[xk8] Replacing a 1996 XK8 engine with one from a 2002 car

XK8
1

All,

I wonder if anyone can help. I good friend of mine is trying to replace
the engine in a 1996 XK8 (which has failed due to the old Nikasil
problem) with an engine salvaged from a 2002 car. Both are UK engines.

The engines appear to be nearly identical, but the 2002 engine clearly
has different Variable Valve timing solenoids, so it is not exactly a
straight swap. As I understand it the variable valve timing was improved
in 1998?

Does anyone have any advice on how to carry out this swap? I am sure we
are not the first to try!

Barry

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

2

In reply to a message from Barry Graham sent Sat 7 Jun 2008:

Yep, VVT changed in 1998 (MY99) (two levels before, continuous
after). There are also some other difefrences between the AJ26 and
AJ27 engines (esp. pistons and throttle body)

Main problem will be IMHO the ECM: this one is calibrated for the
AJ26 or AJ27 engine and checks the car VIN.

So the old ECM will certainly not work with the new engine, and the
new ECM will not accept to work as the car VIN is different.

Certainly solvable for a good mechanic/electronician (on Roadfly
there was a south African guy who managed to put into his XK8 a
Ford Lincoln LS engine, which is even more different, so…), but
it will require some work.

Brdgs,

TC–
Charles_3000
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

3

In reply to a message from Barry Graham sent Sat 7 Jun 2008:

I wrote this for another forum a few months ago, and never posted
it:

Rock Meathammer was asking about the interchangeability of Jaguar
V8 engines, as he may have to replace the original unit in his '98
XJ8. This question has been discussed in other forums, so I thought
it best to post the details in a way to make it easy for research.

Any amendments from those who catch an omission are welcome! I did
not endeavor to list every detail, please help with the sketchy
ones if you can. I wrote this from memory, please excuse any
relevant omissions.

This information applies to normally aspirated cars only, U.S.
market cars specifically. Perhaps an S/C engine expert could post a
new thread for those engines as well. We have no 3.2 V8 equipped
cars in the States to my knowledge, so our overseas colleagues may
wish to do the same.

Basic: 1998 XJ8, and 1997-1998 XK8, all are fitted with the AJ26
engine.

Easy identifiers:
Vacuum dashpot on throttle body for cruise control
V V T solenoids mounted on front face of timing cover.

1999 through 2003 XJ8 and XK8 are fitted with the AJ27 engine.

Easy identifiers:
No vacuum dashpot on throttle body (cruise is electronically
controlled)
V V T solenoids protrude up through cam covers at front
Timing cover has blanking plates instead of front mounted solenoids

You can swap any '98 (and '97) AJ26 directly in place of the
original. Change over only whatever accessories you need from the
original unit. Upgrade water pump, thermostat and timing components
at your discretion ( highly recommended).

You can swap any '99 through 2003 AJ27 directly in place of the
original. Most sources will show a change point at 2001: That
signifies the end of the Nikasil lined engine bores, and
commencement of dry cylinder liners. The exact change was at engine
number 00 08 18 XXXX. The number is hard to find, stamped on a boss
at the base of the thermostat housing tower, driver’s side. On 2001
and later engines, the number is stamped on a rib of the engine
block, driver’s side, above the steering rack…again, not very
easy to locate or read.

The most desirable option is to fit an engine after # 01 08 13
0000. This was the commencement, as best as has been documented to
date [credit A. Voss, Belgium from a PUBLIC post], of the multi row
timing chains and third generation tensioners. This engine fitted
to a '99, '00, or early '01 car requires no adaptation and is a
major reliability upgrade. So there’s even more reason to buy the
latest engine you can find and afford.

Note: the V.I.N. number, model year, or built date of the vehicle
are not reliable for identifying these change points. You must
refer to the engine number. The engine number is itself a date and
time stamp: 97 08 17 1130 means 1997 August 17th 11:30 A.M. That
would be an XK8 block in the U.S., we didn’t have XJ’s yet.

…Continued on next post–
The original message included these comments:

All,
I wonder if anyone can help. I good friend of mine is trying to replace
the engine in a 1996 XK8 (which has failed due to the old Nikasil
problem) with an engine salvaged from a 2002 car. Both are UK engines.
Does anyone have any advice on how to carry out this swap? I am sure we
are not the first to try!
Barry

–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

4

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

Continued from previous post:

That would be an XK8 block in the U.S., we didn’t have XJ’s yet.
00 06 04 1720 was screwed together on June 4th of 2000: even
though it was installed in a 2001 model year car, it still had
Nikasil bores.

Forget about the earlier 4.0 six cylinder, and the later 4.2 V8.
Just like everything else in life, it can be done: just like a
supermodel, it won’t be worth the effort and expense.

