XJ XJ8 / XJR ( X308 ) 1997 - 2003

Valley hoses reassembly, a little stuck

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Old 05-04-2019, 08:56 AM
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Default Valley hoses reassembly, a little stuck




Putting the XJR back together after replacing the valley hoses,
I can't remember where the vacuum tee goes after the elbow?

Also, what's the best way to get the hoses for the charge cooler tanks back on?
I've removed the bypass valve bolts but I can't seem to get enough clearance to pull it off,
Unless I was supposed to remove it before installing the elbow?
(I just pulled the whole thing off and left the hoses attached to the tank when I removed it)
 
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Old 05-04-2019, 09:18 PM
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First it would help greatly if you could provide your year and model Jag, its kind of a big deal... ...vacuum lines are routed differently between design changes.
There are 2 ways to put the intercooler lines on...one (not highly recommended, its been my method), you shoe horn it on while installing the intake elbow. You have to loosen everything up and well, shoe horn it. The other is to lift the intercoolers.

For example, this if for the 97-98 model years....
 
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Old 05-04-2019, 10:19 PM
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I first installed the charge coolers and the supercharger (pic). Then, I attached the bypass valve to the elbow, put the two short hoses onto the bypass valve ports and clamped them at the bottom with the two top clamps on the hoses placed as far down as possible. You can then insert the complete elbow by forcing a bit the two hoses up onto the charge cooler ports, insert the gasket and the bolts to the supercharger, tighten and finally move the top clamps of the two short hoses up into position.


 
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Old 05-04-2019, 11:15 PM
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Originally Posted by Highhorse
First it would help greatly if you could provide your year and model Jag, its kind of a big deal... ...vacuum lines are routed differently between design changes.
There are 2 ways to put the intercooler lines on...one (not highly recommended, its been my method), you shoe horn it on while installing the intake elbow. You have to loosen everything up and well, shoe horn it. The other is to lift the intercoolers.

For example, this if for the 97-98 model years....
It's a 97 so that diagram is perfect, I was wondering where the 90 degree elbow came from lol.

I've got the bypass valve off so I might try and struggle to get it on with the elbow in place (so I don't break the breather hose again) but looks like I'll be pulling the elbow off again,
The first thing I tried was with the hoses still attached to the intercoolers, but just managed to get it all really stuck, didn't think to put the hoses on to the elbow first.
 

Last edited by owas; 05-04-2019 at 11:19 PM.
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Old 05-05-2019, 02:46 AM
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Pulled off the elbow, fitted the hoses and got it squeezed on, now I can't for the life of me get it to line up

Pulling up on the hoses as much as I can, it's lined up with the bracket holes

I hate this job.
 
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Old 05-05-2019, 08:21 AM
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Its tough, if those spring clamps had been made narrower or the down connectors shorter, the process would probably be easier. I use a cordless 12v hex head drill with an angle head driver, w/multiple extensions and swivel (bendy to the Euros). This gives me the ability to just bump the trigger to get the screws started as I'm able to use my other hand to align it. The hardest thing for me is the gasket. Nothing is more frustrating than to get the screw started after a good fight, only to see the gasket partially down in the valley.

You may say this is not one of Jaguars better designs, but that's because the motor is put together outside the car, which gives you better angle and room for this.
 
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Old 05-05-2019, 08:42 AM
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I managed to get it in after a good 2 hours of struggling!

I also managed to snap the bleed hose to the tank, snap the bolt holding the supercharger outlet cover thing so I need to wait for a helicoil kit and it seems to be an absolute PITA getting the heater hose to the bottom of the thermostat housing, weirdly my other XJR has a short connecting peice between the thermostat housing and the heater hose.

I should really stick to working on 30 year old land rovers lol.
 
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Old 05-05-2019, 09:03 AM
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That thermostat hose is a big PITA!! I found using a bit of dish soap, it was an easier application.
 
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Old 05-05-2019, 09:50 AM
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Originally Posted by Highhorse
That thermostat hose is a big PITA!! I found using a bit of dish soap, it was an easier application.
I gave up for the day, I'll deal with the hose when I don't feel like setting the car on fire
 
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