billy_bunter Posted September 24, 2020 Share Posted September 24, 2020 I would be tempted to remove the "cloudyness" on the metal with some very fine emery/sandpaper. BUT that is not vital to brake function the seal will still work move properly in that bore. Opinions may differ on that as more people give feedback. Getting really anal could be useful to have compressed air and test the piston movement. Obvs have to turn the pressure of the air down so you do not create a dent in the garage door dome and jaypee 1 1 Link to comment Share on other sites More sharing options...
SRi05 Posted September 24, 2020 Share Posted September 24, 2020 20 hours ago, dome said: Few updates on the Jag front. Brake lines are all cut, flared and in place. Not finalized yet. Fronts are ready but the front to rear line runs alongside the fuel flow and return lines. I'll tidy it up when I run the fuel lines. I've decided to go cupronickel with them, it'll match the brake lines I've fitred and means I can use the existing clamps. I had thought about running rubber the full length but decided against it. I'll need to join them to the existing hard lines with rubber hose. I've also had to order a new fuel filter with push on fittings instead of the screw on type it should have. @SRi05 that means there's a fuel filter here for you if you want it? Onto the caliper rebuilds. This is tricky, having never done one before. I managed to tear one of the rubber boots on a front one but here's one front with new piston, seals and rubber boot. Onto the rears. Piston pressed out Cleaned up and new seal installed Boot stretched over the piston. And this is the tricky bit. You have to install get the lip of the seal into the caliper but you can't fit the piston afterwards. So I held the piston just inside the caliper and massaged the seal into the groove. Not easy. And there we go I'll swap you for the CD changer 🤓 dome 1 Link to comment Share on other sites More sharing options...
Broadsword Posted September 24, 2020 Share Posted September 24, 2020 Very impressive work on the XJ40. Will be exciting to see it back on the road! dome 1 Link to comment Share on other sites More sharing options...
Angrydicky Posted September 24, 2020 Share Posted September 24, 2020 Yeah, people commonly think that pitting or corrosion in a caliper bore renders it scrap but that's not the case, providing there's no raised rust and it's all clean any pitting doesn't matter as it's the piston and seal that are the working surfaces. Interesting to see the calipers on that Jag are ATE. They look very similar to BMW E30. dome and SiC 1 1 Link to comment Share on other sites More sharing options...
dome Posted September 24, 2020 Author Share Posted September 24, 2020 3 hours ago, SRi05 said: I'll swap you for the CD changer 🤓 Deal! Link to comment Share on other sites More sharing options...
jaypee Posted September 24, 2020 Share Posted September 24, 2020 Good stuff man, she's getting there! dome 1 Link to comment Share on other sites More sharing options...
sierraman Posted September 24, 2020 Share Posted September 24, 2020 Car mechanics did a XJ40 project in the early 2000’s. I’ll see if I can find any copies in the loft. dome 1 Link to comment Share on other sites More sharing options...
dome Posted October 1, 2020 Author Share Posted October 1, 2020 I had a weekend off doing this as I had other stuff on and fancied a break from rolling about under cars. It must've helped as when I saw the forecast for the coming weekend here I decided to take Tuesday off as I had some holidays to use up. So, where were we up? All 4 calipers were now rebuilt with new pistons and seals New dizzy cap, rotor arm and leads were fitted Thermostat was changed and cooling system was flushed out. Kunifer fuel line had arrived New rubber hoses and a new filter were here. I also had a catering size bottle of Vactan and wasn't afraid to use it... So, before we fit shiny new parts lets start getting things a bit more respectable looking. The first thing I wanted to clean up was the suspension arms and subframe. Basically anything I could get access to while the car was on axle stands. I'll delve further underneath post MOT. Everything was solid but there was a lot of surface rust. Time to break out the wire brush attachment for the death wheel. Here's how it all looked before. Not great. And after wire wheel, Vactan and a first coat of paint. I also cleaned, Vactaned and painted the metal clips which hold the front and rear lines in place. Note my bench* grinder* Next up was the fuel lines. I'd went for 5/16 kunifer pipe-this is the correct size to fit 8mm fuel hose too. Only trouble is the hard lines on the feed side were larger. I had to get some 10mm diameter rubber hose and a couple of step down unions, one at the tank end and one at the engine end. A bit of a faff but now done. Here they are trial fitted. And done with the clips installed. Yes, I know they're not straight. Fuck trying to straighten them any more though! Hardest bit was the fuel and brake line clip on the inside of the trans tunnel. Trying to get 2 fuel lines and a brake line located into the rubber grommets and then the clip put years on me. I took me over an hour but I got it and the rest of the lines in place. I could also get the brakes back together. Lunchtime today and I decided to get this finished off. Firstly, underneath the back end and tighten up all the brake unions. I could then flare the pipe and fit it to the master cylinder. What, me? Forget to put the union on before flaring? Never... Zip tie is handy to stop the union sliding it's way down the pipe. I could then see if we could get a brake pedal... I used my pressure bleeding tool and gave it a crack. Worked round all 4 finishing here and I have a pedal! I'll give it another bleed up as it's still a bit spongey but that was a relief. I then stuck the battery back on it and cycled the ignition a few times to build up fuel pressure-sure enough a loose union cause a leak. Nipped this up and fired her up and she's sounding good VID_20201001_133347330.mp4 Oh and I managed to get the rear seats cleaned and condinitioned. They came up well Split_Pin, stuboy, jaypee and 20 others 23 Link to comment Share on other sites More sharing options...
