Jaguar XJ (X350). Service manual — part 593
G234419t1 : VISUAL INSPECTION
1. Visually inspect for loss of coolant. 2. Carry out a system pressure test. See component tests in this
section.
•
Is the engine cooling system leaking?
-> Yes
Rectify the leak as indicated by the test result. TEST the system for normal operation.
-> No
Verify the customer complaint.
PINPOINT TEST G234419p2 : THE
ENGINE OVERHEATS
G234419t2 : CHECK COOLANT
1. Check the coolant level and condition.
•
Does the system contain sufficient coolant of the correct specification?
-> Yes
GO to Pinpoint Test G234419t3.
-> No
Top-up the system.
Cooling System Draining, Filling and Bleeding Check for coolant loss. GO to Pinpoint Test
G234419p1.
G234419t3 : CHECK THERMOSTAT
1. Check the thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 4.2L, Vehicles With: Supercharger (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) See component tests in this
section.
•
Is the thermostat OK?
-> Yes
<<303-14A>> Cooling fans, modules, circuits, sensors, etc. are tested in this section.
-> No
INSTALL a new thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 4.2L, Vehicles With: Supercharger (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) TEST the system for normal
operation.
PINPOINT TEST G234419p3 : THE
ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURE
G234419t4 : CHECK THERMOSTAT
1. Check the thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 4.2L, Vehicles With: Supercharger (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) See component tests in this
section.
•
Is the thermostat OK?
-> Yes
<<303-14A>> Cooling fans, modules, circuits, sensors, etc. are tested in this section.
-> No
INSTALL a new thermostat.
Thermostat - 3.0L (26.45.07)
Thermostat - 4.2L, Vehicles With: Supercharger (26.45.07)
Thermostat - 3.5L/4.2L, Vehicles Without: Supercharger (26.45.07) TEST the system for normal
operation.
Component Tests
Pressure Test
WARNING: Never remove the coolant expansion tank cap under any circumstances while
the engine is operating. Failure to follow these instructions may result in damage to the cooling
system or engine and/or personal injury. To avoid having scalding hot water or steam blow out of
the cooling system, use extreme care when removing the coolant expansion tank cap from a hot
cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant
expansion tank cap and turn it slowly until the pressure begins to release, step back while the
pressure is released from the system. When certain all the pressure has been released (still with a
cloth) turn and remove the coolant expansion tank cap. Failure to follow these instructions may
result in personal injury.
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1 . Switch the engine off.
2 . Open the hood and install protective fender covers.
3 . Carefully remove the coolant expansion tank cap from the coolant expansion tank to relieve
pressure in the cooling system. Add coolant to coolant expansion tank as necessary.
4 . Install the adapter fitting from Pressure Tester tightly between overflow/air purge nipple and
overflow/air purge hose at the coolant expansion tank. Reinstall the coolant expansion tank cap.
5 . Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to
the coolant expansion tank cap lower limit. Refer to Specification.
6 . Pressurize the cooling system. Observe the gauge reading for approximately two minutes.
Pressure should not drop during this time.
If system holds pressure, proceed to step 8.
If the pressure drops, check for leaks at the engine to heater core hoses, engine to radiator
hoses, bypass hose, water valve hose (if applicable), thermostat housing gasket, radiator and
heater core, etc. Also refer to engine system checks if a leak cannot be located in the cooling
system. Correct any leaks found and recheck the system.
7 . Release the system pressure by loosening the coolant expansion tank cap. Check the coolant level.
Replenish as necessary with the correct coolant solution.
8 . Check the radiator overflow hose for any obstructions which may block the flow of coolant either
to or from the coolant expansion tank.
9 . Conduct the coolant expansion tank pressure cap pressure test in this section.
Coolant Expansion Tank Pressure Cap Pressure Test
WARNING: Never remove the coolant expansion tank cap under any circumstances while
the engine is operating. Failure to follow these instructions may result in damage to the cooling
system or engine and/or personal injury. To avoid having scalding hot water or steam blow out of
the cooling system, use extreme care when removing the coolant expansion tank cap from a hot
cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant
expansion tank cap and turn it slowly until the pressure begins to release, step back while the
pressure is released from the system. When certain all the pressure has been released (still with a
cloth) turn and remove the coolant expansion tank cap. Failure to follow these instructions may
result in personal injury.
1 . Remove the expansion tank cap from the radiator coolant expansion tank.
2 . Use water to clean in area of rubber seal and vacuum relief valve. Immerse expansion tank cap in
water and install expansion tank cap pressure test adapter from Pressure Tester on the expansion
tank cap.
3 . NOTE:
If the plunger of the pump is depressed too quickly, an erroneous pressure reading will result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing, and note highest pressure reading obtained.
4 . Release pressure by turning the pressure relief screw counterclockwise. Then tighten the pressure
relief screw and repeat Step 5 at least twice to make sure the pressure test reading is repeatable and
within acceptable gauge reading limits of the expansion tank cap.
5 . If the pressure test gauge readings are not within acceptable gauge reading limits, install a new
expansion tank cap.
Thermostat Test - mechanical
Remove and inspect the thermostat, note its opening temperature and immerse it in water. Heat the
water until this temperature is reached. The thermostat should begin to open. If it does not begin to
open, install a new thermostat. Continue to heat the water until the thermostat fully opens, 5.8 mm
(0.2 in) or more off the valve seat. If it does not fully open, install a new thermostat.
Radiator Leak Test - removed from the vehicle
CAUTION: Do not leak test an aluminium radiator in the same water that is used to leak test
copper/brass radiators. Flux and caustic cleaners may be present in the test water which will
corrode aluminium.
Clean the radiator before leak testing to prevent contamination of the test tank. Leak test the
radiator in clean water with 138 kPa (20 psi) air pressure.
A separate clean test tank is recommended for aluminium radiators. If a separate tank is not
available for aluminium radiator testing, rinse the test tank each time before testing an aluminium
radiator.
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