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XJ40 Turbodiesel

katar83
Posts: 2932
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 Turbodiesel

Postby katar83 » Thu Sep 03, 2020 3:19 pm

Its amazing how your inner arches look like, they are normally heavily rusted where the arch liner is secured to it, cant see any holes in there in your pics :)
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: 102
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Thu Sep 03, 2020 4:29 pm

@nestori Thanks dude :) it has come along rather nicely which is good. Hopefully there's some bits that other people will find useful, even if they're not thinking of swapping in an M57 :)

@katar83 Yeah this is an odd car really. Where it has started to go the rust is quite advanced, but there's some places that just don't seem to be rusty where they normally are. There's a couple of spots I've put a washer-sized patch around the plastic mounting bungs for the arch liners, but really nothing more than a bit of frilliness around the edge (they still held the bungs in place). It's not even as if it hasn't done significant mileage as it's 158k. Weird...

Not that I'm complaining of course!
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 102
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Sat Sep 05, 2020 11:02 pm

It's in!

180.jpg


No engine mounts yet, but it's in. After a bit of fettling got the turbo to fit as well. The actuator was fouling on the subframe, but you can get it adjusted to clear.

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Looks a little lost in the engine bay at the moment. It's definitely a much shorter engine, although about as wide with all the ancilliaries. The front axle centreline runs between cylinders 1 and 2, which bodes well for handling :)

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

Indiana_Jones
Posts: 108
Joined: Wed Sep 14, 2016 9:46 pm
Location: New Zealand

Re: XJ40 Turbodiesel

Postby Indiana_Jones » Sun Sep 06, 2020 10:53 am

Great stuff mate, keep it up. Looking forward to seeing the end product.
1987 3.6 Auto Sovereign 506111

BiTurbo228
Posts: 102
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Thu Sep 10, 2020 9:31 pm

Thanks man :) its steadily coming together!

After a fair bit of jiggery pokery I think I've got the engine in the right place now. Raised the front a little to make sure the sump was above the bottom of the subframe to make sure I don't rip the sump plug out if I hit a log. I've also found that the diff pinion flange is angled 6.4deg nose up, so I've got the gearbox flange to point 6.2-6.4deg nose down. Should keep them both in the same plane for UJ speed variation.

With that done I could start fashioning mounts :)

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185.jpg


The nearside mount wouldn't really fit in the stock location behind the turbo so I tried to do some research on ideal engine mount locations, but there really isn't a great deal of information out there for the layman so it's down to looking at standard practice. Seems like having the mounts a little above the crank centreline, and pointing in towards the engine. The sort of hydraulic mounts the BMW has tend to be a bit more vertical than most. So with that, I just put them where they fit best :)

The other side was much closer to the original mount location (for both cars).

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Now it's just lifting the engine up by another 5mm or so to take up any squish in the mounts, then making some brackets to attach to the engine :)
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

Walker
Snr Member
Posts: 305
Joined: Fri May 01, 2015 8:10 am
Location: Inverness

Re: XJ40 Turbodiesel

Postby Walker » Fri Sep 11, 2020 10:05 am

Just catching up on this, great work very well done. Delighted to see another bulkhead panel getting sorted, fond memories of doing mine but the work involved up to reaching that point is less than cheerful! I bet your hands looked like you had been boxing with gloves filled with broken glass also :roll:
Kingfisher Blue '40 1993 3.2S #690760 L399GYP

BiTurbo228
Posts: 102
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Sep 11, 2020 1:12 pm

Thanks man :)

Yep! Hands looked like I'd been crawling through barbed wire! Not a particularly pleasant job. Gloves would have helped, but I'm stubborn and like the dexterity you get without them.

Overall I'd say the Jag's one of the less sharp cars I've worked on though. The Bimmer that donated the engine has a lot more pointy spiky bits, unfinished casting flashes and things like that. I think there's something about having cars that were put together (at least in part) by hand which makes people design or fix stuff that makes working on them unpleasant. It's all very well having to repair bits of robots that get chafed installing parts, but being the guy who designed that one spiky thing all the line workers hate is probably a much more effective social pressure!

Could just be that I haven't done much work on the interior yet though... ;)
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

katar83
Posts: 2932
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 Turbodiesel

Postby katar83 » Fri Sep 11, 2020 3:54 pm

There aren't many sharp edges on a Jag, I've worked on a few, only once almost lost a finger while undoing exhaust studs......
Anyhow, I do use gloves all the time now, if its heavy stuffs then mechanix wear are best, if just normal spannering etc then I use single use vinyl/latex gloves, and just change them as soon as they tear up and to give hands a minute to breath, no issues that way and my hands are much better these days. It does mean that I can go through 40 gloves in a day but then again, these multipacks have 120 pairs I think and are generally cheap.
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: 102
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Thu Sep 17, 2020 10:34 pm

Yeah if I was a bit more organised I'd have a good stock of gloves! Will be careful around the exhaust manifolds ;) sadly the BMW engine is filled with nasty pointy bits, as we'll soon find out...

Some more jiggery pokery with the engine as I wanted to make sure I could fit and remove the wiper mechanicsm without dislodging the intake manifold. Moved it forwards by about half an inch which sorted it.

189.jpg


At this point I'd lucked into having the engine dead central in the car, angled at 6.4deg and clearing all of the major components nicely so I thought I wouldn't tempt fate and try and raise it to take up the squish in the mounts. Just make them while it's central and sort any issues by shimming the mounts with metal plates (which can later be welded to the underside of the mounts themselves).

With that, I started making the mounts! They're not the prettiest, but I went for strength and using materials I had to hand over aesthetics. Nearside...

190.jpg

191.jpg


...and offside.

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Also, someone needs to be kicked in the shins for the upper engine mount bolt placement on the LH side. It's hidden way way up behind loads of tightly packed wiring, and exits directly into a plug that's really difficult to remove so you can't get a socket on it nicely. If they'd moved the mount 10mm forward or down, or the plug 10mm up or either side (or even outward) then it would be fine. I reckon designers should be made to spend a year working on cars every now and again so they experience these sorts of things!
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD


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