New intake upgrade.

[crustodd]

Hey folks,
I will be adding the '99+ intake to my '94 XJ as part of my stoker build. What challenges are there for doing this? Is it a straight bolt on swap? Different hose lengths? Wiring?

Thanks

[seanyb505]

Youll need a different power steering pump bracket. Search over on NAXJA for specifics, its well covered. All the hoses on my 97 got to where they needed, but not without some pulling. If youre getting it from the junkyard just grab the hoses from the same vehicle. Would probly work better.

[Comanche91]

Here's an excellent link: http://www.mallcrawlin.com/forum/showth ... ntake+swap.

I modded my original 91 power steering bracket at first by grinding off the ear of the bracker to clear the manifold and drilling/tapping new mounting holes into it, but later swapped it all out for the newer cleaner 1996+ pump, bracket, and idler pulley. Makes adj. the serp belt much easier. You need to remove and reuse your old idler pulley near the A/C pump, same part, or keep it for a spare. Also need a new serp belt for the 1999+ XJs.

As for hoses, etc., the #1 and #2 injector lines had to be discoed and re-routed for better clearance, the O2 sensor harness needs to be re-routed and heat shielded, and I put a slightly longer return hose on the new pump.

[crustodd]

So,
Do I understand correctly that you just need the bracket and the pull wheels and such. You can use the pump itself from a '94 like mine?

[Comanche91]

So,
Do I understand correctly that you just need the bracket and the pull wheels and such. You can use the pump itself from a '94 like mine?

No, you will need the 1996 and above pump too, along with the bracket and idler pulley. Both the 95 and below and 96 and above are Saginaw TC pumps, but the inlet/outlet ports are configured diffrently, as well as the reservoir.

[crustodd]

Thanks Comanche

[crustodd]

Once you have the newer parts, does it all just bolt right up?

[John]

It did on a 93 xj that I converted, using the same route of upgrade.
John

[crustodd]

How do you suggest heat shielding the O2 sensor?

[SilverXJ]

Why would you do that?

[Comanche91]

Why would you do that?

I think he's addressing me. I mentioned as part of the 99 intake install on mine that "the O2 sensor harness needs to be re-routed and heat shielded". This was because I have a Mike Leach header that requires a longer wiring harness because the bung hole is placed farther back than with other headers. With the old intake manifold the harness was long enough to make it to the connector, but with the new intake I had to run it closer to the exhaust manifold and thru one of the intake runners, so I heat shielded it as a precaution. Probably don't need to do this w. other headers........

And I run a WJ O2 sensor (longer harness) that uses thermocouple wire, so extending the harness was not an option.

[crustodd]

I don't recall the Doug Thorley having an O2 sensor in it. My XJ is a '94 with OBD1