Dear All,

Here is another update on the conversion project. The 5-speed manual gearbox has been mounted and runs alright. Still need the following:
(a) a good valve cover to stop oil leak around the gasket and spark plug well as the valve cover is badly corroded inside out
(b) a pair of good exhaust manifolds - the used, welded ones still leak
(c) the aircon is not working - mechanic not sure if it is an old or new system using 134a or R12, as he found both kinds of inlets.
(d) the new clutch is ultra heavy - despite fitting new clutch, pressure plate and clutch bearing.
(e) the stick shift tower stands well, but there is an uncovered notch near the lower end of the wood trim floor because the original trim was meant for the auto-transmission mechanism.

Until and unless I have found a replacement valve cover and exhaust manifolds, the rest is not worthy of tackling at this stage.

 

Qvhk, have you thought about making custom exhaust headers (tube manifolds) for your Jag? It's not that hard for a professional to do. Perhaps a performance shop in UK or Australia specializing in Jag performance parts would carry a set. Also, due to your past problems with unethical privateers, I would strongly suggest dealing with established art sources.

Any chance of putting up pics of your progress so far?

 

Here are some pictures of the project:

First the Adaptor Plates, sourced from New Zealand, which is needed as a go-between before fitting in the gearbox to the bell housing



New clutch kit sourced from eBay UK


Did you know the XJR has Dual Mass Flywheel (DMF)?


Engine removed from car


Exhaust manifolds removed for welding, but there is still air leak after welding


Manual Gearbox, Adaptor Plates Flywheel etc. fitted in place


Notice the badly corroded Valve Cover, and the piping that goes under the exhaust manifold heat shield (the air injection inlets and EGR valve lining, aircon hose etc. which may obstruct the fitment of after-market exhaust manifolds


Would need a pair of exhaust manifolds in stainless steel to replace the toasted originals. Going for non-standard manifolds may require altering the many lines and pipes below the heat shield; not an easy task, and certainly not for amateur or DIY.

I agree I should look for exhaust manifolds made by professional shops; unfortunately none really at that level in Hong Kong. I shall see if I should go it alone or wait till others come along, but the group buy idea seems rather remote at this stage.

 

Here is a picture of the XJR when I bought it

 

Do you have pics of the transmission complete with the interior yet?

 

It is not clear from the one photo showing the exhaust manifold whether an EGR system is fitted. I would expect to see a large black electrical valve (about the size of a coke can, bolted onto the back of the exhaust manifold.

 

Yes, definitely has EGR system. Project has taken exceedingly long. After changing the headers, replacing valve cover, six new coils, etc. engine fired up properly but failed the CO2 test. Mechanic has checked out EGR, O2 sensors, pre-Cat and floor Cat and also installed remapped ECU, but the engine refused to fire up.

 

Sorry, correction. Got wrong information from the mechanic. Car went to emission test with the original ECU and leaking exhaust manifolds, etc. The new valve cover, gasket, stainless steel manifolds, etc. have not been installed. Worse still, car was running alright going to inspection but refused to start up afterwards. The suspects are the alarm system or the starter key module, which can be expensive to replace. The project has too many surprises, and with almost 20 months gone and chances of success now very slim, I am seriously thinking whether to abort. The biggest challenge is the lack of adequate local expertise in Jaguar machines.

 

Don't give up yet. These problems can be overcome. It is just unfortunate that as you say, you do not have access to an independent Jaguar specialist who is familiar with the electrical systems of an X300. Please see my reply to your PM.

 

Thanks for the info. The car has largely been off the road for 3 years so it would be a tough call to finish the project. Hope the info and advice would re-kindle my mechanic's will to sort this out.