juular Posted October 1, 2020 Share Posted October 1, 2020 Looking good. Was just browsing flaring tools. Which one did you go for? Link to comment Share on other sites More sharing options...
dome Posted October 1, 2020 Author Share Posted October 1, 2020 2 hours ago, juular said: Looking good. Was just browsing flaring tools. Which one did you go for? I went for a cheapy Draper one that did the job. I needed male and female flares and most of the ones recommended earlier in this thread didn't seem to do that. https://www.halfords.com/tools/hand-tools/all-hand-tools/laser-10-piece-flaring-tool-kit-121882.html juular 1 Link to comment Share on other sites More sharing options...
dome Posted October 1, 2020 Author Share Posted October 1, 2020 Hoverjag seen here wearing it's grill for the first time in 20 years. You'll also notice the oil leak, the reason it'd been taken off the road in the first place. The oil cooler had failed and been replaced by a length of looped hose by the previous owner. One of the jubilee clips wasn't right so I nipped it up. We'll see if that fixes it. I've also purchased another grill so I can paint the inner section body colour, a la what@SRi05 did to his. If I don't like it I'll have the silver one. It got another bleed and the pedal seems ok. A bit more fettling and the wheels can go back on and maybe a short test drive. Tickman, theshadow, LightBulbFun and 10 others 13 Link to comment Share on other sites More sharing options...
big_al_granvia Posted October 1, 2020 Share Posted October 1, 2020 splendid work sir dome 1 Link to comment Share on other sites More sharing options...
juular Posted October 1, 2020 Share Posted October 1, 2020 Your oil cooler issue is the same problem I'm trying to fix with the pipe flaring tool. If the jubilee clips aren't up to it these style ones have more even clamping force and might be a cheap fix. https://www.hoseshop.net/stainles-steel-hose-clamps/stainless-steel-heavy-duty-hoseclamp dome and Jim Bell 2 Link to comment Share on other sites More sharing options...
dome Posted October 1, 2020 Author Share Posted October 1, 2020 11 minutes ago, juular said: Your oil cooler issue is the same problem I'm trying to fix with the pipe flaring tool. If the jubilee clips aren't up to it these style ones have more even clamping force and might be a cheap fix. https://www.hoseshop.net/stainles-steel-hose-clamps/stainless-steel-heavy-duty-hoseclamp I thought about flaring the fuel pipes but the hose was a good fit and that was exactly the type of hose clip I used! I've got a good supplier close by (Clarik) so can soon pick some up to fit the oil cooler pipes if need be. juular and Jim Bell 2 Link to comment Share on other sites More sharing options...
dome Posted October 2, 2020 Author Share Posted October 2, 2020 Bit more fettling today-rotted out exhaust clamps replaced and I finished securing the fuel and brake lines. Quick pic of each corner More underseal/painting will follow but I don't want the tester to think I'm trying to hide anything. I could then stick the wheels back on and give it a quick run to the end of the road. Brakes feel good and it drove smoothly which was a relief 😃 MOT booked for next week, stay tuned! LightBulbFun, gm, Matty and 22 others 25 Link to comment Share on other sites More sharing options...
