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Discussion Starter · #41 ·
So another day of fun with a big cat. Removed all the injectors and fuel rails, intake manifolds, injector harness - I think this engine has been rebuilt in its past and not long before it was parked up - the intake manifolds are dirty inside, the cylinder head intakes are not.

The owner must have had a fair bit of trouble with running lean / idle issues - the intake manifolds were barely finger tight. All the little vacuum pipes (and there are a vast number of them) are well past their sell by. There is an electrical bodge on the distributor and the wire pulled out of it without any persuasion, a breakdown waiting to happen. I did a quick check on the throttle body setups and they were both completely wrong but I'm going to be deep cleaning the manifolds so not a concern. Just printing up some inlet covering plates then I'll pull the cam covers off.

Removed all fuel lines, tested and condemned the auxilliary air valve, not much more to add really.
 

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Discussion Starter · #42 · (Edited)
Just how much crud can you get in a filtered injection system - take a look at the injector filter on one of my now removed injectors. You can barely see the injector filter for crud, admittedly this is one of the worst ones but this is supposedly filtered fuel - so this can only have come from inside the lines themselves and it seems to be rust, guess I need to assess replacing even the metal fuel lines although fuel comes out clean - I may just insert another filter in the engine bay somewhere although it gets pretty hot under an XJS bonnet.


182264


Take a look how bad the injector mount points are on the fuel rail, any guesses how they got this way ? - thus has to be water damage - but how ??

Every single connection is like this.

182266
 

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Water in the fuel, standing stagnant for a while?
 
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Discussion Starter · #45 ·
Has to be - been standing for 17 years but I sure wasn't expecting to find corrosion in the fuel rail.
 

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Discussion Starter · #47 ·
My goal was essentially just to refurb the system in general, I really don't want the project growing any more arms and legs, it's a matter of where do you stop before it ends up as just a pile of parts on the driveway that is yet a never ending task after task - I'm determined that this project shall not go that way.

I know that it is probably easier to do while I'm in here but I'm into this job for over 4k already and it is getting out of hand (near 6k if you add tools).

Don't forget that there are 12 of these suckers - assuming that they charge between 20 and £30 per injector that bill could hit over £400 by the time the chancellor takes his slice.

I'll ask around but I am likely to stick to my objectives on this one and replace the rubber parts, the internal filters and the pintle caps.

Just need to figure out a way to clean out this fuel rail now.
 

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Discussion Starter · #49 · (Edited)
Since I spotted some activity I thought I should update, I've been a bit tardy in this but the project is very much alive. It is a case of winter stopped play as I simply haven't the garage space for all my projects. The car is under cover and also covered, the goal was to put it into a car **** but it has ended up immobile up on my quickjacks as I am 95% of the way through dropping the front subframe off to deal with inner flitch corrosion.

I purchased an injector cleaner machine, my injectors are refurbed and vacuum packed, all the pintles and filter baskets removed and the bodies reblacked. I have two that are a little over spec in flow rate so I'm still considering sending them to a specialist - just need funds for other stuff. My fuel rail is also fully cleaned up and I'm wondering whether to send it out and get the zinc plating renewed, hot chemical ultrasonic bath and some judicious taps here and there got it to a point where nothing else comes out. I'm on the lookout for another but to be honest I think a lot of these rails will have the same issues especially from cars that have stood, especially any that have had ethanol contaminated fuel sat in them as ethanol is hygroscopic.

185364


I have also refurbished the throttle tower ( re bushed and potentiometer ), the throttle bodies have also been rebushed and both have been 'gapped' and set up ready for installation, the manifolds have been aqua blasted and cleaned up. I have also built a new wiring harness for the fuel injectors and ignition system.

These images show what really brought things to a stand still ... If I hadn't removed the manifolds and throttle bodies I'd likely not have found this. It is much easier to repair without the throttles etc in place. I'm going to clean off the bulkhead and flitch panels and sort them out before I put the manifolds etc back - and the winter weather has put the spanner in that machine hence the seemingly stalled project.


185365

185367


It is pretty much the same both sides, I have new turrets (rare as hens teeth and damned expensive when found) but may not use them, I think I can restore what is there but some of the rot goes bahind the subframe so I plan to drop it off the car. I will then refurb it along with anything exposed when it is off.
 

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Since I spotted some activity I thought I should update, I've been a bit tardy in this but the project is very much alive. It is a case of winter stopped play as I simply haven't the garage space for all my projects. The car is under cover and also covered, the goal was to put it into a car **** but it has ended up immobile up on my quickjacks as I am 95% of the way through dropping the front subframe off to deal with inner flitch corrosion.

I purchased an injector cleaner machine, my injectors are refurbed and vacuum packed, all the pintles and filter baskets removed and the bodies reblacked. I have two that are a little over spec in flow rate so I'm still considering sending them to a specialist - just need funds for other stuff. My fuel rail is also fully cleaned up and I'm wondering whether to send it out and get the zinc plating renewed, hot chemical ultrasonic bath and some judicious taps here and there got it to a point where nothing else comes out. I'm on the lookout for another but to be honest I think a lot of these rails will have the same issues especially from cars that have stood, especially any that have had ethanol contaminated fuel sat in them as ethanol is hygroscopic.

View attachment 185364

I have also refurbished the throttle tower ( re bushed and potentiometer ), the throttle bodies have also been rebushed and both have been 'gapped' and set up ready for installation, the manifolds have been aqua blasted and cleaned up. I have also built a new wiring harness for the fuel injectors and ignition system.

