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| Date | Event | |
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1/10/2002 2 hrs XJ6 Dismantle |
Started the engine for the last time in this
car today. Just to be sure, and to get all the electrics back to square one
(like the radio antenna retracted and to test the electric windows).
Disconnected the battery and loosened a few of the nuts and bolts ready to
remove the bonnet. Cleaned some of the upholstery and the steering wheel
just to see how good it was under all the grime and dirt. Not really
productive or necessary but out of curiosity the engine mileage as recorded
today 63,025. Which is exactly the mileage on the MOT certificate of 1 year
ago. |
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02/10/2002 3 hrs XJ6 Dismantle |
The first serious day of dismantling the XJ6. Removed the battery and battery leads, headlight assemblies but these are “knackered”. Removed the bonnet and engine bay stays. Windscreen washer pump and reservoir. Coolant hoses and radiator. Sent off the V5 documents to declare it’s mine. | |
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03/10/2002
3 hrs |
Not much progress today. Removed the Air flow meter and loosened all the bolts on the lower front grill and cross member. The rest of the time was spent cleaning the spare wheel and reading about engine removal. Sent off the V890 SORN declaration | |
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04/10/2002 3 hrs
XJ6 Dismantle
|
It seems that I should have depressurised
the fuel system before removing the battery. However I’m too far down the
dismantle route to go back and there is hardly any fuel in the car anyway.
Drained the fuel tanks and got about 1 .5 gallons out. Stripped the boot of
fuel pump, fuel filter and associated pipes. Radio antenna, lighting relays,
and ECU. Removed rear light assemblies. The latter are not needed but the
bulbs could be useful. |
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05/10/2002 8 hrs
XJ6 Dismantle
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Another bitty day. I
seem to have worked hard all day without much to show for it. The engine bay
is looking clearer. The engine oil is drained and most of the leads and
pipes have been disconnected. The oil cooler has been removed and the front
cross bracket it was attached to has also been removed. It is not strictly
necessary to remove the font bumper to remove the engine, but it looks a
though that without it, it will make the job easier. However, removing the
font bumper is proving stubborn. All the parts removed are being placed in
plastic storage bins according to their function i.e. fuel, cooling,
electric components etc. |
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07/10/2002
3 Hrs
XJ6 Dismantle |
Jacked the car up at
the front to examine the removal of the exhaust down pipe, the 3 bolts
holding it on are well rusted in. spayed then with WD 40 and left then to
soak. Still unable to shift then or the manifold to down pipe bolts.
Removed the front bumper. There is nothing to impede moving the engine
forward on removal and hopefully I have reduced the angle needed to get it
out. Devised a strategy for tomorrow to get the exhaust down pipe off.
Heat the manifold gently to see if it helps loosen the bolts and once free
cut the down pipe off after the joint and then remove the bolts on the
bench. Whilst jacked up, I noticed the N/S front brake is seized on. |
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08/10/2002 3 hrs
XJ6 Dismantle
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It wasn’t necessary to
heat the manifold. WD40 and persuasion with an extendable wheel nut bar,
fitted to two, ½ “ drive extension bars, and 9/16”AF socket, gave sufficient
reach and space from under the car to remove 3 of the flange nuts easily.
The fourth was impossible to shift because the dipstick and the manifold
were in the way and there was no room to use extension bars in the engine
bay. Put plan 2 in to action: Unbolt the manifold from the engine and drop
it down. This came off surprisingly easy and once down, gave sufficient
room to saw off the intermediate pipe. In the confined space under the car
with a mini hacksaw I had got to the last ¼ of cutting the pipe when the
blade jammed. It was a question of tying up the manifold to keep the saw
cut open. Just ⅛” to go when I notice the pipe was loose. Untying the
manifold and giving it a pull, the pipes separated. So was all the sawing
unnecessary? Probably not, I think it is what loosened the pipe. Now I can
separate the items in the comfort of the garage. |
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09/10/2002 8 hrs
XJ6 Dismantle
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The intention today was to remove the prop shaft, It took a little while to work out how best to tackle it
“Mr Haynes” to the rescue – well sort of.
