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Custom Air Intake Setup on a '98 XJ |
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Posted: February 24, 2004 Last Revision: September 02, 2007 |
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There are a couple reasons for changing the layout
of my engine bay: First, I wanted to make room for a York Air Compressor inline with the engine pulleys (something like this.) I decided to make this room where the factory installed battery sits. Second, I wanted to reroute the ARB snorkel path so that larger tires would not catch and grab the hose from the snorkel to the factory air box. |
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| In order to accomplish these two objectives, I purchased a European Diesel XJ battery tray which fits on the drivers side of the engine, I sunk the computer into the drivers side fender to make room for the battery, I cut a hole in the inner fender to allow the ARB snorkel to pass into the engine bay using a 90 degree fitting off the end of the snorkel, and I added a cone air filter covered by a canister between the snorkel and the throttle body. The following pictures detail how I did this. In the process, I also added a 1" throttle body spacer, chamfered the lower portion of my stock throttle body to ease the transition from the butterfly to the spacer, and installed the solenoids for my xd9000 winch under the hood. I used the solenoid mounting area as a place to tie the battery connections together. I also removed the factory ABS pump and lines since my D44 axles are not ABS compatible. I then installed an ARB air locker compressor in the spot where the ABS pump once was located. | |
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Shot showing all the components of the filter and
canister as purchased from Intense Performance.
(Update: This company appears to have no internet presence anymore. Please let us know who sells these items now. Thanks.) [large image] |
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Different shot showing all the components of the filter and canister as purchased from Intense Performance. (Update: This company appears to have no internet presence anymore. Please let us know who sells these items now. Thanks.) |
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Canister and filter showing where the air goes in..
[large image] |
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Canister sitting on a piece of paper showing the dimensions. |
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Shot showing just the dimensions of the canister.
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Filter and its dimensions. |
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Filter dimensions --more detail.
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Filter output cone and its dimensions.
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Filter with the output cone inserted into the filter the maximum amount. |
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Filter with the output cone inserted into the filter the minimal amount. |
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Fully assembled filter and canister from the output end. |
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Fully assembled filter and canister. |
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1" throttle body spacer. |
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Different view of 1" TB spacer. |
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I cut the chamfer on a drill press with the table locked
in at an angle and a rotary file in the chuck. I free-handed
the actual cutting.
[large image] |
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Throttle body with lower portion chamfered to a larger diameter. I was chicken to go all the way to a straight bore of the throttle body, but did want to do a little something to ease the transition from the TB to the spacer and intake manifold, so I chose to chamfer the lower portion of the TB. |
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Shot showing modified throttle body with gasket. The lower portion of the TB was chamfered to gradually increase its diameter to that of the gasket and spacer. |
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1" throttle body spacer sitting on modified throttle body.
[large image] |
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Canister and hose during construction. 2.5" ID hose pieces are joined with short pieces of 2.5" ID exhaust pipe and hose clamps. ABS pump is loose and shifted back a half an inch or so, but still in use. |
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Canister and hose from the top during construction. All hose pieces are from various radiator hoses. |
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View during construction from the top showing the relationship
between the canister and the battery tray.
[large image] |
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Throttle body spacer, intake tube, and canister/filter installed. This is prior to cutting holes in the inner fender. |
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Shot showing the plumbing fitting soldered to curved piece of copper which is pop riveted to the canister for a CCV breather nipple. |
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Another shot of the CCV breather assembly. |
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Holes in inner fender cut with a plasma cutter. |
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Holes cleaned up and primered. Engine control unit ready to be installed in fender cut out. |
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Final holes in fender with computer sunk in one via a steel box I fabricated, and hose from ARB snorkel coming through the other one. |
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Snorkel with rubber elbow attached. The elbow came from a radiator hose that was cut to fit. |
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Air Canister and hose to throttle body. I built a steel plate which transitions from the snorkel hose to the canister. It is riveted to the aluminum canister and has a piece of 2.5" ID exhaust pipe welded on. This shot also shows the ARB compressor mounted where the ABS pump used to be. |
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Picture of the intake tube going to the throttle body from the other side of the engine. The top joint between the two hoses has been formed into an oval shape for more clearance. It is tight with the hood, but just clears (actually rubs a tiny bit in use.) |
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Clearance between the radiator fill and the Optima battery.
Not much!
[large image] |
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Clearances between battery, sunken computer, and snorkel tube/canister. |
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Different view of all compenents in mostly finished state.
[large image] |
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Battery tray location and hold-down arrangement. |
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Winch solenoids mounted to inner passengers fender and the new battery cables run to the solenoids. I also re-routed the factory battery leads to this area. |
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Four Warn XD9000 winch solenoids mounted to a plate which is mounted to the inner fender. The new battery cables and old wiring that went to the battery are connected here as well as all the winch cabling. |
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1/0 battery cable extensions. |
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Overall view of completed engine bay.
[large image] |
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Final location and configuration of the intake canister and the hose run to the throttle body. One can see the ARB compressor mounted where the ABS pump used to reside. |
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Overall shot of the completed air intake reroute with Optima Yellow top and sunken computer. |
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Original battery and tray removed freeing up room for a York air compressor. The stock air conditioning lines are still in the way, though. |
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Another overall shot of the completed engine bay mods. |
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NOTES: In order to fit the canister as low as possible, I hammered a groove in it to fit around the inner fender strengthening rib. I also slipped a piece of rubber hose over that rib to prevent rubbing through the aluminum canister. Also, if I was more careful, I could have cut the hole for the hose from the snorkel to the canister a bit tighter as one can see a bit of extra hole around the hose. Since finishing these mods, I have added a set of inner fender liners from an earlier model XJ. They shield the snorkel hose and sunken computer from road debris (mud, snow, rocks) and bolt to the flare using the factory stud rails unlike the factory '98 inner fender liners which more or less float in the flare. I used a heat gun and pressure to remold the liner around the corner of the sunken computer tray. |
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All Rights reserved. Photos: Jeff Ayers www.madxj.com |
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