In the process of the intake manifold gasket replacement, the manual says remove the cowl vent screen, held on with retaining clips. Well the clips are out,screen slides left and right, wipers are off, but can not get the screen to come outThe issue seems to be it's hampered by the windshield, and won't come out far enough to remove itWhat tool is used to get it started?Has to be something simple, but seem to be missing it somehow

 

I recall it was just retained in a plastic channel clip that ran the whole width of the car. I started on one side and spread the plastic slightly, and then the cowl piece could be pulled out along this clip. One it starts, it is easy, getting it started at one side is the trick.

 

Sort of sounds like you were there, have not got it free yet. Decided that when a friend of mine shows up, will try taking the air struts loose at the top, tilt the hood back. Then tilt the piece up more before pulling to see if that gives me the needed space.

 

Tilt the cover to about 40 degrees and start at one end then 'tear' it out.

 

Looking at the part, it has cut out's to miss the hinges, so it can be lifted a little higher. The fly in the ointment is, the struts that hold the hood up, are in the way. Remembering my first experience with the British way of doing things with my Triumph motorcycle. Hard for me to think like a limey, blimey they have a weird way of doing things. Almost all to keep you away from fixing it yourself. Little things to trip you up, maybe you break something, that take's supposed take a week to get here, but that can become a month

 

The cover locates into a channel at the base of the screen with no mechanical fixing, the previous advice of 'tearing it out' is a good way of putting it.

​​Start from one side and pull it up over if this is the first time it's been off it will be well stuck but it will come off. It is not necessary to remove the strutts or bonnet to get it out as once freed off it is flexible enough to get past them.

My biggest problem was getting the windscreen wipers off!

Good luck with it.

 

Copy that, did not want to take the struts lose. But was wondering if that was, or could be, the old trick, that anybody in the know, knew already.glad that's not the answer

 

It's sort of scary the first time you "rip it out". But it does come out that way. A warm day helps, but is not required. The first time I did it I said to myself "this is not going to end well", but it did.

 

What manual are you using? I had to replace the hose that goes under the intake manifold and I couldn't find any information online to help me, so I just started removing parts. A manual would be great for the next time I have to do it.

 

Manual is on line download, a disk costs more, to burn, & send, not my choice of a shop manual at all. But a look at the sheer number of pages (6,384) explains it all!!!Factory Service Manual, 2004-2009,XJ, XK8,XJR DISEL SERVICE REPAIR FSMMANUAL. $14.95 Plus the price of a disk if you want one. Pretty much has it in there somewhere, whatever your looking for. Takes a bit of time, but you copy the needed pages, & don't worry about getting them dirty. As a new one is easily had.

 

Well finally got the intake manifold gasket replaced, taking my time, everything seemed to be going pretty well. then found the two E G R valve bolts on the bottom, were rounded off. so took the two horizontal bolts out instead to free it from the throttle body.From the looks of things, this job had been attempted B4, the gaskets were really kinda cheap looking, with no rubber around their openings, were not nearly as nice as the Lincoln ones. The two clamps on the E G R valve coolant hoses, were of a non reusable variety, as well as one manifold bolt did not have the non removable washer, that were on all the others. With the job completed, or so i thought, car runs very rough, throws codes PO300-PO308, with 0316 as well. Misfire on all 1 through 8 cylinders, with a 0316 topper, which says TOO many misfires, put 7, of the 8 new spark plugs in with no help, will do #8 some other day. Any ideas on what went wrong, and or what to do would be appreciated, as i have no idea what went to do The code reader suggest an open E G R valve, what that means, or how to close it, i have no clue.

 

Well today called the Jag dealer, & was told the solution to my issue was 8 new coils, reminds me why i stay away from them!!! Does the E G R come apart to clean??? Mine seems not to want to pull up & out after removing the top bolts, don't want to break it just fix it. Question is did i do something WRONG??? Hate to think about redoing the whole job,but if i buggered things up somehow,i have no other choice.Or could this be a two piece manifold, & another set of gaskets between the plastic, & metal, that i missed WTF???Want to get this fixed B4 it drives me totally over the edge

 

I had a similar problem on my '04 VDP. wouldn't pass smog in CA. Had to replace the intake manifold gasket, but it needed the unavailable gaskets between the two part manifold. Found a seller on ebay that probably had them made aftermarket. Not cheap, but they did the trick, and car ran as good as new afterward.

 

Did you torque the manifold bolts to spec?

 

Got a Jaguar Jones wrote;

I had a similar problem on my '04 VDP. wouldn't pass smog in CA. Had to replace the intake manifold gasket, but it needed the unavailable gaskets between the two part manifold. Found a seller on ebay that probably had them made aftermarket. Not cheap, but they did the trick, and car ran as good as new afterward.

What was his deal, price, where, & how to get them?

Thanks
__________

 

Does Ford Thunderbird, & Lincoln LS use same upper gaskets?

 

I think they probably are, but I ordered the ones specified for Jaguar 4.2. See Ebay item #261840970584

 

4526549, set of 8, for $99.98. with free shipping.= about $12.50 each, supposed to fit, & resolve the slight vac leak.sure hope so

 

After thought; Wonder if the plastic manifolds bad reputation for warping, & or cracking is mainly the result of people over tightening the bolts. Not knowing any better, thinking that they are not near tight enough. Not realising that plastic uses WAY less torque on bolts to get a good seal, than metal.

 

Well everything is back together, it runs great, still throws that dreaded PO101 code. Ordered a new P V C valve, as mine has some oil in it, not supposed to Car drives like a dream, but this is getting to be a nightmare!!!