Fitting a Front Mounted Intercooler on the Jeep Cherokee XJ 2.5TD VM

Before I get stuck into pulling parts off of the engine I thought I would cover some of the changes I have been running with over the last few years with the 2.5 VM Diesel Engine. This engine obviously comes as standard with the European Export XJ but its reputation is poor based upon some its issues with the older head design, gaskets and cooling system. All of that coupled together made head cracking a common problem.
I've made a number of changes to my engine over the years to improve reliability and performance. AMC Cylinder Heads, Front Mounted Intercooler, EGR Delete, Oil Catch Can, Turbo Charger, Snorkel and Exhaust. ALl really to help the engine breath a bit better and drop those EGT temps.
Thanks for watching,
425 OHV Engine Manual - pdfcoffee.com/jeep25tdmotorvm...
VB180086 Turbo Info - www.invasionautoproducts.com/j...
VA180069 Turbo Info - www.invasionautoproducts.com/j...
www.americantechnology.co.uk/
EGR Delete Plate - www.ebay.co.uk/itm/2231438389...
/ @workshoptowilderness
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Intercooler Piping - www.ebay.co.uk/itm/2836025938...
Intercooler - www.ebay.co.uk/itm/3313176736...
Oil Catch Can - www.ebay.co.uk/itm/3827216829...
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Jeep Spec:
1999 Jeep Cherokee XJ 2.5TD RHD.
35x12.50r15 BFG KM3's with 15x8 3.75" backspacing (-19 offset).
Lift Front - RC 4.5" Coils and N2 Shocks (3" Coil Spacer).
Front Shock Bar Pin Eliminator.
Dana 30 High Pinion with Artec Industries Lower Control Arm Mounts with modified upper mount and modified Track Bar mount.
Front RC Control Arm Drop Bracket.
Ruff Stuff Short Arm Single Himes.
RC Extended Sway Bar Links.
Dana 30 Rock Crusher Diff Cover.
Ruff Stuff One Ton OTK Steering.
6" Lift Drop Pitman Arm.
Ruff Stuff Front and Center Frame Stiffeners.
Rear DIY Frame Stiffener and Rear Frame Tie in Kit.
6" x 2" Box Rocker replacement with Tube Slider.
Modified Factory Bumper with Side Sliders.
Rear Tow Hitch Tire Carrier that bolts into Rear Frame Tie in Kit.
Modified upper Shock Crossmember for Rear Shocks
Rear Axle Chrysler 8.25 29 Spline with modified High Clearance Shock Mounts.
Rear Shocks 6.5" Trailmasters.
Rear Leaf Springs 5.5" Rubicon Express
Rear RC Shackle Relocation Bracket.
Stainless Steel Braided Brake Lines front and back.
Warrior 9500lb Winch.
Front Bumper - www.ebay.co.uk/itm/Jeep-Chero...

[@maxitout5333]

At first I thought just another channel. Now I know you are basically a helping Hotline for every 2.5 td owner. Keep going

[@PrisonersNoLongerAccepted]

Absolutely wish you was my next door neighbour. Been following you almost from day 1 a fair few years back but your knowledge of vehicles is what I wished my neighbour had or me of course 😉 👍

[@TonyJaboney]

Cool, cant wait for the next vid!

[@jamesa7506]

Awesome jeep my friend! And your singing voice ain't that bad either! 😃

[@7igerNinja]

I’m loving these engine breakdowns. So good to understand whats happening on our 2.5TD’s. honestly inspirational. Please. keep it up!

[@corheeremans2820]

You are A Genius Mike!!! Thanks for trhi video. exactly what I asked you some weeks before. Now..I can imagine what to do on my VM 2.5 engine. About the snorkel..I had both my in Spain..from CEBEX. but i had to change that air filterbox. anyway we stay in thoughts. keep on workshopping 😉 Cor.

[@powerspeedutube]

Very informative and easy listening and easy to understand. Well done, keep up the good work. 👍

[@user-zj4ly5ye9t]

Greetings to you from distant Russia. I follow your project, you are a great fellow👍👍👍

[@chopperchuck]

thanks to you ,I'm gonna stick with my 4.0 l 6 cylinder the Diesel Engine seams like to much work if you don't al ready have one .

[@WorkshoptoWilderness]

Everything is a lot of work when your me. I like pushing everything towards better always and nothing ever stays the same. It's the way I've always been. I've spent a good 7 years working on my my jeep weekly and a very small portion of that has been engine related. You either enjoy the challenge or your don't. Thanks for watching

[@chopperchuck]

@@WorkshoptoWilderness that's just it Mike you have an attention to detail on your own vehicle that I only possess when I'm working on someone else's vehicles not my own when it comes to my own vehicle I just want it to run and get me back and forth to work and maybe out on the trail once in awhile your engine bay looks like the inside of a nuclear reactor it is awesome

[@matiasbosshardt8888]

Nice Jeep!

