JeffK

I appreciate the positive and kind comments for my amateur overbuild. Thanks and congrats to you as well :thumbsup:. I was just down your way today looking at a Miata for my wife (a small payment for putting up with me). It was kind of strange looking at a vehicle with a trunk. I've had an XJ so long I forgot what that was like. You know if we ever get finish our MJs we should meet up some where and take the both of our wives to lunch or dinner. I know mine deserves it. My treat. :cheers: Jeff

Cut and solder, in hindsight it would have been easier to have gotten a whole harness. Here's the posts from about a year ago... Sure, I'll bring the beer you get the pizza. :cheers: With the seats and the steering column out of the way it wasn't nearly as bad as I had thought it would be. With a little trial and error I decided to solder the wires directly to the terminal instead of splicing all 25+ connections. Kinda like this: Laid the boxes out side by side and did one wire at a time.

This link covers the conversion and parts-->http://www.olypen.com/craigh/rad.htm, Pretty much covers the parts I picked up, except I'm using a '99 2 row factory radiator. You don't have to convert the system to change out the fan(s). The new style electric fan is a drop in, you just have to change the connector. The Napa FC will fit all years regardless of the cooling system, just double check clearance if you are using a 3 row radiator. Jeff

$10 at Pull a Part.

Bolted on the repainted fan with new grade 8s... Installed... Next to the '99 XJ electric fan...

Small progress, I picked this up Weds. Napa fan clutch for 97-98 ZJ... It's roughly the same size as the one on my '00 XJ, but next to the stock MJ clutch it looks massive. Front... Rear view...

Thanks, but isn't that part of the Wikipedia definition for anal retentive? j/k :cheers: Got my PS hoses in today. I had a small leak at both the pressure and return fittings on the box, and I wanted replace both of them. The pressure line wasn't an issue but the return line was out of stock. So for $10 more I decided I'd put a PS cooler in... Probably worthless, but it is a higher ration ZJ box...at least that's the excuse I gave the wife. Lines run through the old air box hole. There's about a 1/4 inch of clearance between them and the lower radiator hose... Installed and painted (of course). I had to pull the grill to finish pulling the wires for the Hellas, so it wasn't a total waste of time.

appreciate it.

Thanks. It's a new AutoZone lifetime warranty pump. Yeah I know AutoZone :nuts: , but I;ve had good luck with their pumps. The last one I installed on my '92 XJ lasted almost 8 years.

Still have a few lose ends to tie up and a few parts on order, but it's getting there...

Installed the belt and now I'm waiting for the lines to come in... Fresh Radiator... Installed...

Picked up a new 100 amp alternator to replace the stock 61 amp along with a Dayco belt... Installed... Cleaned the PS reservoir and repainted the pump...

Cleaned and painted the AC compressor... Installed with painted the bracket... Also went back with a late model idler pulley...

Thermostat, housing and gasket installed along with the power steering bracket I painted Cast Coat Aluminum. The Housing and water pump I clear coated. Alternator brackets... Overall...

Painted with new water pump installed... Another shot also used a late model heater hose tube... Picked up some goodies at AutoZone...

Little update. Been working on the front of the motor, noticed a glob of RTV where one of the water pump bolts was supposed to be and discovered another PO gift... Much later the broken bolt is removed and the grime washed away... Ready for paint...

I yanked the radiator and remaining hoses tonight. I also flushed the block and heater core. The stock radiator is toast, no big surprise... Water pump and lower radiator hose are both OE and will be replaced. Upgrades will include T-stat and late model electric fan.

Since my old headliner was ruined, I had to start from scratch. I found this guy that "remolded" (his word) the backer boards and then covered them in any color fabric you want. $100 shipped. Fair enough I thought that will save me some time and when I get it I'll just toss it in. While it looked good out of the box, and I followed his directions for installation it now resides at the dump. Poor fitment, misaligned holes blah blah blah. So I posted a WTB in a local forum to find an old factory backer, this is the first $20 backer... My son picked it up for me, and it is even uglier in person. It's unusable without major work and there is a least an inch and a half missing off the bottom edge. I went to the pull a part on the other side of town to pick up some nuts and bolts and scrounge around. Seems they had just gotten an '88 long box in that had been hit in the drivers door. The headliner was in great shape just dirty. So here's the second $20 headliner... I'm going to pick up some fabric and glue this weekend, and hopefully this will be the end of the headliner ordeal.

A little gift from the PO... Ford injectors and fuel rail installed... Also used an HO injector harness to replace the flex conduit... Still need to do the vacuum lines... I'm about 90% done on the lighting and underhood wiring as of now. Still need to redo the cooling system and few more details under the hood to finish up. Then back the the headliner...

97+ Valve cover test fit... The old cover had a small leak at the rear corner. This should take care of all but the last leak at the filter housing and upgrade the PCV system as well... Ford injectors, the old #1 injector was leaking... Taylor engine to firewall ground strap... Installed...

I got in my head I wanted a cone style air filter. Instead of getting my brother in law to fab one up I broke down and ordered one from Rustys. Not exactly as pictured on their wed site... I ordered a lift kit from Rustys a long time ago, and the lift and service were pretty good, but this time they broke it off in me on shipping. $18 :mad:, Whatever, live and learn. Picked up a AFE filter off Ebay for $20 shipped. So I'm into the whole thing for $68. Test fit, not too bad... Checking the injector harness out and replacing a couple of broken connectors... Found another one of those famous Renix duct tape splice/connectors at the back of the harness...

More splices and repairs... Removed and cleaned the intake and throttle body... Took about 2 hours to clean the crudded up throttle body... Accel goodies installed... I love Ebay. 8mm Accel Super Stock wires-$14.99.:thumbsup:

Made a power lead out of welding cable... Running flex tubing... I hid most of the big factory connectors under the box and used friction tape at the joints for a factory look... Diagnostic connectors installed... Got some Accel goodies in...

The diagram shows the most current layout of the PDC. It includes the fuses and relays for my offroad lights as well as a few open spots for future use. The only relays not included are the 2 for the H4 high and low beams... Bundling the wires The 2 heavy gauge wires are for the alternator feed, stock V-8 ZJ... My booty fabbed bracket for the PDC. It's a pieces from both the old Renix bracket and a '95 XJ. I cut most all of the bracket that held coolant reservoir away except for a small section in the front... The H4 relays will be mounted on this section...

I went with a '96 ZJ, PDC mostly because the main wire bundle exits the side. Wiring labeled and underway... More... 90% of the wires reconnected... with about 6 feet of shrink tube... Relays and Fuses in...