1968 E Type roadster (PN) Classic Jaguar Service Department

As part of a new initiative we are going to be showing you some of the work that goes on in the CJ Workshops other than the total restorations that we are known for.  In this particular case, we have been asked to complete a 1968 roadster that has been under restoration in various shops for the past six years. Our main task will be to rebuild the engine, upgrade the ignition and cooling systems, and install a CJ5 five speed transmission. The object is to provide our customer with a good, reliable driver.

I am delighted to report that we fired up and test ran your rebuilt engine yesterday and everything went perfectly. We hooked the car up to the gas analyser and fine tuned the carbs and ignition. If it wasn't for a bad clutch master cylinder, we would have already begun the road testing process. Unfortunately we did not have a replacement clutch master in stock so we will have to wait until Monday before we can start shaking the car down for you. It won't be long before you are driving it yourself  

Rebuilt engine running perfectly	Tuning the car on the gas analyser

The following photographs show the installation of your rebuilt engine and CJ5 five speed, as well as some new headers, adjustable reaction plate, etc, etc.

Installing the engine		Outer trans mount holes were stripped out
Easily solved by dropping new bolts thru from the top	Spin-on oil filter installed	Headers are a tight squeeze between oil pan and torsion bars
New CJ cooling system		Installing your carbs

Your CJ engine rebuild is now complete and should be re-installed during the coming week.

With the cylinder head removed the cause of your reported engine problem was clear to see. Basically, the pistons have been galling the cylinder walls because they were installed with insufficient skirt clearance. There are a number of other issues too, not least of which that the engine is actually from a 3.8 sedan. In the circumstances, we decided the best course of action was to set aside this particular engine and to rebuild a correct 4.2 E Type unit for you.

The machine work on the replacement block should be completed in the next few days and I will cover the impending rebuild in these pages.

With the head removed the cause of your engine problem was revealed	Pistons were installed with  insufficient skirt clearance
		Pistons have been gouging the  cylinder wall
3.8 sedan block will be replaced with correct 4.2 E type unit	Damaged camshaft will be replaced	Rod bolts/nuts will be upgraded during the rebuild