[@pedroquiros1863]

Greetings from Costa RICA, Mike 🤙🏼. I don't recall seeing a video about the gearing, when you put bigger tires. There are plenty of those videos out there. But it would be great to see you doing one about that. Keep up with the great videos buddy. PURA VIDA

[@WorkshoptoWilderness]

I will be regearing before the summer so I will surely film it. I'm no expert but It has to be done!

[@051biohaz]

Another great video, thanks for the upload dude..:)

[@FilthyMcNasty666]

Classy badassery :)

[@gregnorvell9730]

Like what your doing to upgrade your XJ. But coating the intercooler with Raptor liner is not good. It won't let air touch the metal fins that need to be exposed in order for it to cool. Instead it will act like an insulator for the coil and keep the heat in.

[@WorkshoptoWilderness]

Yeah its dumb but it's due to be replaced hence my lack of concern. Thanks for watching

[@marcoslmartins]

Great video. Many thanks. I'm doing an extra line of collant to the 4th cilinder. Thats a usual mod where I live. Keep going.. your videos are great!

[@WorkshoptoWilderness]

That's really interesting, how do you do that? Many thanks!

[@marcoslmartins]

Plug in a T adapter in the hose that comes from the expansion tank, and substitute the brass collant plug on the 4th head with a plug with a connector to the watter line that you just added. I can send you pictures if you like. Also the original banjo on the watter breather hose is so thin that easiy clogs not letting the collant circulate trough the heads. Also substitute it with a larger one. Tell me if you want me to send pics.

[@WorkshoptoWilderness]

@@marcoslmartins Genius! I would love some pictures. My email is [e-mail]

[@JackFalltrades]

My Subaru Outback Wilderness has a top mounted intercooler

[@forreststrong797]

You could look into an SPOD or something similar for cleaning up your wiring, I recently got 2 of them with their touch screen. An electrical controller like that cleans everything up incredibly nicely and it's super easy to add on to it. I originally bought a cheaper light controller then found out about everything an SPOD is capable of so I upgraded to the SPOD's. It's kind of a weird name if you don't know what I'm talking about but it's pronounced s-pod

[@WorkshoptoWilderness]

Nice, I will check that out. I'm absolutely rubbish with electronics haha. I really need to redo my whole setup to be honest. Thank you for the information and for watching

[@FilipGomukiewicz]

Maybe for the coolant sensor You can use wiper fluid sensor? I think it operates based on the level - i think there is some sort of floater.

[@WorkshoptoWilderness]

Yeah that's a good idea. I guess I will have to fit it to the tank so it can take the pressure and not pop out. Should work, I just have to find the right design. Appreciate the suggestions!

[@blott-mtb5528]

Great vid Mike! Just my 2 pennies but look into ‘vent to atmosphere’ catch cans. I know with those type of cc the baffle system isn’t too great, some people stuff steal wool into them to keep the blow by from going back into the intake track. IMO the only way to totally eliminate blow by and slug is vent to atmosphere catch can with a solid baffle system. When I used to race autocross I had a custom one made and had one of those T fitting drain cocks plumed into the bottom. Switch-pro is the best for controlling and cleaning up accessories, lmk I’ll shoot you some pics. Also im curious how are you controlling boost? Just a internal gate spring? Thanks

[@OMGWTFBBQSHEEP]

Thanks for sharing your advice. I might do something like that for the ventilation on my 99 xj.

[@WorkshoptoWilderness]

Thanks for the information and advice. I didn't realise that you could run a vent to atmosphere can on these. Perhaps I don't fully understand how they work as I thought the crank case needed constant suction to equalise pressure? Well that's what someone told me on the Internet anyway, they said you can vent the sump to atmosphere as it needs suction or the pressure with get too high. Would be great to debunk that. I will look into the vent to atmosphere models. Thanks you again.

[@andriyponomar3389]

It was a treat finding this channel! Thank you for sharing the info. I'm hoping you can help troubleshoot an issue. My Jeep struggles with hot starts. Have you come across this issue before?

[@WorkshoptoWilderness]

I've not some across a hot start issue? Is that with the diesel?

[@andriyponomar3389]

@@WorkshoptoWilderness yes 2.5 TD, it starts perfectly fine when cold but after running it for a bit, it struggles to start up

[@WorkshoptoWilderness]

Ah okay. Sounds like the fuel pump possibly. They can show issue's when pressure builds up and it causes a pressure drop and fuel restrictions which would mean the engine would fail to start and possible judder. If you can test the fuel pressure at start up and when warmed up then that would be good start

[@andriyponomar3389]

@@WorkshoptoWilderness Much appreciated! I will try that

[@WorkshoptoWilderness]

Let me know how it goes. The engine manual should be in the description and it may list the correct pressure.

