Project Dark Knight Rising

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Tapps33

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Today was another good day! Didn't get as far as I wanted to, but I made some good progress, and now it'll all have to go back together tomorrow.

Today's accomplishments include: Rolling the frame out from under the body, disconnecting the final bits holding the engine in the frame and pulling the engine. I was then able to get the right bank header swapped over, the alternator installed, some more of the fuel lines, the right engine mount bracket - I have new engine mounts I need to install on the brackets....and a few other random tasks.

Things to note:
1. Both front and rear drive shafts have to be disconnected at the transfer case (at least) in order to get clear of the transmission.
2. The starter is different between the Jag and LR engines.
3. The power steering pumps are different too...but I totally cheated and looked up their respective part numbers.
4. The fuel supply hard lines are similar but not the same between the Jag and LR. Aka, I had to pull my hard lines off and swap them with the existing ones from the LR4. It was no biggie as I had forgotten to put the stupid little foam boot things on the HP Fuel pumps anyway.
5. Discovered that when I installed the right bank heads, the exhaust manifold heat shield got tucked under the head and I pinched it when torquing the head bolts....I can't prove it yet, but this could be why I couldn't pull a coolant system vacuum....maybe....although I'm still fairly convinced the block is cracked on the left hand side somewhere.
6. the engine and transmission together weight less than 1 ton...or at least the 1 ton engine lift was able to handle it.
7. the engine mount brackets are different between the Jag and LR....it looks like the LR's mounts are slightly farther back than the jag's, which would make sense given the fact that transfer case is hanging off the back of the transmission shining the weight a little further back.

Finally got some pictures....probably gonna make 2 posts out pf the pics:

Frame's out:



IMG_0202.jpeg


Engine's Out!!!!


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IMG_0223.jpeg


Finally starting to look like a finished engine...



IMG_0222.jpeg


IMG_0221.jpeg
 

Tapps33

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Ok, so a couple other....OOPS! moments.

First off, swapping the PCV valves in an NA engine is pretty darn easy.....not as much with an SC model. I went ahead and picked up a set of PCV kits from Atlantic British when I ordered my hose kit...well, just because. Anyway, I didn't think about it much and went ahead and put the supercharger on.....which was right in the way of the PCV valves. Thankfully, because the engine was not in the engine bay I could easily get to the outside, and found that if I "screwed the caps on I could get them to track into place. I accomplished this from the outside of the engine, a feat I don't think I would have been able to do if the engine were in the engine bay. Which means, if you want to do PCV valves on an SC engine, you gotta pull the whole supercharger!!!! UGH!

I also wanted to show y'all the aluminum rear crossover tube. I'm not gonna lie, I used a little bit of rtv with the o-rings to help with longevity. Of course, there's a chance that "pinning" them in place wont allow them to shrink/shift with vibration and they'll leak sooner, but I figured it was worth a shot in hopes the aluminum pip far outlives the plastic one.

I also included a shot of the Symposer block off plate...just because.

PCV valves:

IMG_0199.jpeg


Rear crossover pipe:


IMG_0196.jpeg


Symposer block off plate: (for reference it's on the right hand side, rear of the supercharger)


IMG_0201.jpeg
 

djkaosone

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Love the metal rear crossover pipe. Where can I get one? Did you ever change out the fuel flange? If not, it's a good time to do it.
 

Tapps33

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Love the metal rear crossover pipe. Where can I get one? Did you ever change out the fuel flange? If not, it's a good time to do it.

Not gonna lie, I totally picked mine up off eBay. I tried to find what I thought was a reputable company, but honestly, it's a shot in the dark. Here's the company I used:


Hopefully the aluminum flanges hold better than the plastic ones. My guess is that there's probably only one company actually making these and everyone is reselling them as their own. I could be wrong though.
 

Tapps33

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Not too much to report today. Most of the day I spent packing the final odds and ends in the house. The Uhaul arrives Monday. Tomorrow is the big push to get the new engine into the frame and then the body back on.

Yesterday I kept buttoning up odds and ends, got the power steering pump on, AC compressor, left hand exhaust manifold and engine mount brackets. Installed the serpentine belt, alternator and spa car pulley.

