevent freezing down to
at least -20° F, or lower if local climate
requires it. It also provides protection against
corrosion and increases the coolant boiling
point.
The cooling system should be drained,
flushed and refilled every 24,000 miles or
every two years (see Chapter 1). The use of
antifreeze solutions for periods of longer than
two years is likely to cause damage and
encourage the formation of rust and scale in
the system. If your tap water is “hard”, i.e.
contains a lot of dissolved minerals, use
distilled water with the antifreeze.
Before adding antifreeze to the system,
check all hose connections, because
antifreeze tends to leak through very minute
openings. Engines do not normally consume
coolant. Therefore, if the level goes down, find
the cause and correct it.
The exact mixture of antifreeze-to-water
you should use depends on the relative
weather conditions. The mixture should
contain at least 50-percent antifreeze, but
should never contain more than 70-percent
antifreeze. Consult the mixture ratio chart on
the antifreeze container before adding
coolant. Hydrometers are available at most
car accessory outlets to test the ratio
of antifreeze to water (see illustration). Use
antifreeze which meets the vehicle
manufacturer’s specifications.
3 Thermostat-
check and renewal
2
Warning: Do not attempt to
remove the radiator cap, coolant
or thermostat until the engine
has cooled completely.
Check
1Before assuming the thermostat is
responsible for a cooling system problem,
check the coolant level (Chapter 1), drivebelt
tension (Chapter 1) and temperature gauge (or
light) operation.
2If the engine takes a long time to warm up
(as indicated by the temperature gauge or
heater operation), the thermostat is probably
stuck open. Renew the thermostat.
3If the engine runs hot, use your hand to
check the temperature of the lower radiator
hose.
Warning: Do this check with the
engine off. Do not get your
hands near the fan blades. If the
hose is not hot, but the engine
is, the thermostat is probably stuck in the
closed position, preventing the coolant
inside the engine from travelling through
the radiator. Renew the thermostat. Do not
drive the vehicle without a thermostat. The
computer may stay in open loop and
emissions and fuel economy will suffer.
4If the lower radiator hose is hot, it means
that the coolant is flowing and the thermostat
is open. Consult the Troubleshootingsection
at the front of this manual for further diagnosis.
Renewal
5Disconnect the battery negative cable.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
6Drain the coolant from the radiator (see
Chapter 1).
7Remove the bolts from the thermostat
cover (see illustration). If the cover doesn’t
3•2 Cooling, heating and air conditioning systems
3261 Jaguar XJ6 2.4 An inexpensive hydrometer can be
used to test the condition of your coolant
3.7 Remove the two bolts (small arrows)
holding the thermostat cover to the
housing (large arrow)

3Remove the screws holding the cruise-
control ECU in place (see illustrations), then
remove the four screws holding the ECU
mounting plate in place.
4Disconnect the vacuum lines and electrical
connectors at the blower housing, identifying
each connection with marked masking tape
for reassembly, or write down the colour
codes of the vacuum tubing. Remove the duct
tape connecting the blower housing to the
duct from the heater/air conditioning unit.
5Remove the two bolts holding the top of the
blower housing to the cowl (see illustration).
6Pull down and back on the housing until itsqueezes past the metal brace below it (see
illustration).It will take some force at first.
7To access the left blower motor, remove
the left-hand brace rod from the steering
column forward to the body(see illustration),
then repeat Steps 4 and 5 on the left blower
housing. The blower housing should now drop
straight down and out.
8If the blower motor does not operate,
disconnect the electrical connectors at the
blower motor and connect the black wire
terminal to chassis ground, and the purple
wire terminal to a fused source of battery
voltage. If the blower doesn’t operate, itshould be renewed. If it does operate, there is
a problem in the feed or earth circuit.
9If the motor is good, but doesn’t operate at
any speed, the problem could be in the
heater/air conditioning control assembly or
the heating/air conditioning computer.
Diagnosis either of these electronic com-
ponents is beyond the scope of the home
mechanic, and should be referred to your
Jaguar dealer or other qualified repair facility.
10If either blower motor must be renewed,
remove the five clips and one screw holding
the blower housing halves together (see
illustration).
3•8 Cooling, heating and air conditioning systems
10.2a The right blower housing (arrowed)
is located behind the glove box area
of the dash10.2b Apply heavy duct tape to the sharp
edge of this brace (dotted line) when
working behind the glove box area of the
dash - the metal is very sharp10.3a Remove the screw (A) holding the
wiring harness in place, then remove the
two lower cruise-control ECU screws (B) . . .
10.3b . . . then remove the upper ECU
screw (arrowed) and pull down the ECU,
then remove the ECU mounting plate10.5 Two bolts (arrow indicates the left
bolt) hold the top of the blower housing
to the cowl10.6 Pull down and out on the housing
until it clears the sheet metal brace
below it
3261 Jaguar XJ6 10.7 Remove this brace rod (small arrow)
for clearance to remove the left blower
motor housing (large arrow)
10.10 Remove the five clips (two shown
here with arrows) and one screw holding
the halves of the housing together

