dzJeepChic's '92 XJ Expedition Vehicle Project

Number 7

Adventurer
Poor Clifford had his annual physical today at the emissions testing facility in North Scottsdale.

To start with, I completely embarassed the poor kid getting in the wrong line, so when we were 2 cars back, and could finally read the fine print, the technicians had to move pylons so we could get over 1 lane and into the correct bay.

Now on the rollers, I got into the passenger seat. The technician, who was shorter than me (in my platform flops) and out-weighed me by at least 200 pounds, had one heck of a time getting his right foot, and then the rest of his body into the driver's seat. While there, he put Clifford in drive and took him through a battery of 'Highway Simulation' tests. Our attention rapt upon a computer screen, the technician kept 'cyber' Clifford on a hilly road. It was actually pretty cool to be going 60 mps and not moving. Clifford seemed to like this part, and he performed flawlessly. The technician kind of rolled out of the driver's seat, and said that I could get back into it. He was taking a big funnel off of Clifford's exhaust, and we almost crashed into each other on my way around the back!

Then he asked me to open the hood, so I did. He then made several passes - driver side / front / passenger side / front / driver side, before he went and got a metal folding chair. He put the folding chair next to the driver side open hood and hopped (well, maybe not hopped) up onto it. He got down. He took the chair in front of the Cherokee and again got up on it. He got down. He took the chair to the passenger side, stepped up on it. The guy was actually using Clifford's cage, and VERY lucky I don't care about paint smudges! Got down. He said something I couldn't understand to a woman who worked there. She breezed past Clifford and said 'It's right there'. So the tech got back up on the chair on the passenger side and I saw him put a clamp thing on something near the firewall.

I don't know exactly what the test was for, nor can I recall the acronym they used. The screen kept flashing 'Pressurising' and 'Holding Pressure', seemingly over and over; I was holding my breath! Then it was time for the ever popular 'Gas Cap Test'. As I watched in the mirror, they put what looked like a vaccuum hose on his gas cap.

"That'll be $27.75 please", the tech said. "Did he pass?", I asked? "I don't know yet", the tech said, "we won't know until after I enter the payment". Well that figures, right? Clifford passed with flying colors and I bought him a great big tank full of of fresh gasoline to dilute the 'Guarenteed to Pass' solution he'd been sipping on all morning.

On my way out of the emissions testing station I asked one of the techs if they had a scanner they could plug in and clear my 'Maint Reqd' light. They don't. I also stopped at Vato Zone on the way home, neither do they.

DSCN8225.JPG

Clifford had a great day and is obviously feeling great! He's ignoring the 'Maint Reqd' light, why can't I? d
 

jmxj

New member
Awesome jeep. On the Maint. reqd light, comes on at 82,500 as a reminder to check o2 sensor and emmissions, either can be reset at the dealer with a DRB 2, or there is a little relay that must be replaced, but they are only supposed to reset the light if they change o2 sensors, so if you change them yourself you either live with the light or take out the bulb.
 

Number 7

Adventurer
We had an over-heating issue a couple weeks ago while up in at Mingus Mountain. Click the 1st picture if you want to link back to the full write up on my build thread, go to post 168.

Here's something nobody wants to see:


That nor the fluid spew out of your hood vents while you're driving on a 2 lane highway...

DSCN0167.JPG

Luckily, there's an easy trail repair and the part is cheap. This is something you might want to think about carrying if you drive a '92 XJ:

DSCN0185.JPG

Happy Trails!
d
 

Number 7

Adventurer
Man we're having some overheating issues.


Clifford will idle it all day long, even with the A/C on, and run at normal operating temperature. As soon as you put the vehicle under any sort of load, namely driving up a hill, it heats up. Notice that's the opposite of practically every 'XJ Running Hot' situation you read about: usually the Jeep heats up while at a stop light and cools back off after you get moving again. I drove it around FH this morning without the A/C on and it got up to 225 just between the Zumba class and home.

