1989 Jaguar XJS
Major mechanical overhaul


Specification (briefly) for this project is as follows:

Major mechanical overhaul including full engine and transmission rebuild.



Update report - November 28, 2012

Putting final touches to this rebuild...

Assembly of the short block underway...

 Balancing the crankshaft
Weighing and checking balance of rods 









 Sizing piston rings
Measuring ring gaps in honed cylinders 



 Pistons hung on rods and ready to install



 Installing the crankshaft
Measuring crank thrust 




Custom forged CJ pistons are a thing of beauty...

The following photos show Kevin measuring the crank journals and honing the cylinders to size...

 Measuring crank journals
Torque plate honing cylinders on the A bank 



 Note cross hatch pattern on cylinder walls

Repairing the badly damaged cylinder head, align honing main bearing housings...

Oil pump is well out of spec and must be replaced
Close up of damage to the cylinder head deck surface



Damaged area ground out and ready for welding
After welding, the deck surface is cleabed up on the mill



Main caps are ground square prior to carrying out a
much needed align hone



Align honing in progess


One of your cylinder heads was seized solid and required extreme force to remove it. Once the head was off, we found some severe damage lurking beneath. One of the liners was cracked, one of the pistons was holed, and the cylinder head itself is also damaged. It is amazing that this engine ran in this condition!

 Custom puller plate used to remove head
Head finally starting to separate from the block 



 Note crack in liner



 Note hole in piston at 11 o'clock
Amazing engine ran in this state! 


I am pleased to report that your car arrived safely at Classic Jaguar and we already have the mechanical rebuild underway.



Go to main CJ workshop