Jaguar 2000-06

Removal & Installation

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XJR And XJ8 2001-03



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Move the front seats to fully rearward position.
  8.  
  9. Place steering wheel in straight ahead position.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Selector lever finish panel
     
    Center console veneer panel
     
    Radio
     
    Center console
     
    Center console A/C duct
     
    Driver air bag
     
    Steering column covers
     
    Wiper switch
     
    Warning speaker
     
    Glovebox
     
    A pillar trim pads
     
    Drive storage bin
     
    Center console and footwell electrical connectors
     
    Steering column electrical connectors
     
    Fascia mounting bracket
     
    Instrument panel end trim pads
     
    A/C unit fascia plate
     
    A/C unit to driveshaft tunnel bolts
     
    Electrical connectors underneath and behind instrument panel
     
    Instrument panel fascia panel retaining bolts
     
    Instrument panel fascia panel, with assistance
     
    Key transponder module
     
    Light switch module
     
    Control processor behind glove box opening
     
    Instrument panel veneer
     
    Trunk release switch
     
    Left side ducts
     
    Passenger side air bag
     
    Right side ducts
     
    Center vents
     
    Clock
     
    Defroster vents
     
    Air vents
     
    Air distribution box
     
    Aspirator motor assembly
     
    Harness retaining clips from fascia
     
    Fascia assembly
     
    A/C lines at evaporator
     
    Heater hoses
     
    Steering column mountings and lay column on floor
     
    Remaining blower ducts
     
    All connectors and lines to heater core
     
    Heater core
     

  12.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm). Tighten steering column lower bolts to 15 ft. lbs. (20 Nm). Upper bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Tighten all instrument panel retaining bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten air bag module to 62 inch lbs. (7 Nm).
  8.  
  9. Reconnect negative battery cable.
  10.  
  11. Refill the cooling system.
  12.  
  13. Recharge the air conditioning system.
  14.  

XJR And XJ8 2004



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Cowl vent screen
     
    Engine compartment brace
     
    Pollen filter and housing
     
    Engine compartment panel
     
    Heater hoses
     
    Cap the air conditioning ports
     
    Expansion valve manifold and tube assembly
     
    Instrument panel lower trim panel
     
    Steering column lower shroud
     
    Driver air bag module
     
    Clockspring
     
    Steering wheel rotation sensor
     
    Multi-function switch wiring harnesses
     
    Steering column electrical connector
     
    Steering column pinch bolt
     
    Steering column
     
    Steering column lock actuator connector
     
    Instrument panel temperature sensor hose
     
    Instrument panel console
     
    Ashtray
     
    Floor console register duct
     
    Transmission selector switch connector
     
    Lateral/yaw rate sensor connector
     
    Wiring harness ground connector
     
    Instrument panel retaining bracket
     
    Floor console duct retaining clip
     
    Front door opening weather strip
     
    Scuff plate trim panel
     
    Cowl side trim panel
     
    Footwell electrical connectors
     
    Climate control electrical connectors
     
    Instrument panel end panel
     
    Sunload sensor
     
    Defogger duct
     
    Instrument panel retaining bolts
     
    Instrument panel
     
    Floor console ducts
     
    Heater motor electrical connector
     
    Rear footwell vent ducts
     
    Heater and evaporator core housing
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Use new O-ring seals on expansion valve manifold and tube assembly. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Tighten air bag module to 62 inch lbs. (7 Nm).
  10.  
  11. Reconnect negative battery cable.
  12.  
  13. Refill the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

S-Type



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Heater hoses
     
    Throttle body on supercharged models
     
    Expansion valve manifold and tube and cap ports
     
    Heater core housing retaining nut.
     
    Instrument panel lower trim panel
     
    Steering column lower shroud
     
    Driver air bag module
     
    Clockspring
     
    Steering wheel rotation sensor
     
    Steering column connectors
     
    Steering column pinch bolt
     
    Steering column
     
    Floor console register duct
     
    Instrument panel multi-switch pack
     
    Ashtray
     
    Parking brake switch
     
    Floor console bracket
     
    Instrument panel support bracket connectors
     
    Instrument panel support bracket
     
    Hood release handle
     
    A pillar trim panels
     
    Instrument panel end caps
     
    Door weather stripping
     
    Defroster vent
     
    Passenger side trim panels
     
    Instrument panel connectors
     
    Instrument panel bolts and screws
     
    Instrument panel
     
    Rear footwell ducts
     
    PCM retaining bracket
     
    Heater core
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Use new O-ring seals on expansion valve manifold and tube assembly. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm). Tighten steering column bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Tighten air bag module to 62 inch lbs. (7 Nm).
  10.  
  11. Reconnect negative battery cable.
  12.  
  13. Refill the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Heater hoses
     
    Throttle body on supercharged models
     
    Expansion valve manifold and tube and cap ports
     
    Heater core housing retaining nut.
     