These images show what really brought things to a stand still ... If I hadn't removed the manifolds and throttle bodies I'd likely not have found this. It is much easier to repair without the throttles etc in place. I'm going to clean off the bulkhead and flitch panels and sort them out before I put the manifolds etc back - and the winter weather has put the spanner in that machine hence the seemingly stalled project.


View attachment 185365
View attachment 185367

It is pretty much the same both sides, I have new turrets (rare as hens teeth and damned expensive when found) but may not use them, I think I can restore what is there but some of the rot goes bahind the subframe so I plan to drop it off the car. I will then refurb it along with anything exposed when it is off.
Other than the obvious hole, the rest of the suspension look pretty much corrosion free
 

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Discussion Starter · #51 ·
Other than the obvious hole, the rest of the suspension look pretty much corrosion free
It is pretty much that way, the floors, sills, seatbelt mounting areas, rear valance, rear arches, doors have no penetrative rust at all, the car has clearly been waxoyled, as you noted there isn't even rust on the suspension parts - they're dusty not rusty. I could post picture after picture of the usual corrosion hotspots if the forum allowed that many. Somebody pumped a lot of love into this car at some time in its history. The suspension bushes etc also look fine although the damper top rubbers were shot, I'll not be replacing them unless I absolutely must but do plan to make sure bolts that should move do move and the spring turrets in the subframe are cleaned out and protected - they look OK but may as well belt and brace things once the subframe is off - the challenge with the bushes is that almost all aftermarket bushes for the Jaguar subframes are garbage and don't last near as well as the originals which are becoming hard to find and eyewatering expensive when you do.
 

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It is pretty much that way, the floors, sills, seatbelt mounting areas, rear valance, rear arches, doors have no penetrative rust at all, the car has clearly been waxoyled, as you noted there isn't even rust on the suspension parts - they're dusty not rusty. I could post picture after picture of the usual corrosion hotspots if the forum allowed that many. Somebody pumped a lot of love into this car at some time in its history. The suspension bushes etc also look fine although the damper top rubbers were shot, I'll not be replacing them unless I absolutely must but do plan to make sure bolts that should move do move and the spring turrets in the subframe are cleaned out and protected - they look OK but may as well belt and brace things once the subframe is off - the challenge with the bushes is that almost all aftermarket bushes for the Jaguar subframes are garbage and don't last near as well as the originals which are becoming hard to find and eyewatering expensive when you do.
I can sense you are really enjoying it, I have a soft spot for the XJS, especially the 5.3 😁
 

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You’re making great progress on this.

Harry Metcalf on YouTube (Harry’s Garage) has just dropped his XJC off for a full body restoration. The engine is to come out and it’s a V12 as well. Worth a look if you haven’t seen it.
 

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Discussion Starter · #54 ·
Thanks guys, I wish I was making more progress, I've watched a couple of Harry's vids - the one he took an XJS to France was interesting. I think he and I are from different sides of the universe though, for me the owning isn't near as much fun as the journey of bringing something back to life, I don't enjoy my completed models near as much as I did building them.

Harry didn't even flinch when he was told 15 to 20k ... I'd need CPR although I reckon I've spent 4.5k so far and reckon I'll spend at least that again.
 

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Keep up the updates please.
 

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Having an undercover space to work on an old car is key. I hope you get something sorted out.
 

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Discussion Starter · #57 ·
Having an undercover space to work on an old car is key. I hope you get something sorted out.
I here ya. alas I have more projects than cover, the car is covered but not in a way that makes unplanned impromtu work sessions viable, I also can no longer cope with the cold on my hands so anything less than a heated workshop is pointless. I'm currently hoping that a decent commercial grade marquee offers itself at sensible money. I have three cars currently covered by a Gala Tent PVC but it has no sides etc installed just the cover. The challenge with anything you can't heat economically is condensation which is brutal during the dark months whether under a car cover or a marquee the result is about the same. I don't have the funds for a heated warehouse like Harry and I'm sure 'er indoors would get real upity if I removed the bay window and put it in the lounge.

Besides the big cat I have a Scimitar Sabre, two Scimitar SST's and a Kitten Estate - not to mention two Passat estates and the SV8 ... I hadn't planned on the XJS becoming immobile so soon, thought I could get it MOT'd and in a carcoon for winter but it had other ideas. It is all a bit of a logistics nightmare, I can't work on the Scimitars without moving stuff around, right now the XJS is stopping me moving any of them, I can't work on the Kitten which is in the garage because it is surrounded by 3 engines, 2 axles, 3 gearboxes, 2 compressors, generator, 2 workbench, lawnmower. lawn scarifier/aerator, commercial transmission jack, 10 ton trolley jack, 5 ton Trolley jack, a pair of 2 ton trolley jacks, 2 sets of wheels, various XJS parts, Mig welder and gas bottle, various axle stands, 2 bottle jacks, garden shredder, numerous gardening tools, bicycle, 5 large bags of marquee poles for a 3x6 and a 4x6 marquee along with said marquees (a left over from our festival trading days), a 6 x 8 metre market stall and sheets likewise, the cars were all under this once upon a time but keeping sheets on in high winds and heavy rain (not to mention snow) is nigh impossible - wait theres more ..... oh hell I'm sure that paints the picture well enough. Really should sell some of it off but just isn't economically worth the hassle but it is too good to throw out, local storage places are urine extractors price wise.
 

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Good grief!

Sent from my SM-G977B using Tapatalk
 
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Jeepers.
And I thought my big garage was bad before I started on the GT...

You need a modest clear out. Lol.
 
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