[@forreststrong797]

Is there a way to get a custom angled flange welded onto an intercooler to run your upper charge pipe through the same location but having both pipes come from the same side of the intercooler like your friends but have your upper pipe flange pointing up kinda.. if that makes sense. I'm not familiar with turbo stuff. I have a friend that replaced his headlights with 2 led offroad style lights on each side for high and low so 4 total but they are a lot smaller than the original headlights so he has more room and the lights perform much better than any aftermarket 5x7 headlights. His lights are also DOT approved for driving lights. It looks pretty good the way he did it. That could be a option without hacking up the headlight mount to make more room. Another great video! I was excited to see you had posted.

[@WorkshoptoWilderness]

The aftermarket led lights are definitely better for dimensions at the back. I use them and there is more clearance. I guess with the right person you could modify the cooler but I saw one on ebay for about 100 pounds. So it's pretty affordable. Some 2 inch pipe and that setup and it should be pretty nice. It's something I really want to do once this turbo setup is working but I kind of want to drive it again also haha

[@forreststrong797]

@@WorkshoptoWilderness nice, well I'm sure you'll get it sorted out the way you want it. It sounds like you have a plan. It seems like there's always something to do on these cherokees. I really enjoy your videos and it's interesting to see the diesel cherokee. Like I mentioned before we just don't have any diesel cherokees here in the states, they are very rare I'm not sure it was even an available option here it may have been a special order thing.

[@danielmagalhaes5739]

Hi! Awesome job on that engine. But i think you should use the Seat Leon TDI Cupra intercooler, you will not have turbo lag issues

[@WorkshoptoWilderness]

Thank you, I will check them out!

[@MrNeutross]

2:45 aluminium can fatigue and break easily. That much play might mean that long term, the studs at the bottom will break of or perhaps tear a hole in the intercooler at the base of the studs. I might be wrong but putting a support up top to limit the movement and vibrations might be good.

[@eyeofthetiger4184]

G'day Mike, really interesting once again mate. I was think'n if you went for a single sided intercooler, could the top charge pipe have a dog leg fitting or formed piece to bring it up away from the headlight mounting ? essentially pass through the same point as the existing one. I assume the top single sided outlet will sit higher/closer to where you want it too, so a less severe angle to contend with. Cheers Duke.

[@WorkshoptoWilderness]

I think thats the key, just a small bend using the same pipe at the top. I will see if I can do it, should be pretty easy! Thanks again Duke.

[@bobelot6302]

Great vid, couldn't you replumb the metal coolant tube you ran across the front of the rocker covers to go around the PCV housing to keep it from freezing?

[@WorkshoptoWilderness]

Yeah quite possibly! It would probably keep it warmer. I may just relocate the catch can but I will have too see how it goes with the manifolds and turbo. Thanks for watching

[@insaynbcr]

Wouldn't that spray on bed liner inhibit the cooling ability of the aluminum fins of the intercooler and the radiator>? Kind of like like what mud, dust and dirt will do..

[@WorkshoptoWilderness]

Yeah most likely. I'm replacing the cooler soon so I got lazy on spraying. To be fair it's winter now so I doubt it would matter but I'm sure it wouldn't do it any favours in summer.

[@aaronenglish7968]

What year hilux is the snorkel from?

[@maxitout5333]

Just saw the Video where you thought about selling the rooftent. I mean you could buy a trailer that is supposed to be for the H1 that the Army has. It's good for offroading and you could but all the stuff in it and make some room in the jeep. And as far as I know children really like rooftents. Oh dammet wrote too much...

[@maxitout5333]

kzbin.info/www/bejne/aqSteYSOrcipsNk

[@WorkshoptoWilderness]

I think it might cost too much for it to be ab option. I was considering building one from an existing trailer as I can fabricate. Should be fairly simple (he says). Going forward I'm not too sure what we wil do. Thank you for the link, I will look into it some more.

[@nostressjusttravel]

Hi,what radiator do you have on jeep? I have to replace it mine and i thinking for an upgrade. Thank you!

[@WorkshoptoWilderness]

Hey, its the standard copper and brass OEM radiator. Although I bought it five years ago new so its in pretty good shape. I've seen the aluminium ones although from knowing people who run them, there seems to be no noticeable cooling improvement. I thicker one would be good I think.