We're beginning to suspect its a cracked head or blown head gasket. Although there is no oil in the coolant and there doesn't appear to be any water in the oil, G did notice a green tinge on the plugs in cylinders 2 & 3. I actually read somewhere that if it heats up while running it without the thermostat that's a sign of a leak at the cylindar head, so ran it today without the thermostat & it acted the way it always does. Also, a compresion test revealed low compresion on all cylindars: around 100 psi vs. spec. of 120 - 150(?) psi...

Now we're researching cylindar heads - they're pricey and there's all kinds of machining going on out there. The only OEM head I found is at MOPAR for $1100. Then there's a bunch of remanufactured for anywhere from $500 - $800. There's a newly cast one which is a 'one size fits all' from like '91 - '01, which doesn't make sense to G.

And then of course it's crossed our minds that we should just get a new engine and install it...

Anybody with expertise, advise, a good story, please chime in.

d ::Just.Empty.Every.Pocket.Blues::
 

Number 7

Adventurer
I guess I should have added that we've basically done everything you can do to address over heating. New: 3 row aluminum radiator, OEM water-pump, fans all over the place, electric and mechanical...
 

ROKTAXI

Adventurer
After you take the head off, it should tell the story of a leaky head gasket or cracked head (or both?). Check with the bone yards. There should be heads for your application available without too much searching. NAXJA (search) should be able to give you all the info you need regarding what years are REALLY compatible. And of course, if you do find one, have it magafluxed!
 

Bodo

Adventurer
Now we're researching cylindar heads - they're pricey and there's all kinds of machining going on out there. The only OEM head I found is at MOPAR for $1100. Then there's a bunch of remanufactured for anywhere from $500 - $800. There's a newly cast one which is a 'one size fits all' from like '91 - '01, which doesn't make sense to G.

Those prices sound ridiculously high. Call Dover Cylinder Heads ~$250 will get you a decent re-manufactured head.
Alabama Cylinder Heads makes a nice new casting based off of the later model 2000+ (0331) heads that have the nice intake/exhaust ports. All HO cylinder heads fit the HO 4.0 engine. They run ~$500.
Hesco makes a really nice Aluminum head. That puppy is ~$2000 though :Wow1:

For under ~250 you can get your current head rebuilt at a machine shop even if it requires welding a crack and re-surfacing.
 

CRJeepin

Observer
LOL "pardon me, do you have any grey poupon?". "No but I got some raddyater sprinkles if ya like!"

Good lookin jeep, good luck w the cylinder head!


Got some stuff done today on the Jeep. Click the picture to go to the build thread, updates begin on post 13:


Enjoy! d
 

Number 7

Adventurer
I've finally posted an update on everything that's been going on. Link back to the write-up by clicking the picture; the update begins at post 270:


We're going out to Florence Junction today - cross your fingers...

Diane
 
Last edited:

Number 7

Adventurer
Great News! Clifford is running mucho cooler now - stays right at the halfway mark on the guage through most conditions. Climbs a little above halfway on grades. As usual, runs cool on the trail. Click the pic to link back to pictures from Florence Junction, post 284:


Ciao,
Diane
 

Number 7

Adventurer
Update on Clifford: Now that cooler weather is here, the Jeep doesn't overheat, although it still heats up to about the 3/4 mark on long grades. We took him to southern Utah for the Hole-in-the-Rock Trail, and on the way home that long climb into Flagstaff from the north on Hwy 89 he got to 3/4 with all the fans and the heater on. But he didnt' overheat...

My conclusion is Clifford is a winter vehicle. George is going to change the fans; he's looking at a triple fan set up which produces something like 4500 cfm. In the meantime I'm driving him all the time and he runs great.

