Job # 1984 (DU) - Jaguar 4.2 E Type
Full Stage One engine rebuild

Update report - February 24, 2012

Yesterday afternoon we installed your rebuilt carbs and fired up the engine for the first time. All systems were functioning perfectly. Earlier today we ran the car through four break-in heat cycles on the dyno and dialed the carbs in. The car is idling smoothly and pulling strongly.

Click on the photo below for a video clip of the car in action on the dyno.

Update report - February 23, 2012

I am pleased to report that your car is now safely installed at Classic Jaguar. Congratulations on putting together a great looking car, Dave!

Reported oil pressure problems...

After you were told by the shop in Santa Barbara that your freshly built Stage One CJ engine had no oil pressure, you will be pleased to hear that in fact she has excellent oil pressure. I can only assume that the Santa Barbara shop was using the (inoperative) gauge in the dash to determine the oil pressure, because as soon as we hooked up a mechanical gauge, we instantly had around 60 psi at cranking speed. Incidentally, the oil pressure gauge in the dash was not working because it had been wired backwards with the water temperature gauge. Total time invested so far - 10 minutes.

Onwards and upwards...

Next step is to install the carbs and fire the beast up!

 Car will be test run on the CJ dyno later today
 Engine was pre-lubed prior to cranking


We now have your engine and CJ5/600 five speed wrapped and loaded onto a pallet. It should be with you in the next few days!



I am pleased to report that your engine rebuild has now been completed.

We have now completed the repairs and machine work to the cylinder head and should have your engine assembled and ready to ship in the next couple of days.

 Darrell welded up the corroded water jackets
Water jackets were then re-shaped on the mill 



 After surfacing, deck surface and water jackets good as new



 Base line flow numbers on the intake side



Nice pick up of about 45 cfm following porting


With the short block now completed, we are turning our attention to the cylinder head.



Short block assembly, continued...



Time to start assembling the short block...

Polish crank journals
Balancing the crank
Balancing flywheel and pressure plate
Crank now installed

I am pleased to report that we have now completed the block machine work. The following sequence of photos show Kevin measuring bearing clearances, honing the cylinders and surfacing the deck of the block. Next we will use the measured bearing clearances to calculate requisite crank journal sizing.

Measuring main bearing clearances after align hone
Torque plate used during honing process



Surfacing block after cylinder hone completed



Painting interior of block with Glyptal


We have now completed an align hone and begun the cylinder honing process...

Align hone in progress
Main caps machined to perfection
Block then moved to cyl hone machine


The water jackets behind the cylinder liners were completely blocked on this engine. There were also a number of minor cracks in the cylinder walls and between the sleeves on the deck surface. None of these cracks represent a signififcant problem and will be dealt with during the resleeving process.

Cutting out old sleeves
Blocked water jackets behind sleeves



Cylinder walls also cracked

We now have your engine completely disassembled and the rebuild underway.

 A number of head studs were seized and required a little 'heat' 
before they would part company with the block



 Engine now completely disassembled


I am pleased to report that your engine has arrived safely at CJ and we will have the rebuild underway in the next few days.



Go to other CJ engine rebuilds

Go to main CJ workshop