• Advertisement
Xclusively Jaguar
SNG Barratt
David Marks Garages
Make a donation to XJ40.com

XJ40 Turbodiesel

panarabica
Posts: 140
Joined: Sun Apr 19, 2015 7:00 pm

Re: XJ40 Turbodiesel

Postby panarabica » Wed Jun 24, 2020 12:32 pm

A very cool project that you are executing (attempting would suggest lack of skill) here. Please keep on posting pics of the conversion and the steps, it looks like this is going to be a great story. The 400BHP with a 335 engine will require some serious modifcations, right? I had a 2014 335 that I brought to 350 ish with Chip tuning. Amazing engine and gearbox that was able to handle the power.

I am watching and looking forward to your updates! Any chance of brining this on to Youtube? I am sure you will be able to reach a even bigger audience
- Jaguar DD6 MY'93
- Mercedes S500 Lorinser MY'99
- VW Phaeton MY'15
- Mercedes S300 MY '67
- Mercedes SL280 MY`94
- Mercedes C220 MY'15

naki_k
Super Moderator
Posts: 28846
Joined: Sun Feb 21, 2010 9:25 pm
Location: Kirton, nr Boston, Lincolnshire

Re: XJ40 Turbodiesel

Postby naki_k » Fri Jun 26, 2020 12:23 am

This is one of the few active build threads on here currently. It’s good to see someone really getting stuck into a protect and making fast progress.
These things normally take years to do.
88 3.6 XJ6 PDH/CEM
90 Range Rover Vogue SE 3.9 V8 LPG
91 4.0 XJ6 Manual
92 4.0 XJR Manual
92 4.0 XJR
93 3.2s - 4.0 Manual conv
93 4.0 Sovereign
93 6.0 XJ81 DD6 x2
93 6.0 XJ81 XJ12
94 4.0 XJR
94 4.0 Daimler
96 4.0 X306 XJR
96 4.0 X300 D6
97 4.0 X300 Sport Manual
2000 LR Discovery ES TD5 A
Breaking 40/ 300

BiTurbo228
Posts: 77
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Jun 26, 2020 2:17 pm

Haha thanks @panarabica :) definitely attempting, but with high confidence ;) will definitely keep the thread going til it's finished. I also plan to do a bit of a financial write-up afterwards as well. I should be able to split out the cost of the basic conversion, and then the cost as I've done it (which will be higher thanks to the significant scope creep and other modifications).

I was surprised by the 400ish bhp figure quoted by the guy I bought the turbo from, but looking at his spec it seemed believable. The difference from the 330d engine is mostly in the turbo which is quite aggressively hybridised. Most 330d hybrids seem to take things to around the 350bhp mark that you got out of the standard 335d twin-turbo setup. There's upgrades needed to things like intercoolers, but seeing as the 330d intercooler doesn't fit the Jag you have to get a different one anyway :)

I hadn't thought about youtube before. I've got some basic recording equipment (GoPro and a Zoom H1). Used it to record some driving videos way back when, but never anything bloggy. The editing for those took forever! Props to anyone who does it. Very time consuming. Will see what I can do about a bit of a walkaround video once it's running though, and some driving footage as well :)

@naki Yeah I'm a bit surprised by my progress tbh. I think I'm in quite a lucky situation with lockdown as everything I need is pretty much on-site so I don't have to negotiate access to a lockup or something. Working for the NHS my job's quite secure so I don't need to worry so much about spending either (if anything, it's good for the economy), but it's a behind the scenes one so I've been working from home for the whole thing. Amazing how much more you can get done with 2 hours of commuting reclaimed each day. The lack of commuting also means I can put some of the regular upkeep on the other cars on hold for a bit to make better progress on the Jag :)

Bit of a golden opportunity for me to get some stuff done.
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

naki_k
Super Moderator
Posts: 28846
Joined: Sun Feb 21, 2010 9:25 pm
Location: Kirton, nr Boston, Lincolnshire

Re: XJ40 Turbodiesel

Postby naki_k » Fri Jun 26, 2020 7:44 pm

Yes indeed. There’s definitely some benefits to the current situation for some people. Always look at the positives.
88 3.6 XJ6 PDH/CEM
90 Range Rover Vogue SE 3.9 V8 LPG
91 4.0 XJ6 Manual
92 4.0 XJR Manual
92 4.0 XJR
93 3.2s - 4.0 Manual conv
93 4.0 Sovereign
93 6.0 XJ81 DD6 x2
93 6.0 XJ81 XJ12
94 4.0 XJR
94 4.0 Daimler
96 4.0 X306 XJR
96 4.0 X300 D6
97 4.0 X300 Sport Manual
2000 LR Discovery ES TD5 A
Breaking 40/ 300

BiTurbo228
Posts: 77
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Mon Jun 29, 2020 3:06 pm

I think you need to develop a doggedly positive attitude in general when you're working on rusty old cars ;)

Next steps are around sorting the bulkhead area rust. There's some crustyness peeking out from the seam running along the top panel:

116.jpg


Turns out the spot-weld guy was definitely keen to make an impression as there's a billion of them. Makes a nice change from earlier British cars where the relationship with the construction workforce was diabolical, but it does make removing the panel a bit of a task.

