I am getting ready to do my annual maintenance and think I will tackle the valley hoses. I replaced the octopus hoes last year but still get an occasional whiff of coolant ( but no significant coolant loss ). I have searched the forum and seem to find references for parts only for 4.0L cars. I have to order parts from thousands of KM away so I want to get it right the first time

Here is what I THINK I need:

valley hoses (1 x NCA3945CD Heater Fees and 1 x NNE3946CA Heater Return ) are these the correct numbers for a 2004 ?
intake manifold gaskets - two upper - AJ82528 or do I need the lower gaskets AJ89062 ?

Will I need any throttle body gaskets ?

Is there anything else I should replace while I have the intake manifold off ?

Thanks for any and all input

 

Off the top of my head:

Fuel line disconnect tool

Both plastic intake manifold end gaskets (good time to replace)

You may or may not need any of the EGR steel gaskets (I did not)

There are a number of short coolant hoses around the throttle body, good time to replace them. Count 4.

Maybe the T plastic connector with the octopus hose, driver side

Vacuum line to the fuel pressure sensor. New does not hurt.

Be prepared to have to clean the inside of the intake manifold. pretty greasy in there.

Be prepared to want to clean some EGR vomit in the throttle elbow. Carb cleaner, steel brush?

Be prepared to want to refinish the steel end plate to the plastic manifold. Might be a good time to primer/paint it.

Be ready to deal with the brake booster hard plastic line and the brass connector. Check part#C2S15816 for the o-ring and plastic collar. It is not listed for an XK8, but it is apparently the right part anyway.

All the lines to the throttle body will have to be removed, so be ready for cracked Norma connectors.

Probably an excellent time to replace that thermostat tower. Maybe even consider doing the brushes in that dreaded heater pump as there will be a ton more access with the intake completely off.

See if you can do a smoke test to locate all air leaks. Might be a great time to address all of those as everything intake related will be off.

This is not a terribly fun job. You get to open a lot of stuff, and realize how many areas could use some attention. Having all the parts on hand would be a great jump start on things. OTOH, you can go for the kill, and replace those 2 hoses and be done.

Best of luck, keep us posted.

 

A lot of excellent advice there.

 

I plan to do this also. It would be good to have a list of the associated parts for both the 4.0 and 4.2 in the sticky's.

 

I concur, great info and details for STICKY

 

 

Wow! Amazing job on the valley cleanup. Now I have Valley Envy!

 

Thanks all

 

I agree. Need to do this soon and figuring out all the pieces I need is tricky.

 

JBD714

WOW. Now that’s an amazingly detailed Engine Bay! Pics are fantastic!