AVOS, you are the true prophet of AJ swaps. I did just as you directed...and I think it worked I was astonished at the amount of plastic that I was able to remove.




As you might notice, the sensor that I'm using is not the same. Well I learned the hard way that the valve cover screws are not created equal as one killed my original sensor. Since the build is on the budget, I'm willing to gamble if the 4.2 right sensor is same with just different orientation and connector which I swapped. $120 is way to much for it.....

 

So is that particular screw shorter?

 

That's a good question. Here's what I did thou:

I used the bolts from the 4.2.

I used to 4.2 gaskets on the 4.0 covers which I think were thinner with a good amount of RTV. So basically, watch out for the bolts going into the sensors.

 

Today's progress:

M112 5th gen elbow conversion:



Slight porting and there is a good 1mm left top and bottom to match up:

 

Custom matched gaskets:

 

I'm having a hard time connecting the gen 5 supercharger to the aftercoolers. Is this normal?

 

The blowers are exactly the same, but Iirc when you use the 4.0 intake manifold on 4.2 heads the intercoolers are pushed back somewhat (5mm or so?) is that the issue? You should also use the later style 4.2 intercooler connections, so the 2 rubber rings and their 3 fittings.

 

Yep, if you compare the supercharger bases by holding them together, you'll see the adjustment you need to make to the 4.2 charger bolt down holes. A good slim hole file should get you the required distance, just slot them back to the 4.0 charger hole centres?

Are the snouts the same length Andre?
I just wonder at how exact Adam's got be to avoid thrown belts...

 

O think that this might be the issue as I think the blower bases looked the same.
It is impossible to use 4.2 aftercoolers with the 4.0 intakes as the spacing is totally different. I also cannot use the 4.2 transition part (from the blower to the coolers) as the 4.0 exits towards the back and the 4.2 shoots air to the sides.

 

I used to have a COG setup on my mustang. I definatelly don't want thrown belts ever again

 

What is the purpose of the foam under the SC? The parts manual says "sound insulator". Is it necessary? Does it have anything to do with the knock sensors?

 

Sorry, it was obvious for me, but for the 4.2 XKRs which shares the same intercoolers, Jaguar came out with better parts as mentioned, and they have discontinued the old 4.0 ones long ago even.

 

The 4.0 and 4.2 SC are the same in length, no difference in outside dimensions, so no adjustments should be done or you will get a misalignment.

 

It’s purely for noise reduction, have always re-used the item so am not sure how much more noise it would make without. If you want more noise, then better to stick to the 4.0 supercharger as the 4.2 is somewhat quieter.
Actual engine knocks have a much different frequency than the supercharger is producing, so I can't see any relation with the KS.

 

[quote=avos;413909]Sorry, it was obvious for me, but for the 4.2 XKRs which shares the same intercoolers, Jaguar came out with better parts as mentioned, and they have discontinued the old 4.0 ones long ago even.


I'm confused now. So the 4.2 XKR uses the same aftercoolers as the 4.0 XJR?

I'm looking at JEPC and it looks like it... so the intake manifolds might allow to use the older intercoolers with the newer style injectors right? of one can be sourced?


So, again to clarify, I need to source the XKR transition piece to make this work?

 

They are of the same type, but will only fit the 4.2 intake manifold, and you have used now the 4.0 manifolds, so they will not fit. The connection between the intercoolers and the V8 piece (SC outlet) have exactly the same dimensions, and are beter.

I will be swapping mine, you can PM me if you are intersted. Not that I am biased, but I believe they are better than the 4.0 ones, and also flow a little more.

The newer connection should allow for a little bit more flexibility, but it might still be tough to get it to fit. You may need to move the manifold/intercoolers a bit more forward by drilling out the bolt holes, that should help a little (unless you move to the 4.2 manifolds/intercoolers).

 

So, the distance that is needed to make a perfect fit is about 11mm.



I wish I could somehow make/ source 1cm longer rubber seal pieces but it looks more of a challenge. What exactly is the difference between the old and new kind?



You can see on this pic as to how much shift there is.





I'm thinking about re-drilling and tapping the supercharger housing, but it will kill some airflow as the SC case opening will be restricted and I might have a hard time sealing it.

 

Depending how much work you want to go to, you could find someone experienced at aluminum welding. Could build up the short side, then machine it down on a milling machine. Would require some care to keep the rest of the casting from warping. I have used this technique in an R&D setting to accommodate mismatched pieces. But you might need a spare housing or two in case things go wrong!

 

I was thinking about that. I'm looking into someone machining a spacer for me to fit between the v8 piece and the rubber connectors/coolers

 

I have just checked the difference in distance, and I come to 7mm. I was also going to suggest to make a spacer on the intercooler side. Just make sure it looks the same (so similar sunken in), and use the newer rubbers/rings from the 4.2 XKR.