    Instrument panel lower trim panel
     
    Steering column lower shroud
     
    Driver air bag module
     
    Clockspring
     
    Steering wheel rotation sensor
     
    Steering column connectors
     
    Steering column pinch bolt
     
    Steering column
     
    Floor console register duct
     
    Instrument panel multi-switch pack
     
    Ashtray
     
    Parking brake switch
     
    Floor console bracket
     
    Instrument panel support bracket connectors
     
    Instrument panel support bracket
     
    Hood release handle
     
    A pillar trim panels
     
    Instrument panel end caps
     
    Door weather stripping
     
    Defroster vent
     
    Passenger side trim panels
     
    Instrument panel connectors
     
    Instrument panel bolts and screws
     
    Instrument panel
     
    Rear footwell ducts
     
    PCM retaining bracket
     
    Heater core
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Use new O-ring seals on expansion valve manifold and tube assembly. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Tighten steering column bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Tighten air bag module to 62 inch lbs. (7 Nm).
  12.  
  13. Reconnect negative battery cable.
  14.  
  15. Refill the cooling system.
  16.  
  17. Recharge the air conditioning system.
  18.  

X-Type



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Heater core drain tube
     
    Heater hoses
     
    Instrument panel console
     
    Climate control panel
     
    Navigation screen, if equipped
     
    Instrument cluster
     
    Passenger finish panel
     
    Passenger air vent
     
    Passenger air bag electrical connectors
     
    Passenger air bag
     
    Multi-function switch
     
    Steering column electrical connectors
     
    Steering column
     
    Headlight switch
     
    Transmission gear selector
     
    Reverse gear interlock
     
    Right side end panel trim
     
    Support panel
     
    Lower vent
     
    Instrument panel retaining screws
     
    Instrument panel
     
    Center register air duct
     
    Glove box mounting frame
     
    Remaining electrical connectors
     
    Instrument panel cross beam
     
    Heater core
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm). Tighten instrument panel cross beam bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm). Tighten steering column bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten air bag module to 80 inch lbs. (9 Nm).
  8.  
  9. Reconnect negative battery cable.
  10.  
  11. Refill the cooling system.
  12.  
  13. Recharge the air conditioning system.
  14.  

2004-06 XJ Series



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Cowl vent screen
     
    Engine compartment brace
     
    Pollen filter and housing
     
    Engine compartment panel
     
    Heater hoses
     
    Cap the air conditioning ports
     
    Expansion valve manifold and tube assembly
     
    Instrument panel lower trim panel
     
    Steering column lower shroud
     
    Driver air bag module
     
    Clockspring
     
    Steering wheel rotation sensor
     
    Multifunction switch wiring harnesses
     
    Steering column electrical connector
     
    Steering column pinch bolt
     
    Steering column
     
    Steering column lock actuator connector
     
    Instrument panel temperature sensor hose
     
    Instrument panel console
     
    Ashtray
     
    Floor console register duct
     
    Transmission selector switch connector
     
    Lateral/yaw rate sensor connector
     
    Wiring harness ground connector
     
    Instrument panel retaining bracket
     
    Floor console duct retaining clip
     
    Front door opening weather strip
     
    Scuff plate trim panel
     
    Cowl side trim panel
     
    Footwell electrical connectors
     
    Climate control electrical connectors
     
    Instrument panel end panel
     
    Sunload sensor
     
    Defogger duct
     
    Instrument panel retaining bolts
     
    Instrument panel
     
    Floor console ducts
     
    Heater motor electrical connector
     
    Rear footwell vent ducts
     
    Heater and evaporator core housing
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Use new O-ring seals on expansion valve manifold and tube assembly. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Tighten air bag module to 62 inch lbs. (7 Nm).
  10.  
  11. Reconnect negative battery cable.
  12.  
  13. Refill the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

2002-03 XJR And XJ8



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Move the front seats to fully rearward position.
  8.  
  9. Place steering wheel in straight ahead position.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Selector lever finish panel
     