Jacked up the rear of the car and removed the centre section of the exhaust
pipe and the two rear primary silencer boxes then undid the rear flange,
followed by the centre bearing plate. Jacked up the front of the car to get
more room under the car it is now on 4 axle stands. I took some time to
remove the rear engine mounting but it eventually came off. I had noticed
a broken speedo cable in the jack bag. I was suspicious that the mile meter
was the same as the MOT certificate of a year ago but I had not noticed that
the speedo was not working. When I disconnected the speedo drive there was
no inner cable. So the speedo is or was disconnected. Not important, but
just kicking myself for not noticing it when I test-drove the car. I made
another nasty discovery, The n/s rear wheel is held on with a nail instead
of a split pin. It’s a good job I’m taking this to pieces. God knows what
the rest of the vehicle is really like. The prop shaft to automatic
transmission flange is proving difficult to remove. A job for tomorrow. |
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10/10/2002 2 ½ hrs
XJ6 Dismantle
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Only a little progress
today. I managed to get just a couple of bolts out of the prop shaft
flange. One came out he conventional way the other was partially sawn
through with a hacksaw and this freed it up enough to complete the job with
a spanner. The other two bolts are rounded off and will require surgery. I
hit in the idea of using a cutting disc fitted to the Dremel this worked
well until the Dremel decided to stop working. I examined it using a
multimeter but could find nothing wrong. Put it back together and it worked.
Maybe it has some kind of safety cut out. Anyway, try again tomorrow. |
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11/10/2002 ½ hr |
Just got started on cutting the remaining
prop shaft bolts when the Dremel gave up the ghost completely. I replaced
the Dremel with a chord less one. But it needed charging overnight. |
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210/2002 7 hrs
XJ6 Dismantle Engine Removal
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The New Dremel cut through the bolts sufficiently for
me to break one and loosen the other. Once the prop shaft was off it was an
easy matter to disconnect the power steering lines at the steering rack and
the gear selector cable from the Automatic Transmission. I anticipated the
engine mounting bolts would be stubborn but they came undone, surprisingly,
easily. I then tied up all loose leads and pipes so that they wouldn’t
obstruct the engine on removal then connected up the engine hoist. Removed
the engine mount bolts completely. Greg came over and with him providing
the muscle power to move the hoist while I guided the engine. We removed
the jack that was supporting the back of the automatic transmission. Pumped
up the hoist and the engine was free. We carefully guided the engine out of
the chassis and rested it on a pallet. This was a major goal achieved. I
was extremely lucky with the weather, it was raining before 9:00 a.m. but
after that it was fine and dry all day. Lets hope tomorrow is the same I’m
off to Thruxton in the Westfield for the Thames Valley monthly meeting. |
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14/10/2002
2 hrs
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Yesterday the weather was appalling and
today wasn’t much better. However it was dry at 3:00 pm so I just did a
couple of hours removing the wing mirrors and preparing to remove the
instrument panel. Removed the clock and the sub panel switches for fuel tank
change over, heated rear windscreen, and heater fan switches. Also removed
several interior trim panels and the rear view mirror. Only the clock and
one of the heater fan switches are required, but the rest comes out with
them. |
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16/10/2002
4 hrs
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The weather was somewhat improved today but
still cloudy and dull and not very warm. I got on fairly well. I removed
the steering wheel and the upper steering column and ignition switch /
steering lock. Also the lower sub panel including the radio and heater
switches. Continued and finally removed the dashboard complete with
instruments. As I suspected the Speedo cable has no inner drive. Not a
problem I just feel a chump for not noticing it, when I drove the car. In
my defence I only drove it up and down the drive at very slow speed. Removed
the wiring loom from the gear selector tunnel and undid the gear selector
All this work involved removing quite a bit of the interior trim. |
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17/10/2002 2.5 hrs
XJ6 Dismantle |
A bright sunny afternoon but a bit on the cool side. Not much to show for my efforts today undid lots of bolts trying get the heater and a heater blower out but it seems I can’t find the right one that is still holding them in. Just the upper steering column bracket to show for my pains. Hopefully lots of things will come out all at once tomorrow ,as a result of my efforts. |
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19/10/02 4 hrs
XJ6 Dismantle
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I returned to the removal of the heater
blowers. Using a deep reach socket I removed the upper mounting bolt, but
the blower was still stuck. I decided to remove the LH blower motor to see
if it was any easier, and ended up with the same problem, stuck at the top.
Eventually applying BF & I, it came off, the air flap at the top was
catching on the top of the scuttle. In the process I broke a couple of nylon
pins but these can be easily replaced. Using the same technique I removed
the RH blower motor. Freed up lots of the wiring loom. Determined that I
would need to remove the wiring to the doors (Electric windows motors and
speaker wiring) before I can remove the loom. Will do this later. Removed
the wiper motor and the drive cable. Can’t remove the wiper wheel boxes.
