Jaguar XK 2002 User Manual

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

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

Page 2 of 5 Bulletin Number 303-48 Date of issue 02/02 Amended 05/02