Page 1
V8 XJ Series/XK
DA TE
02/02
amended 05/02
303-48
SERVICE
Coolant Leakage –
Heater Hoses –
Repair Procedure
Remove and destroy Bulletin 303-48, dated 02/02.
Replace with this Bulletin.
Revisions are marked with a bar and in bold text.
ISSUE:
On some 1997-99 MY XK and 1998-99 MY XJ vehicles within the above VIN ranges,
customers may complain of coolant leaking from the heater hoses.
ACTION:
In case of a customer complaint of coolant leakage on the above vehicles, replace both heater
hoses. Once the heater hoses have been replaced, carry out chemical/water flush to coolant
system as detailed in Technical Bulletin 303-11.
TECHNICAL BULLETIN
MODEL
1997-99 MY XK Range
1998-99 MY V8 XJ Series
VIN
010343-042635
812256-878274
To replace both coolant heater feed and return hoses, follow the workshop procedure.
REMOVAL PROCEDURE - ALL VEHICLES
1. Open luggage compartment and disconnect the battery. (See JTIS CD-ROM, section: 41401, SRO 86.15.01).
2. Open hood and fit fender protection covers.
3. Raise vehicle.
4. Drain radiator coolant.
SUPERCHARGED VEHICLES - ONLY
1. Place drip tray under vehicle.
2. Undo supercharger cooling radiator drain plug and allow coolant to drain.
3. Install and fully tighten supercharger coolant radiator drain plug.
4. Lower vehicle.
5. Remove supercharger assembly. (See JTIS CD-ROM, section: 303-12, SRO 18.50.15).
6. Continue with removal procedure.
NORMALLY ASPIRA TED VEHICLES - ONLY
1. Lower vehicle.
Date of issue 02/02 Amended 05/02 Bulletin Number 303-48 Page 1 of 5
Page 2
2. Remove engine cover set.
3. Remove air intake tube, air flow meter, and air cleaner cover assembly for access.
4. Remove throttle housing. (See JTIS CD-ROM, section: 303-12, SRO 19.70.04).
5. Disconnect vacuum pipe from center of induction elbow.
6. Remove throttle induction elbow support bracket upper securing bolts.
7. Disconnect vacuum pipe from front of throttle induction elbow.
8. Disconnect engine breather ‘T’ piece from throttle induction elbow.
9. Loosen but do not remove throttle induction elbow support bracket lower bolts.
10. Disconnect fuel injector electrical connectors.
11. Remove expansion tank breather support bracket securing nut.
12. Remove support bracket from expansion tank breather pipe.
13. Disconnect fuel feed hose quick fit connector using special tool JD182.
14. Disconnect fuel return hose quick fit connector using special tool JD203.
15. Remove intake manifold securing bolts.
16. Remove intake manifold from cylinder head.
17. Continue with removal procedure.
REMOVAL PROCEDURE - ALL VEHICLES (CONT .)
1. Remove clip from heater feed hose at heater pipe and disconnect hose.
2. Remove clip on heater feed hose at coolant outlet pipe and disconnect hose. (Illustration 1)
HEATER FEED HOSE CLIP
ILLUSTRATION 1
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Page 3
3. Remove clip from heater return hose at water pump housing and disconnect hose.
HEATER RETURN HOSE CLIP
ILLUSTRATION 2
4. Remove clip on heater return hose from three-way connector and disconnect hose.
(Illustration 2)
Caution: Immediately wash away any coolant spilled on the vehicle
bodywork.
5. Remove heater feed and return hoses.
INSTALLATION PROCEDURE - ALL VEHICLES
1. Install and fully seat new heater return hose to water pump housing and tighten retaining
clip.
2. Install and fully seat new heater return hose to three-way connector and tighten retaining
clip.
