Thanks for the advice, currently trying to reinstall everything. Where do the 2 o-rings go? I can’t find any place for them.

 

Pianoman90,

Thank you for all the pics. Some of your views/angles made more sense than when I was looking inside my own engine!

 

I have the same o-rings left over from the Christopher kit, I researched at the time and could not find where they fitted my vehicle

 

Looks like the kit includes the AJ26 VVT seals (on the front cover) but I remember them as being thinner 'O'rings.
The AJ28 front cover has some seals that the AJ26 and AJ27 don't for idler pulley bolts.

 

Glad the pics have helped! I'm still trying to figure my way around this motor but the forum has been a huge help along the way.

Sounds good, I just want to make sure before sealing up the front cover.

 

Yep, mine has been running fine for the last 10,000 miles without them.

I would recommend looking into replacing the plastic thermostat tower. It is a PITA because the two rear bolts are difficult-to-near-impossible to remove as the intake manifold restricts them. I changed my thermostat tower when I removed the intake manifold to replace the two heater hoses that run under there, another age-related maintenance project that is recommended.

 

Thanks, actually the pics don't show it well, but it is the updated metal thermostat tower. The PO had replaced it some time ago and looks like it has held up well.

While we're on the subject of o-rings, I also have 2 small ones that say they go the the cam positioning sensor on the valve covers but I can't figure out where they should go. Any ideas?

 

You are probably referring to these (see pic below), I couldn't find a place for these either.

The Christopher kit also covers the Lincoln 3.9 motor, so i can only assume that there are some o-rings in the kit that do not fit the Jag 4.0 motor.

 

The cam sensors have o-rings on them.

 

Are the cam sensor the solenoids on the VVT? I couldn't locate them.

 

Also, the Christopher instructions state to press the timing cover oil seal on the rear of the crank pulley and then install the pulley to the cover. But I have heard other members talk about installing it to the front cover first before putting the cover back on. Which do you all recommend?

 

The cam sensors are at the rear inner corners of the heads. The o-rings the sensors come with are viton and usually do not need replacement so I would leave them. The front crank oil seal is pressed into the timing cover first. A thin o-ring is installed on the crank pulley.

 

Definitely press the crankshaft oil seal into the timing cover, for subsequent fitment of the timing cover I always lubricate the oil seal to aid it slipping on to the crankshaft.

And yes, don't forget that really thin o-ring that goes inside the harmonic balancer.

 

Sounds good, I have already replaced the small thin o-ring in the pulley. I'll plan to skip the cam sensor o-rings and press the seal into the cover then. I was wondering how well it would have gone if I just left it pressed on the pulley during re-installation.

Working the next couple of days but will get back to the car soon!

 

Nice work, pianoman. So would a 2003 XJ have the updated timing chain guides?

 

As far as I know, the 03s have the upgraded dual row primary chains, different from the ones in my car. They should also have the upgraded metal primary / secondary tensioners. Not sure about the primary guides though, maybe someone else could chime in?

 

Next question, I replaced the thermostat gasket and the 2 smaller gaskets circled in red. Where are these other cooling gaskets supposed to go to?



Also, does the thermostat just sit back in the housing or do I need to add any sealant? The PO upgraded to the metal housing before I bought the car and someone had put some black sealant around it...it was a struggle getting the thermostat out because of it and I spent an hour removing gasket residue from the housing.

 

Not sure where the surplus o-rings go, but you do not need any sealant on the thermostat.

 

Got it all buttoned back up tonight. The car started immediately and idled well! Just glad that nothing went wrong, no one like surprise rattles / knocks / CELs.

Here is a picture of me and my dad after the initial startup, making sure everything was working appropriately. Also cleaning up a bit of spilled coolant lol



My only issue right now is that I have a small coolant leak from the metal thermostat housing connection. It is dripping about once every 1-2 seconds, from the area circled in red. I tried tightening the 3 bolts more but the leak persisted. The thermostat o-ring is new and I never removed the actual housing.



Turned off the car once I saw the leak, figure I will have to drain the coolant again and I can remove the hose without too much hassle. The question is, what should I do about it? Do I need some sealant around the housing or could the aluminum be warped? I didn't visually see any cracks when I reinstalled everything.

 

I had a leak in that area as well. But it was due to me using a gasket where it attaches to the tstat housing. In your case, i'd imagine the aluminum cracked, or re torque them. Glad it is running well!

Dumb question, but did you line the 3 bolts up correctly?