So what if you want to swap out a '97-'98 AJ26 engine with a later
AJ27 engine? You can use the later long block, after you remove the
following:

Flex plate (flywheel) [credit Bob Gaus, Texas, U.S.A.]
Cam covers
Timing cover
V V T soleoids, solenoid brackets (bush carriers)
V V T units
Intake manifold with injectors
Throttle body
Engine wiring harness
Crank position sensor
Left (B bank) cam position sensor
Ignition coils

The major upgrade from 1998 AJ26 to 1999 and later AJ27 was the
change in V V T operation. The early units were on/ off controlled,
the later were continuously variable units as controlled by the
ECU. This change necessitated a higher output oil pump, addition of
an oil temperature sensor, and the addition of a second cam sensor
to monitor right (A) bank cam position. Oil pressure and viscousity
is critical for proper C (constant) V V T operation.

With the components listed above removed from the AJ27, you can now
transfer the AJ26 bits onto the long block. The right (A) bank cam
position stays put as a blanking plug for the hole in the cylinder
head, but will have no point of connection to the harness in
the '98 engine bay. Similarly, the oil temperature switch (just
above the oil pressure switch, right front bottom corner of engine)
will have no harness connector attachment. Leave it in as a
blanking plug.

Exhaust manifolds, alternator, power steering pump, A/C compressor
and water pump are all the same and interchangable: if you don’t
put a new waterpump and thermostat on now, you’re cutting corners
in the wrong places. Most would agree that this is also the time to
fit new primary and secondary timing chains, tensioners, tensioner
blades and guide rails. If your budget is broken and the original
parts are not, as an absolute minimum you should install the third
generation aluminum bodied secondary timing chain tensioners.
Broken plastic ones might well be the reason you are doing this job
in the first place. Once is enough!

You will need the following new parts in addition:

Continued on next post…–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

5

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

continued from previous post:

You will need the following new parts in addition:

(2) V V T bush carrier seals
(2) V V T solenoid O rings
(1) each upper and lower timing cover gaskets
(1) front timing cover seal (unless you need gas money)
(1) O ring for crankshaft damper (harmonic balancer)
(8) intake manifold seals
(1) throttle body gasket, if TB was removed from intake
(1) each left and right cam cover gaskets
(4) spark plug well (figure eight) seals
(1) O ring seal, base of thermostat tower
(2) O ring seals, water pipe outlet
(1) coolant bypass hose
(1) oil pan gasket (best pulling it off to clean out)
(1) oil pickup pipe O ring seal (replace after removal for cleaning
of pickup screen)
(1) oil filter

This is not a list of ‘‘let’s get everything while we’re in there’’.
This is a list of ‘‘shoulda done it when we had the chance’’ items.

You’ll need special tools for locking the flyweel in place for cam
timing, as well as the camshaft lockdown bar and exhaust sprocket
spanner wrench: since you had to swap over the V V T’s, you have to
time the cams whether you renew the timing components or not.

I think that’s about it, so you can see that it requires less time
and expense to replace '97-'98 with '97-'98.

As far as installing an AJ26 to replace a later AJ27 engine, there
are some additional difficulties. Stripped to the bare long block,
you would then have to change the structural sump (to acquire oil
temperature monitoring) and the RH cylinder head (for fitment of
the second cam position sensor). That’s it, as far as I know.********************************************************************

Hopefully you will find this information useful. I’m not a prima
donna, but I don’t like arguing minutia. If you have factual and
substantive information to correct or add, please do so.

If anyone sees fit to reprint all or part of this entry, I think it
would be appropriate and honorable to give me proper accreditation.
I afford that respect to those colleauges cited, and expect the
same in fairness. Best wishes,

Andrew Bernstein
British Auto Care
Powell, Ohio

–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

6

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

Andrew,

You are truly encylopedic on this car and AJV8. If you don’t mind
I’d like to copy this extract for my library. I’ll put your name on
it as author and will include it if I ever use it in an answer
where you haven’t appeared first.

In the past I’ve published info about the engine vin date codes not
knowing who to credit because it floats regularly around the chat
sites. I knew about the changes in VVT, nikasil, etc., but vague on
the dates and changeovers since I only do this as an enthusiast and
not a business.

This writeup is brilliant to the last detail.–
Steve Hannes – 02 XK8 - 96 VDP - 02 X-Type
Phoenix, AZ, United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

7

In reply to a message from skhannes sent Sat 7 Jun 2008:

Greetings Steve,

Thanks very much for the kind words! I learn every day from reading
the contributions of others, and from listening to the cars I’m
talking to. What we don’t know CAN hurt us as far as Jag life, and
it’s a never-ending series of lessons.

I tacked on the bit about accreditation as a result of seeing arm
chair mechanics posing as experts. These forums are a great network
of information when we all share what we’ve got, but there has to
be some distinction between firsthand experience and
authoritatively written regurgitation. People who tune in for
advice can too easily be led down blind alleys. Sometimes they are
under the impression they are corresponding with a mechanic or a
hands-on owner, not a high tech librarian…and that’s fine, so
long as it’s made clear. My criticism is not pointed at anyone in
this particular forum: but if you spend as much time surfing around
as I do, you know what I’m talking about.

When I saw photos and posts of mine being lifted and used by others
without a credit, I thought the line was being crossed. So when
somebody needs to know how to replace plugs on their X Type, I tell
them how I did it and cite the procedure on your webpage. Everybody
who takes the time to share their firsthand knowledge deserves the
same credit, and the same praise. Thank you for yours.