    Center console veneer panel
     
    Radio
     
    Center console
     
    Center console A/C duct
     
    Driver air bag
     
    Steering column covers
     
    Wiper switch
     
    Warning speaker
     
    Glove box
     
    A pillar trim pads
     
    Drive storage bin
     
    Center console and footwell electrical connectors
     
    Steering column electrical connectors
     
    Fascia mounting bracket
     
    Instrument panel end trim pads
     
    A/C unit fascia plate
     
    A/C unit to driveshaft tunnel bolts
     
    Electrical connectors underneath and behind instrument panel
     
    Instrument panel fascia panel retaining bolts
     
    Instrument panel fascia panel, with assistance
     
    Key transponder module
     
    Light switch module
     
    Control processor behind glove box opening
     
    Instrument panel veneer
     
    Trunk release switch
     
    Left side ducts
     
    Passenger side air bag
     
    Right side ducts
     
    Center vents
     
    Clock
     
    Defroster vents
     
    Air vents
     
    Air distribution box
     
    Aspirator motor assembly
     
    Harness retaining clips from fascia
     
    Fascia assembly
     
    A/C lines at evaporator
     
    Heater hoses
     
    Steering column mountings and lay column on floor
     
    Remaining blower ducts
     
    All connectors and lines to heater core
     
    Heater core
     

  12.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Tighten steering column lower bolts to 15 ft. lbs. (20 Nm). Upper bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Tighten air bag module to 62 inch lbs. (7 Nm).
  10.  
  11. Reconnect negative battery cable.
  12.  
  13. Refill the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

2005 X-Type



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Heater core drain tube
     
    Heater hoses
     
    Instrument panel console
     
    Climate control panel
     
    Navigation screen, if equipped
     
    Instrument cluster
     
    Passenger finish panel
     
    Passenger air vent
     
    Passenger air bag electrical connectors
     
    Passenger air bag
     
    Multi-function switch
     
    Steering column electrical connectors
     
    Steering column
     
    Headlight switch
     
    Transmission gear selector
     
    Reverse gear interlock
     
    Right side end panel trim
     
    Support panel
     
    Lower vent
     
    Instrument panel retaining screws
     
    Instrument panel
     
    Center register air duct
     
    Glove box mounting frame
     
    Remaining electrical connectors
     
    Instrument panel cross beam
     
    Heater core
     

  8.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten heater core bolts to 62 inch lbs. (7 Nm).
  4.  
  5. Tighten instrument panel cross beam bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten all instrument panel retaining bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Tighten steering column bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Tighten air bag module to 80 inch lbs. (9 Nm).
  12.  
  13. Reconnect negative battery cable.
  14.  
  15. Refill the cooling system.
  16.  
  17. Recharge the air conditioning system.
  18.  

2006 X-Type




NOTE
If a leak is suspected, the heater core must be leak tested in the vehicle before removal.

  1. Drain the cooling system.
  2.  
  3. Disconnect the drain tube from the heater core.
  4.  
  5. Disconnect the heater hose from the heater core.
  6.  
  7. Disconnect the heater hose from the heater core.
  8.  
  9. Vehicles with automatic transaxle, remove the J-gate surround.
    NOTE
    To aid removal of the climate control assembly place the J-gate selector in the neutral position.

  10.  
  11. Vehicles with manual transaxle, detach the gear selector surround.
  12.  
  13. Disconnect the battery ground cable. For additional information, refer to 414-01.
  14.  
  15. Remove the ashtray retaining screws.
  16.  
  17. Remove the ashtray. Disconnect the electrical connectors.
  18.  
  19. Remove the climate control assembly mounting bracket upper retaining screws cover.
  20.  
  21. Remove the climate control assembly mounting bracket upper retaining screws.
  22.  
  23. Remove the climate control assembly mounting bracket lower retaining screws.
  24.  
  25. Disconnect the hazard lamp switch assembly electrical connectors.
  26.  
  27. Remove the hazard lamp switch assembly. Remove the retaining screws.
  28.  
  29. Disconnect the climate control assembly electrical connectors.
  30.  
  31. Remove the climate control assembly retaining screws.
  32.  
  33. Remove the retaining screws. Remove the climate control assembly.
  34.  
  35. Position the heater core air duct up.
    1. Remove the heater core air duct retaining screw.
    2.  
    3. Position the heater core air duct up.
    4.  

  36.  
  37. Remove the heater core air duct housing.
    1. Remove the heater core air duct housing retaining screws.
    2.  
    3. Remove the heater core air duct housing. Release the retaining tabs.
    4.  

  38.  
  39. Remove the heater core housing retaining clips.
  40.  
  41. Remove the heater core housing. Release the heater core housing retaining tabs.
  42.  
  43. Remove the seal.
  44.  
  45. Remove the heater core retaining screw.
  46.  
  47. Remove the heater core.
  48.  
  49. Installation is the reverse of the removal procedure.
    NOTE
    Make sure the climate control assembly is correctly located into the audio unit.

  50.  

 
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