117.jpg


In doing so I've made a rather interesting discovery. These cars like to rust at the bottom corner of the windscreen, seemingly from the inside out. Turns out, there's a little closed box section sitting just beneath that corner which is filled with this weird silicone gel foam.

118.jpg

119.jpg


There's then a dividing panel between the two which is sealed to the upper and lower panels, isolating the little box section bit off (except for a grommet into the engine bay). When I took the grommet out of both sides, water poured out despite the rest of the car being dry.

120.jpg
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 77
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Mon Jun 29, 2020 3:11 pm

Someone on Retro Rides mentioned that a fair few moderns have something like this as well and it's to stop NVH echoing up the a-pillar, but in all honesty it's nothing but a rust trap on these cars. I'm sure people would happily sacrifice a bit of NVH for stopping their car rusting out at the corner of the screen like so:

121.jpg


That also lets water capillary-action all the way along the seam on the bulkhead panel, rusting behind it.

122.jpg


Luckily, I reckon you can fix the problem by drilling a drain hole right here:

123.jpg


You'll have to drill a hole through the main bulkhead panel just to the right of the two vertical spot welds that hold the little blocking panel in place (to the left on the opposite side). Then, using that hole as a guide, drill at a diagonal through the bottom corner of the blocking panel. You can then excavate the foam through the grommet, and any water that gets in there now has a route to get out through the new drain hole. It's not a cure if the process has already started, but if you have a good car then it would prevent it from happening in the future.
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

katar83
Posts: 2889
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 Turbodiesel

Postby katar83 » Mon Jun 29, 2020 5:18 pm

I had my old x300 baking in the sun for 2 months without rain, last year, and when opened up that corner section it was packed with water and that damn foamy crap that Jaguar packed in there. Whoever thought it was a good idea to do it should be rounded up against a wall... :evil:
Its an old design going back to 60s, all Jaguars to at least x308 has this section, and it would all be fine if it wasn't for this water absorbing stuff, once water gets inside there, there is simply no way to get rid of it unless you cut it all out and remove, and it of course rots from the inside in all direction. To make it even worse on my XJS all drains in that section were of course factory plugged by an overzealous factory worker that applied seam sealer everywhere... :evil:
Since you have the whole thing open up at the moment, you can get creative with drains but keep all sections open so they can always drain out.
1996, 3.2 SWB X300 - Finally a rust free daily driver :)
1997, 4.0 LWB X300 - Unlucky car.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, October 2015. Gone!
1994, 3.2S XJ40 - Long gone.

BiTurbo228
Posts: 77
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Jun 30, 2020 12:26 pm

Yeah it's a bloody awful idea from a rust prevention perspective. Wish I'd known about it when I got the car as I'd have pulled it all out straight away. Might have saved the screen corner.

Yeah I plan on sorting a drain hole in the little plate so it'll at least drain when I corner, and allow a bit of air circulation to dry out the rest. I'll need to thoroughly de-rust it as well. Cutting out bits of beneath the screen where it's properly rotten, and using the trusty Aldi-special media blaster to get the rest of the crustiness out. I've put up a marquee around the car now so it should be dry-ish for me to take the screen out. Had 'HEAVY DUTY' written on the advert, but it's just as flimsy as every other marquee I've ever come across so fingers crossed it stays up for the duration!

I think I'll go for a bit of a hunt for hidden foam-filled box-sections on my other cars. There's none on my Spitfire as that's a rattly old thing anyway, but there might be on the X/9, 75 and BX. Given their reputations for rust I tihnk some preventative work would be quite useful. Oh, and the MGF is starting to bubble at the bottom of the screen. I bet that has some too!
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

ChrisW
Posts: 1627
Joined: Sat Apr 14, 2012 6:05 pm
Location: Whatlington, East Sussex

Re: XJ40 Turbodiesel

Postby ChrisW » Tue Jun 30, 2020 4:33 pm

Really useful to see the bulkhead structure so well exposed. Thanks for those pics. I have issues on both of mine in that area around the scuttle panel under the front screen. I see you havent removed the wings yet. On mine the additional moisture traps just forward of the scuttle panel under the wing tops have done some additional rotting out. I wont be going to the same lengths as you to make good (not yet anyway) but at least I can see where I may be able to slow down the inevitable rot. I wonder if a lot of the rotten footwells you see are a result of corrosion in this area that works its way down over the years.
http://www.springballchange.co.uk
'93 XJR
'93 XJ12
'73 MGB Roadster
97 Range Rover Autobiography

BiTurbo228
Posts: 77
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Thu Jul 02, 2020 3:01 pm

No worries :) I reckon you're right about the rotten footwells. If it gets through the underside or back of that little closed box then there looks to be foam sound deadening behind it (judging by what comes out when I was a bit too zealous with the spot weld drill). From experience if that gets wet it pretty much stays wet so would rust out the floors if there are any little nicks in the paint or seam sealing.

As for progress I've managed to get the front screen out. As it was cracked anyway I thought I'd have a go at getting it out with the little knife tool I had. Pretty hard work, and very easy to nick the paint around the screen so would have to be very careful on a car I wasn't painting afterwards. Still, it works!

124.jpg


Wings are coming off soon so I'll see how far it's crept along under them!
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD