I'm in the process of replacing everything I can get my hands on as preventative maintenance since we recently purchased a '05 to replace our aging '97.

The problem is that there is one coolant hose that comes off from under the throttle body and ducks down under the intake manifold. It then hangs a "U" and connects into something (can't see it after it ducks under the intake manifold-I have a replacement hose so see that it turns around).

Anyway, I have a service manual that says it is a 30 step process to remove the intake manifold.

So a few questions:
1. What does that hose plug into?
2. Has anyone had one go out, and how many miles did you have if it did?
3. Any shortcuts (leaving everything hooked up but just lifting it enough to replace the hose?

I've already done all of the other hoses, the serpentine belt, the water pump, idler pulley, belt tensioner, thermostat housing tower, bled the brakes, etc. Next on my list is the transmission pan/fluid. So I do NOT want to spend half a day to replace this one hosel.

Suggestions?

Thanks,

 

Is your car an XJR, (i.e supercharged) ? If so, then a lot of dismantling is necessary to replace this hose. Most folks do it if it fails, not on a PPM basis due to the labour costs.

 

Nope. NA. The good news is that the process has nothing to do with the process to replace the rest of the hoses, so at least I'm not dismantling what I already finished. But not replacing that one hose is going to bug me......

Happy 4th to all of you in the US!

 

Gordon,
I had that hose go bad on my 07, it went fast too, no warning. I let the dealer replace it.

 

Not what I wanted to hear....

How old/how many miles when the the hose went? Was there any alarm on the dash as the temp went up or did you just happen to catch the gauge going up (just curious)?

 

Me too - that hose went out on me at about 75k miles, and I also let the dealer take care of it (didn't know of a good indy shop around here at the time).

 

Dang! I'm at 75,550 as of last night..... No idea how bad the dealer would rape me, my previously very reliable independent mechanic has been unresponsive, and I don't know enough about another independent mechanic to be comfortable with him. So I may very well be doing it myself anyway.

Oh well, if no-one else has pulled the intake manifold before and I end up doing it, I'll take pictures and document the process.

 

my 2005 has just had one (only one) coolant hose start to sweat at a joint, and it's only done 62k in a cool climate, so I applaud your intention to replace the hoses now. I reckon you can start to expect failures soon, and you know that if there's one hose you don't change at your leisure in the comfort of your well-lit garage,with all your tools to hand, that's the one that will fail at the most inconvenient moment.

 

Yeah. I'm going to do it. However, I'd sure like to wait until the fall and do it in 60-70F temps rather than 80s. Same thing with the transmission pan. That one I may wait until December..

 

Okay, folks, for a myriad of reasons, I have not been able to work on this until now. I've gotten most of the way to removing the intake manifold to replace that STUPID hose, but I'm stumped with fuel hose removal.

The JTIS pdf just says to remove it. I can't find anywhere in a 6,000 page document on how to remove it, not only the supply line coming into the fuel rail, but the hose that connects the two fuel rails. While the supply line has some sort of weird connector, the hose between the fuel rails is apparently just pressed on. It is a semi-rigid hose, but assuming it is at 40-60psi of fuel pressure, I'm surprised there wouldn't be any clamp or other mechanism to keep it from leaking or coming off.

How do I get it off (just twist and pull)? And can I re-use it (if so, how does it go back on securely?)?

Any replies are greatly appreciated. I was trying to get this done today, and after about 4 hours, I still haven't gotten to the intake manifold (some of those connectors you have to disconnect are a bear!.

Thans in advance,

Gordon.

 

So, as I've done a little more digging into the service manual, it appears that you don't pull the hose between the two rails off, but instead undo the four bolts that hold both rails down, and remove the rails along with the injectors (so both rails and the interconnecting hose all come off as one unit). If four bolts is all it takes, then that seems pretty easy. Once the rails and hose is off, then it should be easy to remove the intake manifold/throttle body assembly and get to that stupid hose. Am I missing something?

 

On my 03 xk8 (very similar) when i removed the intake, i left the fuel line and injector rail connected, just unbolted it and 'folded' it back after pulling each injector out of the manifold. You're on the right track.

 

Bear in mind JTIS is for trained techs who already know ordinary tech/mech things like how to uncouple hoses.

 

Fair point. This is much more than I really want to know at this point. I've done work on my MPFI boat engine, but the fuel line connect was different. Finally figured that part out. Big problem now is the routing of the knock sensors. Unlike all the other wiring, connectors, etc. that were secured/attached somewhere, these were not, but I didn't know it. So now I've got two loose connectors coming out from under the manifold. I know where they go to connect (I labeled them), but there are several places where they could potentially come out from under the manifold, and none seem to be where the wires will be long enough to get them back to the end point. Granted, I haven't tried it yet simply because you have to finagle the manifold back in around wiring harnesses, etc., so won't be easy (while trying not to mess up the intake manifold gaskets). So I'm hoping someone knows how they are routed out so they'll actually reach their destination and I don't get them in a place where they'll get damaged.

 

So, you're just looking for someone to possibly take a photo of where the knock sensor wiring exits each side of the manifold?

 

I went to the dealer and they happened to have an X350's top cover off so I was able to see where they come out from.

I've got the job done; I'll be doing a write up on it shortly.

Thanks everyone for the help.

 

write up will be appreciated!

I've found that each make has it's own 'way of doing things' mechanically. i.e. if you work on Audi's, you'll recognize the fasteners/attachments/way they do things over the years. You'll also see the evolution of the engineering as you work on different years which is cool - you can see where they made things better, and also where they saved money.

I've had other mechanics tell me the same.

I was a specialist in miatas only; I always had people asking me to work on other things but I always said no - not unless you were my family or I was dating you.
Every time I wrenched on something else it was a learning curve that cost a lot of time.

 

we're looking forward to the writeup!

 

I promise I'll do the write up just a soon as I find/fix this stupid vacuum leak and the job is 100% completed.....

 

Gordon,

My wife drives an 06 XJ8 (90K miles), and I just replaced the thermostat housing last weekend to cure a coolant leak. . .well, the leak actually appears to be from the very hose you mention above. I imagine the throttle body comes off again, and then the intake manifold (and both frame rails?) The hose is only about $10, but labor (if I wasn't doing this myself) would be well over $500 I imagine. Any photos or further advice?

Cheers,
Chris