The Moog Posted October 3, 2020 Share Posted October 3, 2020 Looking good dome 1 Link to comment Share on other sites More sharing options...
hairnet Posted October 3, 2020 Share Posted October 3, 2020 thought only the 2.9 had the four lamp front or do i need to go and buy more nerd? hubcaps = base? Link to comment Share on other sites More sharing options...
Fraz Posted October 3, 2020 Share Posted October 3, 2020 6 hours ago, hairnet said: hubcaps = base? Hubcaps = awesomeness dome 1 Link to comment Share on other sites More sharing options...
dome Posted October 7, 2020 Author Share Posted October 7, 2020 I dropped this off for an MOT last night at my local station as I was in the office today. Frankly, anything could happen. It's not been driven more than a mile nor has it ran for more than about 15 minutes. Who knows what would happen when it sat in a testing station for an hour running. Anyway, it appears that what happens is that it passes I'll send my girlfriend round to pick up the keys (and pay for it) and we can try an exploratory drive tonight! Spiny Norman, puddlethumper, Jim Bell and 35 others 37 1 Link to comment Share on other sites More sharing options...
juular Posted October 7, 2020 Share Posted October 7, 2020 Result. Happy days. dome 1 Link to comment Share on other sites More sharing options...
320touring Posted October 7, 2020 Share Posted October 7, 2020 Congratulations ! dome 1 Link to comment Share on other sites More sharing options...
Broadsword Posted October 7, 2020 Share Posted October 7, 2020 Congratulations on the MOT. I'm seriously impressed with your work here. Drive and enjoy it for a bit! dome 1 Link to comment Share on other sites More sharing options...
SRi05 Posted October 7, 2020 Share Posted October 7, 2020 Minimad5, juular, MJK 24 and 11 others 3 11 Link to comment Share on other sites More sharing options...
cort16 Posted October 7, 2020 Share Posted October 7, 2020 Excellent , well done . Link to comment Share on other sites More sharing options...
lesapandre Posted October 7, 2020 Share Posted October 7, 2020 39 minutes ago, SRi05 said: Cousin of Pam Dimick Related to Mavis Sematism - she is my auntie. I have an Irish neighbour - M O'besity - first name Morbid Link to comment Share on other sites More sharing options...
Saabnut Posted October 7, 2020 Share Posted October 7, 2020 Well done @dome a good result there. What you need* now is an X308 to go with it. Step this way........ dome 1 Link to comment Share on other sites More sharing options...
Jim Bell Posted October 7, 2020 Share Posted October 7, 2020 Fantastic result man. Bet you cannit wait to get out and about in it. dome 1 Link to comment Share on other sites More sharing options...
dome Posted October 8, 2020 Author Share Posted October 8, 2020 Well, somewhat inevitably, the first drive ended with a walk home😪 My GF called me after picking it up from the garage, saying it was running badly and misfiring. I thought it was low on fuel again having sat running during the test-I'd not had a chance to put fuel in it before dropping it off. I stuck a couple of gallons in and it started and ran fine so off we went. It was fine for the first few miles then started to run rough. I limped it in to the next village and walked home. After dinner I got a lift along to collect it, again it started and ran fine from cold and I made it the mile home. Not before the oil cooler bypass hose fitted by the previous owner failed, leaving a lovely* trail of oil for the last couple of hundred yards to the house 😟 So, I've ordered a crankshaft position sensor in a bit of a lucky dip parts replacement. I've also ordered up an oil cooler blanking plate-seems the coolers failing is a common thing and a bypass kit was available from Jaguar. Just need to clean up the mess now... Saabnut 1 Link to comment Share on other sites More sharing options...
juular Posted October 8, 2020 Share Posted October 8, 2020 Hopefully just snagging, I think this wants to live on. Someone is looking out for you with that oil cooler hose as it could have emptied the engine quite quickly. I'm thinking of blanking the one on the Ovlov rather than making up new hoses. I don't think the older style coolers in the radiator were that effective anyway. I keep this stuff handy as any time I do an oil change I make a pigs arse of it dome 1 Link to comment Share on other sites More sharing options...
cort16 Posted October 8, 2020 Share Posted October 8, 2020 A pat on the head then a boot in the balls. Sounds like you've got it in hand. dome and 320touring 2 Link to comment Share on other sites More sharing options...
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