11Separate the housing halves and pull up
the plastic plate holding the motor and fan
(see illustration). The fan doesn’t come off
the motor, but loosen the clamp-bolt on the
motor’s mount bracket and slide the motor
and fan out for renewal (see illustration).
Note:Some 1988 models had problems with
cracking of the fan blades and noise from the
blowers. These blowers and fans have been
superseded with improved parts, available
from your Jaguar dealer.
12When either blower housing is separated,
you’ll find two relays mounted inside (see
illustration). These are the blower isolation
relay and blower relay. Before refitting the
blower housing in the car, refer to Chapter 12
for testing of these relays.
13Refitting is the reverse of removal. Check
for proper operation.11 Heater core-
removal and refitting
4
Warning: Later model vehicles
are equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering wheel or instrument panel.
The manufacturer recommends that, on
airbag-equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.1Disconnect the battery negative cable.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Drain the cooling system (see Chapter 1).
Disconnect the heater hoses where they enter
the bulkhead (see illustration). Note:Use
compressed air in one of the pipes to blow out
any remaining coolant and collect it. This will
prevent any spills on the carpeting when the
heater core is removed. Plug the pipes to
prevent any remaining coolant from spilling out.
3Refer to Chapter 11 for removal of the
under-dash panels on both the driver and
passenger sides, and removal of the glovebox.
Warning: When working around
the area behind the glove box,
watch out for a strip of sheet
Cooling, heating and air conditioning systems 3•9
3
3261 Jaguar XJ6 10.11a Separate the housing halves - the blower motor (arrowed)
is attached to a plastic plate sandwiched between the
two housing halves
10.11b Loosen the clamp bolt (arrowed) on the motor bracket and
then pull the motor and fan out as an assembly
10.12 Inside the blower case are the blower and isolation relays
(arrowed) - while the case is apart, test these relays for
proper operation11.2 Disconnect the heater hoses from the pipes at the bulkhead
(small arrows) - the large arrow indicates the evaporator case
retaining nut

metal bracing that has a very sharp edge
(see illustration 10.2b). Apply some heavy
duct tape to the edge of the brace before
beginning work in this area, or you could
injure your hands.
4On the passenger’s side, under the dash,
remove the screws holding the plastic cover
where the heater pipes enter the heater/air
conditioning housing (see illustration).
5With the cover off, there is access to
remove the four Allen bolts holding the two
pipes to the heater core (see illustration).
6Move to the right side and unbolt the
climate control computer and pull it down and
away from the heater/air conditioning housing
(see illustrations).
7Remove the four small screws and remove
the plastic plate over the heater core, right
behind where the climate control computer
had been (see illustration).
8Carefully slide the heater core out from the
right side of the heating/air conditioning
housing (see illustration). Note:Keep plenty
of towels or rags on the carpeting to catch any
coolant that may drip.
9Refitting is the reverse order of removal.
When refitting the heater core, make sure all
of the foam insulation strips are in place and
refit new O-rings where the heater pipes enter
the core (see illustration).
10Refill the cooling system, reconnect the
battery and run the engine. Check for leaks
and proper system operation.
12 Heater and air conditioning
control assembly- check,
removal and refitting
4
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering wheel or instrument panel.
The manufacturer recommends that, on
airbag-equipped models, the following
procedure should be left to a dealer service
department or other repair workshopbecause of the special tools and
techniques required to disable the airbag
system.
Removal and refitting
1Disconnect the battery negative cable.
Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Refer to Chapter 11 for removal of the
console heater control/radio assembly trim
bezel.
3Remove the mounting screws retaining the
heater/air conditioning control assembly to
the console (see illustrations). Pull the
assembly out, and disconnect the electrical
connectors.
3•10 Cooling, heating and air conditioning systems
11.4 Remove these screws (small arrows)
to remove the plastic plate over the heater
core pipes on the left side11.5 With the cover off, remove the Allen
bolts (arrows indicate three of the four) to
pull the coolant pipes out of the left side of
the heater core11.6a Remove three screws (one arrowed;
one at the top-back and one below) to take
out the climate-control computer on right
side of heater/air conditioning assembly
11.6b Pull away the climate control
computer (arrowed)11.7 Remove the four screws (arrowed)
and the heater core cover plate11.8 Pull the heater core out to the right
3261 Jaguar XJ6
11.9 Retain the original foam insulation on
the heater core or transfer to the new
core, and replace the two O-rings
(arrowed)
12.3a Remove these six screws (arrowed)
to release the control panel/radio
assembly from the console