3. Install and fully seat new heater feed hose to heater pipe and tighten retaining clip.
4. Install and fully seat new heater feed hose to coolant outlet pipe and tighten retaining clip.
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Page 4
NORMALLY ASPIRA TED VEHICLES - ONLY
1. Clean inlet manifold faces.
2. Install and fully seat new seals to inlet manifold.
3. Install and tighten inlet manifold.
4. Reconnect fuel return and feed hoses.
5. Reposition and install support bracket to expansion tank breather pipe.
6. Install and fully tighten expansion tank breather support bracket securing nut.
7. Reconnect fuel injector electrical connectors.
8. Reconnect engine breather ‘T’ piece to throttle induction elbow.
9. Reconnect vacuum pipe to front of throttle induction elbow.
10. Install and tighten throttle induction elbow support bracket upper securing bolts.
11. Fully tighten throttle induction elbow support bracket lower securing bolts.
12. Reconnect vacuum pipe to center of induction elbow .
13. Install throttle housing. (See JTIS CD-ROM, section: 303-12, SRO 19.70.04).
14. Install air intake tube, air flow meter and air cleaner cover assembly.
15. Install engine cover set.
SUPERCHARGED VEHICLES - ONLY
1. Install Supercharger assembly. (See JTIS CD-ROM, section: 303-12, SRO 18.50.15).
INSTALLATION PROCEDURE - ALL VEHICLES (CONT .)
1. Follow battery reconnection procedure (See JTIS CD-ROM, section: 414-01, SRO
86.15.15).
2. Refill cooling system with XLC Extended Life coolant (specification: WSSM97B44-D)
Caution: Before the use of havoline XLC extended life coolant is
permitted on Jaguar vehicles (prior to VIN 042636 XK series vehicles and
VIN 878274 V8 XJ series vehicles), the chemical/ water flushing procedure
outlined in steps 1 “Heater Core Coolant Circulation Test” and step 2
“Chemical Flushing Procdure“ of technical bulletin 303-11 must be carried
out.
Note: If T echnical Bulletin 303-11 Insufficient Heat From Heater has been
carried out previously , coolant flush is not required. XLC Extended Life
Coolant (specification: WSS M97B44-D) may be recognized by its orange
color.
Page 4 of 5 Bulletin Number 303-48 Date of issue 02/02 Amended 05/02
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Parts Information:
DESCRIPTION PART NUMBER QTY
O-Ring - drain plug - XK JLM 20622 1
O-Ring - drain plug - XJ JLM 20628 1
Header tank label - XK-XJ-XJR XR8 13289 1
Supercharger duct seal - XJR AJ8 1446 2
Heater feed hose - XK-XJ NCA 3945CD 1
Heater feed hose - XJR NCC 3945AC 1
Heater return hose - XJR NNE 3946CA 1
Inlet manifold gaskets - XK-XJ AJ8 3356 8
Inlet manifold gaskets - XJR NCC 3018AB 8
Hose clip - XK-XJ-XJR JHC 501401 1
Radiator flushing Kit - XK-XJ-XJR JLM 20361 2
Throttle body gasket - XK-XJ-XJR NCA 3021BA 1
Outlet elbow seal - XJR NCC 7735BA 1
Water outlet seals - XK-XJ-XJR NCA 2268BA 1
Induction elbow to supercharger gasket XJR NCC 7754BA 1
Supercharger bypass valve o-ring - XJR KSC 137624 1
XLC Extended Life Coolant - 1 liter XK-XJ-XJR JLM 20972/2 1
XLC Extended Life Coolant - 5 liter XK-XJ-XJR JLM 20972/3 1
Warranty Information:
FAULT R.O. TIME
CODE NUMBER DESCRIPTION ALLOWANCE
DJ BC 01 26.31.38 Heater Feed and Return Hoses- Renew
XK Series 2.4 hrs.
XJ Series 2.1 hrs.
XJR Series 2.9 hrs.
DJ BC 01 26.91.03 Chemical/water flush procedure
XK Series 3.5 hrs.
XJ-XJR Series 3.2 hrs.
Date of issue 02/02 Amended 05/02 Bulletin Number 303-48 Page 5 of 5
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