Andrew Bernstein
British Auto Care–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

8

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

Andrew. I guess you remember my story of the guy who swapped the
AJ27 engine to his AJ26 car and did not change the Torque Converter
Drive Plate (different number of reluctor segments) and neglected
to tell me after I spent HOURS testing and swapping sensors and
checking the timing of EVERYTHING. Great write-up!!! I don’t think
you missed a thing. bob gauff Texas USA–
The original message included these comments:

So what if you want to swap out a '97-'98 AJ26 engine with a later
AJ27 engine? You can use the later long block, after you remove the
following:
Flex plate (flywheel) [credit Bob Gaus, Texas, U.S.A.]

–
Owning and Repairing Jaguars Since the Early 70’s
Decatur, TX., United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

9

In reply to a message from motorcarman sent Sat 7 Jun 2008:

Very good post indeed!

Another thing that is different between the AJ26 and AJ27 is the
cam shaft position, as the AJ26 has 1 vane ring, and the AJ27 has 4
vane ring. The camshaft is slightly different, but I am not sure if
you can reuse that from he AJ27, if you do, then you need to put
the AJ26 camshaft positioning ring (1 vane).

Also the knock sensors seem to be different, so better to reuse the
AJ26 one too.

Andre.–
avos
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

10

In reply to a message from motorcarman sent Sat 7 Jun 2008:

Greetings Bob,

Yes, that was one of your many gems that I made careful note of
when I read it. I am sure I would have led myself into the same
trap by now, had you not alerted everyone first. I just wish my
memory was a little better, so I hadn’t butchered the spelling of
your name…sorry about that, chief!

By the way Bob, there is a guy right now on Jaguar Forums who is
asking for info about installing an S Type engine in an XJ8. I
mentioned your name and the fact that you were the best source to
talk to. If you have a moment, please drop him a note.

Andre, thanks as always for your devotion to facts. I will research
the issues you raised and amend as necessary. Best wishes,

Andrew Bernstein
British Auto Care–
The original message included these comments:

Andrew. I guess you remember my story of the guy who swapped the
AJ27 engine to his AJ26 car and did not change the Torque Converter
you missed a thing. bob gauff Texas USA

–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

11

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

Learned a lot here, thanks!

:slight_smile:

TC–
Charles_3000
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

12

In reply to a message from avos sent Sat 7 Jun 2008:

And the AJ28 (S-Type 4.0) has 5 ‘vane-ring’ on the intake cams but
uses the same VVT as the AJ27. I think the CMPS are different
(harness connectors) also. I sent a guy in NV a used S-Type head
for a 1999 XJ8 and he swapped intake cams, reset the tappet lash
and said it worked just fine. bob gauff–
The original message included these comments:

Another thing that is different between the AJ26 and AJ27 is the
cam shaft position, as the AJ26 has 1 vane ring, and the AJ27 has 4
vane ring. The camshaft is slightly different, but I am not sure if
you can reuse that from he AJ27, if you do, then you need to put
the AJ26 camshaft positioning ring (1 vane).

–
Owning and Repairing Jaguars Since the Early 70’s
Decatur, TX., United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

13

In reply to a message from Barry Graham sent Sat 7 Jun 2008:

I’m not in need of, or looking forward to the job, but THANKS to
all the knowledgeable that contributed to this thread. Great info.
Rich–
rich neary
perrineville/new jersey, United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

14

All,

Well I made my original post but was then too busy to check back for a
couple of days, so I have just read all the replies…

All I can say is WOW thanks guys! Andrew thank you for taking the time
to spell it out in such detail, I’ll let you all know how the guys gets on!

Barry

rich neary wrote:

In reply to a message from Barry Graham sent Sat 7 Jun 2008:

I’m not in need of, or looking forward to the job, but THANKS to
all the knowledgeable that contributed to this thread. Great info.
Rich

rich neary
perrineville/new jersey, United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

15

In reply to a message from Barry Graham sent Tue 10 Jun 2008:

Greetings Barry,

Your guys now have enough ammo to be dangerous, glad to have
helped. Make sure they read the addendums posted by Bob
(motorcarman) and Andre (avos). Those two always teach me something
new, which helps to make all of this worthwhile. Thanks also to
Steve, Charles and Rich for their kind words.–
The original message included these comments:

Well I made my original post but was then too busy to check back for a
couple of days, so I have just read all the replies…
All I can say is WOW thanks guys! Andrew thank you for taking the time
to spell it out in such detail, I’ll let you all know how the guys gets on!
Barry

–
JagtechOhio
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

16

In reply to a message from JagtechOhio sent Sat 7 Jun 2008:

test to find forum location…–
Thanks, Willy Q.
Miami, FL, United States
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
–Support Jag-lovers - Donate at http://www.jag-lovers.org/donate04.php –

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

17

I just purchased a 1997 XK8 convertible with egr needs engine replaced. I have found an engine from a 1997 non egr and an engine from a 1998. mine has vin7-7th the other 1997 has vin 7 -7th. the 1998 has vin2-7th. Will either or both work in my car and if so what’s involved?
Thanks , Jay111