So with the new timing chains in place the rattle had disappeared however the worst was to come I could hear a faint knock noise .

After removing the necessary components in order to get the sump off , I had access to the crank now.
Fingers crossed I was hoping it would be a worn big end bearing and I could simply swap it out hmmm not the case the bearing had spun (cyl 6) and scored the crank.

After making numerous enquires and a stack of enquires oversized bearings are not available for 4.2L aj33/34/41 (4.0l yes & 5.0l yes) they would have to be custom .

New crank and OEM bearings would work however new cranks aren't available

The other option would be chance a second hand crank, have it polished, however too risky as you don't know what your getting (I'm in Australia and would have to order from overseas seller)

​​​​New engine $25k (supply only) thanks but no thanks Jaguar.

Moving right along I managed to track down a used 4.4L aj41 out of a range rover sport which I jumped on straight away

Now in order to get the conversion completed it virtually needs to be stripped down completely leaving only the bedplate , crank, pistons , conrods and heads .

The following needs to be done /swapped over in order to make it work
-oil pick up
-sump
-windage tray removal
-timing cover
-resleeve alternator bracket in order to use 10mm bolts
-larger lower bolt for start
-x2 10mm bolts for knock sensors under inlet manifold
-engine mounts
-air con bracket
-p/s bracket
-thermostat housing
-exhaust manifold (egr is routed differently)
- 4.4l use 21lbs injectors same as aj33, the 4.2 aj34 uses 25lbs
-inlet elbow
- unsure if fuel rails or egr can be re routed probably can however a lot easier to change over the entire inlet manifold including injectors, rail, throttle body, egr and harness

As I was swapping over my new chains I also swapped over the vvt and solenoid however this isn't necessary as part numbers are identical

Interesting to see that there is a visible difference in the inlet ports (4.2 has divider 4.4 no divider)



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Sump off

Sump off , subframe out, crank exposed and engine braced from above

Engine/box out

Its a big unit !!

A eery sight


Replacement engine

4.2 vs 4.4





4.4l header log style on top 4.2l header branched below

Inlet manifold

Both engines suspended for sump swap over

Here we go again , camshafts locked down and reusing my new chains that i fitted up last week

Conrod bearing fragments in my oil pick up

Aj34 (4.2l) inlet ports divider

Aj41 (4.4l) inlet port no divider


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Hey, with the engine out, fixing the duckbill would be a piece of cake!

 

So Awesome! I think it was Bud's Jaguar in Toronto that's done similar work... replaced the 4.2 SC with the LR 5.0 SC... big job.

 

hahaha. I was gonna say might as well change the Coolant pump while it's out.

Nice work Steve. thanks for posting. Interesting stuff...

 

Dam man, first a tear down for timing chains and now this? You must either love doing this stuff or just have the worst luck! Glad to see you didn't just throw in the towel though. Keep it going!

 

Haha guilty as charged

 

Hey Chris have you considered fitting a 5.0 NA instead?

 

Would have been a truck load easier as ive had to completely strip the 4.2 and the 4.4 down to make it work... However with the 5.0 I'd get stuck on trying to make the my ecu talk to the engine ( even if I swapped my ecu out for a 5.0l I don't think it would work) would most likely need a stand alone system

 

Yes you're probably right, without a Motec or Haltech wiring kit specifically for the Jag, you have to start from scratch and build your own wiring loom and you need to marry this to the transmission ECU as well. Yep massive job.

 

This option was discussed however deemed infeasible due to not enough being allocated to this project , pretty much want to turn this car around and have it up and going within the week (its my daily)

 

Important not the aj41 dipstick goes straight into the sump the 4.2 goes through the bedplate

Whilst the 4.4 has the hole in the bedplate it has a blocker in place wish I knew this before changing over the sump nevertheless got the job done in the end

 

​​​​​​new power train ready to go in


Running , no leaks and maintaining a good idle

 

If engine still out, on the oil pipes that run from the transmission you should check the connectors on the rubber hoses. If you can move the connector on the rubber hose it is starting to go bad. It's a lot easier to take the pipes off with engine out and change the rubber hoses to new.

 

Pete the connectors were good no splits or no signs of wear & tear ..although I did change the rear main seal before mating gearbox together

 

Thought I'd post up a good pic of my entire exhaust system


Branched style headers in black vs log style (similar to s/c style) . the branched will help with scavenging affect and improve low to mid range torque not need on s/c as has ample torque down liw