Date: Tue, 04 Nov 1997 21:41:54 -0800 From: "Victor R. Breen" Blower Fan Installation and Modification for XJ6 Series 1 71: The overall idea is to replace the two old one speed motors with new two speed motors. I also wanted to get rid of the resistor, (thus 2 speed motors), and use new Bosch relays and get rid of the Lucas. 1. Removed both Fans keeping track of which motor, housing and impeller went on which side. Both fans had seized bearings. 2. There was 2 cracked wires which appeared to have shorted close to the battery by the firewall. This is why the window washer pump, and high speed setting on the fans did not work. My guess is as the motors get into trouble, they tend to burn out wires, relays and probably the resistor. 3. Took motors into S&P Auto Electric on Powell close to Ross Island Bridge in Portland OR. . They said motors fried, and had replacement Everco M868 motors (Everco Industries St. Louis MO 63133), 2 speed reversible which are close to original size. Took mount off of old motors, and filed down inside edges to fit new motors. Had to re drill hole in fan to make it fit the new motor shafts. This made the hole round in the fan, so to keep the shaft from spinning inside the fan, I fiberglassed a spacer with a 1/4 inch whole and a set screw on top of the fan. I actually glued the spacer on while the fan was on the old motor, and than removed the fan prior to the fiberglass hardening and than drilled the new hole after the whole thing had cured. This kept the alignment pretty good. Used another 1/4 inch spacer with set screw underneath fan to maintain proper anatomical distance from motor etc. 4. Took out resistor mounted on firewall, as motors have two speeds and resistor not needed. 5. Wired 2 Bosch relays instead of Lucas.. Used one relay for high speed and the other for low speed. I first found the 2 leads going into the two existing relays from the Fan switch inside the car. In my case the high was burned out and I had to track it backwards and found the cracked wires behind the battery box. Test the leads to make sure you have high and low switching power. (Spouse inside the car flipping the switch is a help). 6. Wired motors as per directions on motor. Note that directions enclosed in the box were different from those printed on the motor which were correct. The original Jaguar switch has low fan lead hot when the switch is on low, and has both low and high lead hot when the switch is on high. S&P said this was OK with the new motors, and on testing, it didn't seem to matter. 7. Unsure of what the two Lucas relays on the firewall were doing other than the fans (probably nothing), but took a new power source and put a 30 amp fuse in it to power the motors through the relays. I grounded both motors, and both relays to the firewall. 8. The only circuitry that worked in the original wiring that does not now is the connection which puts the fan on low whenever the air conditioning is turned on. I could still do this, but don't see a compelling reason to do so.