I’ve been working on fitting up the intercooler. I got a 25x11x3 core with same side I/O which are 2.5” and I am reducing them directly off the IC to 2” and running all 2” tubes. I also had the Map sensor bung welded into the race pipe on the intake. I am going to change how the tube is routed between the intake and IC so that I have more room in front of the engine and don’t have to modify the hood support at all.
I moved the radiator toward the engine 1” to make more room for this intercooler. Very minimal trimming to grille and surround.
How I have it for now:
This is more or less what I’m changing it to, but with a 45° bend in the vertical tube.
Because I could not find a (reasonably priced) 97+ manual pedal assembly I had to make a clutch master support bracket. No big deal.
Here’s what I ended up with to mount the VW throttle pedal. Basically just an adapter to go to the stock XJ throttle pedal bolts.
Finalizing the coolant system. I kept the stock oil cooler, capped the one 5/8” tube that comes out by the thermostat. This tube is for a mustang 2.3 turbo, but in hindsight I should have just made this out of a piece of steel tube and painted it. I ended up using a black pipe elbow at the back end of it anyway and tapping a 5/16” barb fitting into it to connect in that 5/16” hose fitting that comes off the back of the head. The top radiator hose is a 2001 TDI lower radiator hose cut down a bit, it is 1.25” on both ends.
This should be a good spot for the frost heater
A little more bendy than I wanted but it works out pretty well. Napa #8698 with about 4” cut off the radiator end and maybe 3” off the thermostat end. I used one of those stainless coils inside the thermostat end to help the hose keep its shape. The thermostat end is 1.25” the radiator end is 1.5”
Time for a long overdue update! I made a hard push to the end and have been driving it now for 2 weeks. A stage 1 tune, stock injectors, stock turbo, and it was incredibly capable. Really not lacking in any area whatsoever. Of course knowing it could be better I upgraded the injectors to ones I had MecEvo rebuild with his 764 nozzles. I am working with Malone to get the tune dialed in but I think I also have some mechanical issues to worth through, namely timing and fuel lines. I won’t jump ahead to the end with pictures you’ll have to wait for that so my next post will be picking up where I left off!
My Jeep Club's local chapter is having their annual "official" event at Rausch Creek in Tremont, PA the end of June - if you're interested, PM me and I'll send you the details if you think you and the truck will be up for some trail action...