Left then to soak in WD40 to loosen the rust. Removed much of the engine
compartment wiring loom, fuses and relays. |
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20/10/02 3 hrs
XJ6 Dismantle
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It’s raining as predicted. So I prepared the engine
and automatic transmission for separation. Drained the transmission fluid
by removing the oil pan, complete with dipstick. Removed the oil cooler
pipes, the transmission breather pipe and the starter motor. As a trial I
removed one of the torque converter bolts it came out easily. Hopefully the
others will do the same. Removed the viscous coupling and the cooling fan
assembly. I will consider fitting and electric fan when it comes to
re-assembly |
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21/10.02 1.5 hrs
XJ6 Dismantle
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Now the ATF is drained, I refitted the automatic transmission oil pan, loosely, and removed the dipstick by unscrewing the union. Removed the remaining Torque converter retaining bolts. Supporting the Automatic transmission on a trolley jack removed the bolts holding it to the engine.
Carefully separated the engine and
transmission. The Haynes manual warns about keeping the torque converter
pressed towards the transmission to prevent it becoming disengaged from the
oil pump tangs. Almost impossible to achieve with an engine and
transmission which has been together for some time. But with care it is
possible to re-engage it once the engine is separated from the transmission,
make sure the Torque converter has not completely come off the shaft and by
turning the torque converter and gently pressing it towards the
transmission, it works its way up the shaft and re-engages on the tangs. |
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22/10/02
2 hrs
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Today was a bitty day – removed the power steering pump from the engine. Then played with the engine stand mount, to work out where to attach it to the engine and what distance pieces need to be made. I must admit to having some concern about the engine stand with the whole weight of the engine being taken by 4 x 9/16 bolts screwed in to the transmission mounting points. |
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24/10/02
2 hrs
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The weather was much better today cool but
bright sunshine. The wheels came off the wagon today, ready to remove
the suspension. Jacked the car up on to axle stands under the body jacking
points to leave the suspension free. I’m amazed at how little holds
the rear suspension in place and how low it hangs on the trailing arms.
Removed the rear exhaust silencers, tail pipe and intermediate pipes to
facilitate suspension removal. Sprayed all the relevant bolts with WD40 and
left to soak overnight, whilst I read the relevant bits in the Haynes
manual. |
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25/10/02 1.5 hrs
XJ6 Dismantle
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Achieved very little today. Further exploration and a
gradual realisation of why the rear suspension hangs so low. The rubber
mounts securing the sub frame to the body are broken. It would have been
positively dangerous to drive the car in this condition. (I’ve since
discovered that this is a common fault with XJ6 and XJS Jaguars). Testing
for the right size spanner I managed to break one of the front brake lines
which had almost rotted through. It’s an aid to draining the system. I Just
managed to remove the off side track rod end from the upright before it
started to rain. Hopefully, if the weather is good, the front and back
suspension will come off tomorrow. |
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26/10/02 7.5 hrs
XJ6 Dismantle
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Apart from a strong blustery wind it was
fine and dry today. Removed the rear section of the handbrake cable,
disconnected front and rear the brake lines. Undid the rear suspension
trailing arms and with the aid of a puller dropped them off their mounting
post. Lowered the rear suspension assembly to the ground. With the rear
suspension off he car and in the garage I turned my attention to the front
suspension. Removed the anti roll bar. Disconnected the steering column
pinch bolt and withdrew the column. Undid the bolts on the suspension
assembly rear rubber mounts and the upper shock absorber mounts. Undid the
front mounting bolts and drove out the bolts. Lowered the front suspension
assembly to the ground and stored it in the garage. These two assemblies
take up a lot of space in the garage. The next job is to dismantle them and
discard the unwanted pieces. |
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28/10/02 1.5 hrs XJ6 Dismantle |
I only had a short time in which to do anything this
afternoon. I decided to finish removing the gear selector. I had undone all
the interior fixings previously so there was only a shield and a grommet,
where the cable passed though the tunnel to the automatic transmission, held
in by four screws. Simple! Except that the screws wouldn’t budge, and the
front passenger seat got in the way. I removed the front seat, eventually,
having had to drill the head off one of the seat mounting bolts. The cut the
heads off the screws holding the shield and finally removed the selector. |
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Total Hours this month = 74½ hrs |
Total hours to date = 91½ hrs. |
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