In the "others" category, I discovered the supercharger belt is significantly wider than the NA fan belt and it requires a new SC fan pulley. (SMH). I also needed to re-route the start solenoid power wire and it snapped off when trying to unscrew the nut....I'm not saying a foul word left my mouth...but I don't know if I'd be able to deny it either.

In another "issue" the Jag engine's center pulley bracket is different than the LR's. The only thing I can figure is that they run electric fans in the Jags because there was no fan pulley bracket bearing, there was just a belt spacer pulley....as in there was no where to screw a fan onto. Hence, they must run electric fans. Thankfully, I had the bracket from the NA engine that was already in the car. I then just transplanted the spring tensioner pulley from the Jag bracket....of course now I have to wait on a new fan pulley....sigh....It's always something!

I separated the old transmission from the engine, and tomorrow morning I'm going to swap the wiring harness, mechatronic and metal pan over. FYI, when I did the head job, I rebuild the mechatronic with the zip kit, and updated to the separate filter and metal pan. No sense in wasting them, I'm gonna re-use them.

I'll update tomorrow, hopefully with pictures, and hopefully victorious!!!!
 

Tapps33

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There's nothing like moving while trying to rebuild a car at the same time. (Insert facepalm here!!!).

Thankfully, I've been making some good progress on several fronts. First, I got the engine in the frame, transmission and transfer case all bolted back up. That said, I've made some rookie mistakes. while trying to rush...the smallest of which was snapping a front driveshaft bolt. The biggest of which was having the engine slip out of the hoist sling while pulling it off the engine stand. Thankfully, the good Lord was looking out for me and the only thing broken is the left bank valve cover. I dialed the crankshaft and supercharger and everything else is fine....totally dodged a HUGE bullet with that one! Plus, since the engine is still out of the body, it should only take me 1.5 hours to get the valve cover swapped...and I have like 3 spares floating around, so that's good.

The moral of the story is, "Don't rush...take your time...and for the love of God, don't cram an engine rebuild into a move!"

With a little perseverance though....


IMG_0243.jpeg


Today's goals:

Get the valve cover swapped, finish connecting all the little wires and hoses, drop the body back, and re-connect and bleed the brake lines!....then possibly get it on the car trailer, but I think that's going to be a Wednesday thing.
 

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Tapps33

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It's been a long couple of days....

The Uhaul is almost full...except for my tools and random car parts, and the rest of the family is already gone.

While I don't know if it'll run yet, today....today I was victorious!


IMG_0250.jpeg


All but 2 of the body bolts are in. Tomorrow I need to run around and reconnect several of the electrical connectors so I can turn the ignition on and shift out of park so I can get it on the Uhaul car trailer. I also need to reconnect the brake lines, bleed the brakes, reconnect the shift linkage, and (fingers crossed) gain the SC PCM into the security chain so it'll allow the ignition to come on. I may have to cheat and re-connect the NA computer if it looks like I won't be able to easily get it gained into the system. (I'll try and record the steps as this part of the process was one of the steps no one knows how to do...or at least no one was willing to share how they did it.)


On a separate note, I was really worried about how to mount the intercooler to the front....but seriously, the radiator has mounts and holes already there. It's like LR actually did something cool and uses the exact same radiator for both vehicles!!!! So, a few screws later, it was on and ready to connect.

Here's the new stack:

IMG_0248.jpeg


Full disclosure to the crew, once I get this to DC, I'm actually going to have to store it a few hours away and will only be able to work on it sporadically on the weekends. That said, there isn't too much left to do, and I WANT MY CAR!!!!....running. Just a few parts left to track down.... and A LOT of plastic pieces to put back on.
 

16FujiDisco

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I hope you know that a lot of folks are proud of you and also thankful for all of your efforts in documenting this; we’ll be referencing this thread for years to come, not just for the swap, but for pictures of things we can’t see without removing something ourselves, and methods on how to get to something.
 

f1racer328

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Awesome dude!

… hope I don’t have to eat my own words here but if my V8 ever craps out, I’d love to throw a supercharger on it after a rebuild since it’s not my daily anymore.
 

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