Murder trying to fit the rubber boots onto the fans, the square rubber opening hates going onto the square /rectangle fan mouth and wriggles free and is largely inaccessible too.
The round metal pipes (4) that fit (2) either side of the bender box don't like going back in, they hating coming out too. Now they wont squeeze in but when they do they wobble and escape again when you try and attach the rubber shoe to their mouths. I assume the rubber mouth should clamp over the metal ring?? rubber seems too small now.....


Mission : Impossible

 

the rubber fits over the tubes / ports in the picture.
it fits tight to prevent air pressure loss.
If impossible to slide over the tubes, apply petroleum jelly inside the rubber to help it slide over the ports.

originally duct tape was wrapped over each connection to keep the rubber hoses in place and seal every vent and vacuum box.

 

START BY TAPING THE DUCT SECURELY TO THE FAN BODY FIRST!!

Then, with a right angle pick of the type Harbor Freight sells cheap, starting from the back where it's hardest to reach, starting both at once, start the duct on the pipe and work the pick around the metal pipe, seating the duct as you go.

Once started all around, the pliable ducting slips on easily and seats fully.

Being Right Handed. I found the Left side easiest to do, but the Right side has less junk in the way.
(';')

 

Beautifully outlined and spot-on, Elinor. Exactly what I ended up doing, but I cinched the boots down with a ty-rap instead of tape. Done mostly by feel.

Dave

 

Yes, Dave, quite a lot done by braille.
I neglected to mention, as it appeared Aden already has the fan mounted, after taping the duct SECURELY to the fan body, work the whole assembly up around the steering column and all the other stuff in the way and bolt down the fan.

Then work on getting the ducting on the matrix tubes.
(';')

 

Yeah I figured after the fan was mount that strapping the rectangle boot to the fan first would have been so much easier.
I always figured big hands were a plus but i'd love to have midget hands every time I try and squeeze anything into most parts of the Jag body.
I'm doing a lot of putting in part 5 then 4 then 3 then 2 then discovering part 1 need to go in before part 5.

 

As a mere woman with small hands, I often wonder how Guys with normal sized Guy hands could get into some places I have to Squeeeeze my hands into.
I have husband's bad example of this before my eyes quite a lot of the time.
Which is not to say I've never fallen into this trap myself, especially when I'm in a hurry.
Haste Makes Waste and all that.
(';')

 

Long double jointed needle nose pliers, assorted bits of bent/straight wire, double stick tape on the end of a tongue depressor, a piece of string with a weight (usually a nut of some sort), a headlamp (kind worn of your head in the woods) and swivel mirror, magnets taped to sticks, etc.

Tools of the trade, right?

 

it's like being a proctologist for a rock crusher most of the time,
i swear the team who designed this thing were all men with small hands and an envy vendetta against anyone with larger hands.
duct tape cannot be lowered into gaps and pull into place either, it instead adhere to your hands and removes layers of hair.
best done in right order.

 

I opted to 'core' the junction with some extra pipe just a few inches to make sure the gap is bridged and then sealed the outside with duct tape which is so not easy once the fans are installed etc.
Picture below (second) shows the remaining rubber boots ... feel like there is a big rubber T junction for the dash board vents absent. One is for the top of the heater unit and the other for the dash side vents. Something missing in the middle however,


springy pipe tube cheat option 1#

two sets of these left/right but something missing

 

The boots above are for the demisters and side vents.
Left curved one goes to the side dash vents, one on each side, and they are side specific.
The vent itself merely slips INTO the boot. OEM has a couple clips for the purpose of keeping the duct in place, but I found those clips only make it harder to get the two together. Again, as with the flexible ducting from fans to matrix, it's a bit fiddly, but once the the vent is well started, it will slip into the duct with no problem.

Below is an illustration of the entire cabin climate control arrangement:


And a drawing of the demister box:

(';')

 

Yeah, so as I thought i have the smaller vent links but am missing the larger demitser ones that they link to. Might have to get innovative there as I am certain I never had those parts in this car.