Here's some pictures of Clifford on the Hole-in-the-Rock Trail - click the 1st picture to link back to my build thread to see more starting on post #302:


Ciao!
Diane
 

Number 7

Adventurer
Running hot conditions continued this spring, with Clifford reaching the 252* mark on the way home from Red Creek in May. George decided it was time for the last ditch effort of pulling the head and having it checked, and did a bunch of other work while the engine is drained. I updated the build thread, and you can link back to it by clicking here: http://offroadpassport.com/forum/showthread.php?p=18286#post18286. The update begins at post 383.

DSCN9371.JPG


DSCN9374.JPG


DSCN9388.JPG

Ciao Muchachos!
Diane
 

88Xj

Banned
Hey george, glad to see Clifford getting worked on. Its always been my insperation to build my Xj ExPo rig. I'm not on offroad passport, but I saw the comments on changing lifters & such! Figured I would help you out a bit there.
The lifters sit on the cam (flat tappet)& wear in a specific pattern. So if you took them out and didn't number where they came from, then you should buy new ones. As just putting the OGs back in will cause more/excessive wear & could cause a cam/lifter failure..reason is, is because the patterns will not match! New lifters & a used cam is 100% fine & done quite often. Starting new & wearing a specific pattern, vs having a pattern worn already & then wearing a new one...hope you understand?
When I built my 4.2L high compression mini stroker I used the stock cam & new Lunati lifters. Remember, "the lifter wears to the cam, not the cam to the lifter!"
So I would grab a set of sealed power lifters..stock replacements and drop them in! As stated on offroad passport they cost around 5 bucks or so off summitracing. I chose the Lunatis off recommendation...and then found this comparison.
http://www.jeepstrokers.com/forum/viewtopic.php?f=5&t=1262
Had I found this comparison before I bought the Ludnati's, I would have just gotten sealed power! Comp lifters have had a few failures/lifter collapses, and tend to be more noisy at low rpm/idle because they leak down..which can lead to excessive valve train wear.

Grab new lifters, soak them in oil -pre-install- & clean out the pushrods. You can also get a new mopar .043" head gasket compared to the stock .051". It'll bump up the compression a tiny bit & help out with power & efficiency & will be nothing other than buying it vs the 0.51" original. Its a worthy upgrade that won't cost you anything. Let me know if you can not find where to buy one.

Compression before stock 4.0
8.83:1 static compression
6.48:1 dynamic compression

With mopar head gasket,
8.97:1 static compression
6.62:1 dynamic compression.
 
Last edited:

Number 7

Adventurer
You guys are not going to believe this: It was the radiator! Yep, you heard that right; it was the radiator. When I bought the XJ it had a Radiator Barn 3 row radiator that was made of copper/brass, then we upgraded to a Champion all aluminum 3 row radiator thinking it would solve the over-heating problem. The Champion sprung a leak in 1 year. So we re-installed the original Radiator Barn, and it started leaking, so we bought a brand new Radiator Barn - this time a 2 row copper/brass. The Jeep continued to overheat throughout all these radiator changes.

A weird thing happened that made George do some intense research: as he was working on a buddy's Jeep he discovered that the original OEM radiator was leaking. Not able to find an OEM, he ordered a Radiator Barn 2 row copper/brass and installed it. Then that Jeep overheated on the way to the Cinders! Since it had never run hot at all, it made George realize that the radiator was probably the problem.

So he ordered a (difficult to find) 'stock' after market, 1.5" thick aluminum core w/plastic tanks radiator and installed it in Clifford. Thursday I drove to Scottsdale and back with the A/C blasting, and the dash gauge never budged off the halfway mark (normal operating temperature). Yesterday I drove to Mesa and back, A/C blasting up and down the Beeline and the dash gauge stuck at the halfway mark again.

I have no words for how excited I am because I'm afraid I'm going to jinx myself. But it looks like my Clifford is fixed!

Diane :wings:
 

Forum statistics

Threads
188,736
Messages
2,909,670
Members
231,030
Latest member
dterrell
Top