2.5L Coolant Bottle - Wiring Harness Interference?

[OneOverZero]

I've converted my '90 MJ to an open cooling system when I rebuilt a '94 HO, and ran this universal coolant bottle for engine break-in:

 

 

However, that's just janky.  I picked up a repro 2.5L XJ/MJ coolant bottle, and noticed that the wiring harness (headlights, fan switch, etc.) can't easily be pushed aside to drop the bottle in place.  I can shift the fuel pump ballast resistor, now-unused EGR solenoid, and ground, but the bottle can't squeeze between the airbox and the sheetmetal.  (Overflow fitting on the radiator is also 180deg out from where it should be for the new bottle... oh well.)

 

What have other 4.0L folks done to accommodate the 2.5L bottle?

[mjeff87]

It'll fit, but it's pretty tight.  I swapped a 4.0 into mine (was a 2.5) and wanted to keep the open system along with the overflow.  There is a pinch seam in the wheelwell that you have to modify a bit to get the harness to sit flush.  I didn't install any of the EGR stuff on the fender there, and I just spliced the wiring at the ballast resistor to remove it.  Here's a prettty crappy pic, but you get the idea.  I did have to fiddle with it for awhile, but trust me, it fits.  I do have slight interference with the radiator filler neck and the front spring clip on the airbox, but there's enough play in the airbox to gently push it enough to pop the clip.

 

Jeff

 

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[skidoo_j]

I added it to my 4.0 89 with out any issues:  

 

[Strokermjcomanche]

I'm sure if you put a cold air intake in it that would free up some room

[sinkrun]

Where did you guys find the cap for the 2.5 tank?