I recently posted pictures of the air inlet door actuator part removed from the car https://www.jaguarforums.com/forum/x...an-tsb-156851/

My actuator was indeed faulty and I replaced it today with a used part I bought on eBay. I did the replacement as follows. I first made sure the air inlet door was in the open position. You can do this by reaching through the plastic grid above the motor blower housing behind glovebox. Also made sure the climate control setting was on fresh air before turning ignition off. I plugged the actuator into the wiring connector and cycled my fresh air button on control panel. Yes it worked! Next, I used a small screwdriver to pry open the actuator two halves as described in thread link above. Then I rotated the gear that is connected to the shaft and aligned the flat edge of the shaft with the two lines molded into the actuator housing body outside. This is the proper position to begin with outside fresh air as described in TSB on issues with fresh air inlet. I then snapped the two halves of actuator back together. The actuator was then reinstalled into correct position and the three screws installed. This is extremely hard to do in the tight area. What I did was use a torx15 bit to start the screws by hand. Then to tighten them I found a short stubby handle that accepts various bits and it was just short enough to fit. Ideally a torx version of an Allen wrench would work well in the tight spot. My smallest 1/4 socket wrench was too bulky to work. Anyway with deliberate small turns I was able to snug up the screws holding the actuator on. Reinstalled the glovebox and tried it out and the controls will now work to shift the air inlet from fresh to recycle.

 

Good job.. Great Info too..

 

Perfect!!
Rotated the gear that is connected to the shaft and aligned the flat edge of the shaft with the two lines molded into the actuator housing body outside.
Thank you. I would have never figured that out.