Im nearing completion of a climate control unit refurbishment including a repaint, new foam seals, new expansion valve, etc for a Series 2 xj6.
I had the AC evaporator pressure and leak tested and all was fine.
The heater core had lots of green corrosion and failed testing with several small leaks.
The local radiator shop could not source the wide core material to build a new unit…so I went to the usual Jaguar sources.
The first heater core purchased was described as fitting a series 2…and required modifications for series 3.
This had me curious because other than some minor changes in component mounting (servo and vacuum actuators)…the climate control box is the same Delanair MK II unit in series 2 and series 3.
The first unit arrived with a minor downward bend in the pipes and some flaked paint…but otherwise ok.
It quickly became obvious that the new thinner heater core was not going to clear the fan resistor pack.
A phone call to the supplier was generally unproductive. The recommendation was to cut off the offending pipe and replace it with a rubber hose.
I don’t see this as a viable option since the required stub to attach the hose would still interfere with the fan resistor pack.
I checked a second vendor who seemed confident that their replacement would fit and advised I reference the picture on their web page as a good actual picture of the product.
The picture seemed to represent the necessary offset angle and bends on the offending pipe. The tech advised that they have sold numerous units and only had 1 returned. I was hopeful. So being considerably less money than the first replacement…I decided to go ahead and purchase.
The second replacement arrived today…and there is no way this is going to fit either.
It appears this is the same design as the first vendor…
Not only is the top pipe not angled correctly to clear the fan resistor pack, the pipes are set too close together in the end tank to allow the heater box end cap to fit.
As reference, I have heater boxes from series 2 and 3 cars and a later Delanair MK III box…and the supplied heater core is not a fit for any of them.
I am wondering what previous members have done to deal with these issues…or has there been a change in the parts supplied?