Diesel VM Powered XJ
 

So today I started stripping down the Diesel engine in my XJ - the PO had a turbo issue and paid £250 for a new turbo and £750 to have it fitted, very badly!


When I purchased the jeep I spotted exhaust gasses from the back on the engine, easy fix I thought - not so.




As she stands, awaiting MOT work (Annual inspection)
Attachment 311016


Front anti roll bar needed some attention too!


Attachment 311017

Looks tidy enough - just don't get too close
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Drop pipe not really connected, studs missing and bolts loose
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Turbo intake pipe not fitted correctly
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EGR plate not fitted correctly
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Not so well sealed EGR pipe
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Making space
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The engine is adapted from marine use, and has 4 separate head's and head gaskets. To cool this there is a water manifold, something I have never seen on a car before. It was also removed to make space.

Attachment 311015


I spent a bit more time today getting the inlet manifold off, which involved a file and removing a couple of studs. Tomorrow I shall get the turbo off and away for welding!

Following along as one day I am going to import one of these to the USA.

Subbed just because I find this interesting.

Aha here it is! Subbed

Any questions, feel free to ask. A few people have mentioned importing Diesel XJ's to the States - I should look into importing low mileage LHD models from sunny Spain, how much would someone pay I wonder...


More progress today on the engine.

With the inlet manifold off I was able to slacken the exhaust manifold, but due to the proximity of the steering and clutch for a UK RHD spec XJ you cant actually get the manifold off the studs.
Attachment 311000




#RHDproblems
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So, off come the studs and out it comes, and here we can see the starter motor - what a job to replace that!
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Had to take the downpipe off with it too - no access whatsoever to the nuts attaching it to the turbo. Just enough room to do this.
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Here we can see some problems, 2 studs missing, 2 nuts missing, 1nut loose and no spring washers!
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EGR pipe was cut off and a properly blanked off thanks to a bolt and welder
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Next thing is to clean up the engine bay, and the electrics and put it all back together - getting there slowly.

Ordered some new Brass nuts and Spring washers for the engine, and decided to take on the front axle today.

UJ was knackered, and typically once I had it all removed could I find the replacement? :(

Attachment 310972

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New Pads needed I think...
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Anyone know the part number for these little plastic collars?
Attachment 310975

Few more bits ordered and i'll spend some more time on it next weekend.

yeah I ordered some of those a while ago. Let me look for a number

Looking good! Cleaning the engine bay is always rewarding!

Cheers!

Hmm - it would seem getting the part in the UK is not going to happen, wonder how much international shipping will be!

Just need some gunk and I will take on the engine bay - that will be next weekends task!

Some progress has been made - Scottish weather has been holding me back a little, but lots of new parts have arrived, shall get some pictures next time I am home.

Turbo has some new studs, brass spring washers and nuts, and is looking a lot more attached! One front UJ has been replaced, I think I will do both sides while I am working out it.

Then on to the back end.

A few questions if someone can help,

1. How do I adjust the rear drum brakes? The handbrake has no effect.

2. What is the best way to compress the piston in the front callipers?

3. Is there an easy way of refitting the front shafts without picking up the dirt in the axle tube?

Thanks for any advise!

Chris

For front brakes, take a small, flat piece of 1/4" steel or plywood or sturdy surface, place it over the piston, then use a big C clamp to squeeze it in. Usually presses in nice and easy.

For the axles, I can usually get the short axle in by myself without hitting the tube. Just gotta be careful. For the long side, get a buddy to hold the shaft nice and level while you push it in. When I have the axle shaft out, I like to get a piece of 3/8 or 1/2 vinyl tubing and rig it onto my shop vac. Suck all the sand and dirt out while you have a chance.

Thank you very much! should be nice and easy then.... :sweatdrop:

its neat watching the troubles with working on a rhd cherokee its kinda the same problems we have on our lhd gas models no room on the driver side lol