I know it's been a while, but I didn't set aside enough days for the project and unfortunately it got delayed as a result, but alas I now have the S/C removed and I am able to look into the valley!



And upon closer inspection, I am greeted with this:



A lovely hole in the valley hose! At least I know that was the problem!

So, some more observations:-

1. Insulation, insulation, insulation
Removing the false bulkhead is an absolute necessity, however, the insulation will come off in a million pieces and will go absolutely everywhere!

2. EGR stands for "Excessive Grunting Required"
Removing the EGR is no small tasks, it may only be four bolts, but they are in the most awkward places imaginable with almost everything in the way and if your not careful you will round them (I didn't which is surprising considering what happened to the thermostat).

3. The fifth S/C retaining bolt
Very awkward place and needed some special spanners to loosen it, eventually had to lie on top of the engine and turn it with my hand, which wasn't too pleasant to say the least.

4. The hose itself.
I'm sure everyone who has done the job has asked this, but is that the only place it could have gone, flippin heck!

But despite the struggles I have got to the hose, now time to put it all back together... Fun times lie ahead

 

Thank you for your report and very nice, detailed pics.
It seems that this small hose in the front part is the preferred place where it fails.
Maybe higher temp or lesser resistance due to bigger diameter?
Your experience is also valuable for others who would consider doing the job themselves.
Good luck for the continuation

 

First time doing this for me it was a pita! You have to deal with several bolts blind.

What condition was your TB in?

If its coated with carbon deposits so will the matrix in your intercoolers.

Might want to consider cleaning out these now that you have easy access.

Dont forget the bolts that hold the TB are the same as the EGR bolts. Suggestion if the EGR bolts are in anyway rounded replace them.

 

I don't know if I believe this, but my service manager said they can and have replaced the valley hose without removing the SC. My car is going in monday for some stuff I can't do right now as I don't have my lift, and it's going to dump 16" of snow this week. I'll find out exactly how they can do it, but nobody else in the world can. I allready own swamp land, and it's up for sale.
Mark

 

Mark,

We'll be very curious to hear what you learn!

Cheers,

Don

 

I'll be interested aswell, maybe has something to do with getting your hand behind the thermostat and then going down, don't remember there being much clearance there, it sounds like it would still be difficult, but I'll be interested nonetheless

 

I'd love for a tech like Brutal to weigh in. I'm guessing if they can in fact do it, They've forged some unique and specific tools for the job.

Looking forward to hearing their explanation Mark. Fingers are crossed they are changing your O2 sensors and your problems are gone.

 

I'm on my way, need to have both questions answered, and be done with this saga. It would be interesting to hear if Butal has pulled off a valley hose swap with the SC in place.

 

You really do have to ask yourself how a sane and well qualified engineer could have specified such a demonstrably unsuitable component material for a pipe in this location. A stainless steel pipe to the rear of the engine and then a rubber hose connection to wherever it goes.That way if the hose went there would be little need for major dismantling. Some work, obviously, but not a huge amount.

 

As Maine is getting 18" of snow tuesday, all the dealers customers demanded their appointments moved up to today. Dealer still swapped out my O2 sensor, didn't charge me anything, but didn't have time to BS about the valley hose. The service department was jamming 10 tons of %&^ in a 1 pound bag. I didn't want to push my luck. But I WILL get an answer/confirmation, and post it. Still sounds to good to be true.

 

Well what a day!

It has been 6 weeks since I started the job and I can finally say that I have replaced the valley hose and put the car back together!

Was putting it back together more or less difficult? I would say equal difficulty and a high difficulty at that!

Main problems with putting it back together was getting insulation for the false bulkhead and getting all of the hoses in the right place (Que the "I think this hose went there")

It is definitely no small undertaking and there were many points when I thought about throwing in the towel and just taking it to a garage, but persistence has lead me to where I am now!

Golden advice for people undertaking the job, have a quality toolset, that poundland socket set just wont cut it!

 

I took pics to make sure I knew where each hose was supposed to connect along with routing.

 

Well done!
So definitely not an easy job!

Mark, did you finally get the clue about that possibly quicker approach by the dealer?

 

Greetings!

I am trying to help a friend with a 2006 XJR with a leak in the hose that crosses the valley near the front with a U bend. It can be seen in the lower area of the first photo and in the foreground of the second photo. The hose that is leaking crosses over the valley hose with the inverted U bend around the thermostat housing. Does anyone know what this hose is called and if possible the part number? Also, can it be replaced without removing the supercharger? Thanks! Art



And upon closer inspection, I am greeted with this:

 

Where else does it go?
Could this be it?

HOSE COOLANT INLET FOR SUPERCHARGER RADIATOR C2C18160

 

Never did get an answer to that question. I would say its pretty much impossible.

 

Looks like it to me. Goes from one of the two inlet/outlets of each charge cooler, forget which, down to the side of the radiator. Where special clamp pliers to remove and replace the hose clamp is really required.

 

 

Both look like bad jobs. I agree with the stainless hoses. Shoulda been stock.

 

Planed obsolescent not worth fixing that,along with everything else.
Just trade it on another, while it's still working.