[@nostressjusttravel]

@@WorkshoptoWilderness thank you for your answer! The best xj jeep 2.5td with modified is your 😀👍

[@analog5.56]

Glad yours rig doesnt overheat 🙂 Mine started this week, just took out thermostat, flushed all cooling system still gets to 100C in 5mins and goes up all The way. Water chanels over manifold is too hot to touch, but front coolant hose to rad is cold, Any idias?

[@paulwalker427]

dead water pump

[@analog5.56]

@@paulwalker427 could be

[@steveafanador6441]

Water pump

[@analog5.56]

@@paulwalker427 water pump is good :/

[@WorkshoptoWilderness]

So this is with the thermostat removed? the water gallery is too hot to touch but the front radiator hose is cold then the thermostat isn't opening ( that's if the thermostat is in). When running can you squeeze the upper and lower radiator hose, one after the other like a pump. This will basically circulate coolant through the system and burp air. When doing this is the upper hose getting warmer?

[@patrikruzic6173]

Hi, what are the dimensions of the intercooler?

[@WorkshoptoWilderness]

I will try and find it for you. There should be a link in the description

[@chrispascoewhite]

Hi, please 🙏 can you help me!!! My 97 xj 2.5 td is still not boosting after 2000 rpm I’ve had all the leaks fixed and even bypassed the intercooler ( I’m not towing or off roading) what can it be? Are there sensors telling it to switch off at 2000rpm so confused 😬

[@WorkshoptoWilderness]

Its probably the number one injector. It normally is. Its just the resistor in the injector has gone and its throwing a code to the ECU telling it to cut fuel to the ECU on the pump. You will need a replacement injector as its an extremely difficult repair. Personally before you spend the money on an injector pull the plug on the injector and put a multimeter on it and measure its resistance in ohm. It should read between 80 and 100 if its working. Another one is the MAF sensor but first test the number one injector and make sure its dead.

[@chrispascoewhite]

@@WorkshoptoWilderness oh my god! Thanks so much , I was just reading forums and I did fin one saying just that , where is injector no. 1? Thanks again, really appreciate this!!

[@WorkshoptoWilderness]

@@chrispascoewhite Its the first injector at the front of the engine as you look at it. It has a wire coming out of it that goes back to the wiring loom at the back of the engine. You have to unplug it and it has two pins on the injector plug. Put the multimeter there and set the multimeter to 200 ohm and see what it says.

[@chrispascoewhite]

@@WorkshoptoWilderness amazing! Thanks, I'm sure you get loads of questions, massive learning curve for me, I'm a builder not a mechanic , what you've done on your xj is so cool, if I can get it running as it should, I'd like to lift it so I can fit some bigger tyres , have you do e a video covering my issues?

[@raulpop4314]

Hi, where is located the PCV valve on 2.5 tdi VM?

[@WorkshoptoWilderness]

If you stand in front of the engine it's on the right side down by the back fire wall under the fuel filter. It's a black plastic cylinder with two pipes coming out of the top.

[@raulpop4314]

@@WorkshoptoWilderness And did you put the oil catch can between the intake manifold and pcv valve?

[@WorkshoptoWilderness]

@@raulpop4314 yes thats correct 👌

[@7igerNinja]

What model hilux is the snorkel from?

[@WorkshoptoWilderness]

topdelar.se/products/1725-snorkel-jeep-cherokee-xj-diesel here is the link, its from a 167. It fits really good actually. Just a small gap near the bend at the bottom.

[@7igerNinja]

@@WorkshoptoWilderness THANKYOU!

[@tricky4g63]

Thank you soooooo much, I've been searching for a right side mounted snorkel. I'm in the US and have a 2000 xj with a 5.3l and can't stand left side mounted snorkels since it's the driver side here. Once again, you are an amazing wealth of knowledge and greatly appreciate your willingness to share with the rest of us. I've been subbed since your first xj video and look forward to every time you post!!!

[@ReodorF1]

Do you know those vm engine loves used vegetable oil instead of diesel just clean the used oil first

[@WorkshoptoWilderness]

Yeah I ran mine on a 80/20 mix in the UK. I've not tried it here but I've always wanted to make a filter system to recycle oil for fuel. You know, just in case. Fuel prices are criminal these days

[@lastmanstanding1954]

are you ever going back to making bushcraft videos ???? if not , your talent is being wasted.........

[@WorkshoptoWilderness]

I'm pretty sure you have commented this same comment on multiple videos on this channel and each time I reply you ignore my reply and continue to ask this again on another video. Your comments tells me your pretty young and you probably don't understand really what your asking. I think explaining to you why I no longer film my camping and bushcraft would be like telling a 2 year old why the ice cream machine isn't working at pizza hut. He just ain't gonna get it....