here are my new motor mounts, they are pretty small, but rated at 320#'s each and supposed to be specially designed for less than 4 and 5 cyl diesel vibrations.
I rigged up a visual indicator for my wastegate, at 20#'s of boost in 4th gear the wastegate still did not open, or at least my indicator did not move. So I guess I may need to do another more aggressive intake leak test.
The engine seems to be running pretty darn good, I am not sure I really want to mess with it. I will set up the new mounts and get them ready to install, but I think I will wait a bit to tear it all up to put the new mounts in.
I decided I want to get another MPG figure with the intake leaks fixed , before I add any more fuel.

 

dieselxj I will say one thing. They do look a bit odd. But I really hope they work well.

Sometime this week I should start my Tear Down.

 

A update. 2100 miles clocked. best MPG was yesterday at 38.5. Worst was 32.8. The MPG is very dependent on load, mostly wind load. So even at 65mph if there is a headwind it makes a big difference. I put in a new 180F thermostat, not much change. The Kuboata OE thermostat was also a 180F, but it has a little bypass hole that was keeping the temps down
Still running the same settings on the rack. max boost I can hit is a little above 20#. I checked the wastegate and it starts to open at about 22-23psi. I have another 400 mile trip tomorrow I am going to back the rack out a quarter turn.
I get a little black and blue smoke on start up after it has been sitting. and I get a little blue smoke on takeoff after a quick stop from hiway speeds. This makes me think that I might still have a bit of oil back up in the turbo oil drain.
The intercooler is giving a temp drop of about 100degF. With out the intercooler some weeks ago the intake temps were 160+ on a 45 deg day, Now they rarely get above 80F.
I am going to try a 2.71 ring and pinion next, but I am not in a hurry on that as it is running pretty well

 

Well, I just finished putting on the little stiff motor mounts I picked up a few weeks ago. WOW what a difference , and NOT in a good way. I did not even try for a test drive they are that bad. The new little mounts increased visible vibration and seat of the pants vibration throughout the jeep, and increased the interior noise level by double probably, A real step backwards from the MB mounts. As it turns out the MB mounts don't look that collapsed at least now that they are out of the jeep. I will look a little more for some softer mounts in the donut style. but for now the MB mounts go back on. I will see if I can't find some of the little MB mount hydraulic shocks . I just found a pair of the hyd shocks for $70 for the pair, plus $35 for their mount bushings and nuts. I thought they were $70 each. So that is bad, but not that bad. Now I have to engineer and fab for them as well.
I will think about it, but It still seems like it will be more of a PIA to re-manufacture the whole mount setup to use the larger ford style stud mounts, than to just add the little hyd shocks.
maybe I can find a shorter set of ford style stud mounts.

 

Just my .02. I ran these duralast 2817 mounts in both my ranger with the kubota and my 4bt f150. They held up great an i never had any vibration issues or annoying harmonics and they are. Cheap

 

thanks, rangmar I just got in to work, so I will look at one of these when I get home in some months

 

A couple of updates. I decided against the 2.71 ring and pinion for now, until I test out the ratio with a bigger set of tires for a temporary test. I did replace the pinion, carrier, and axle bearings. I got a set of Rangmar's motor mounts, I am pretty happy with them. I still want to try a set of the MB vibration dampers shocks, but these mounts were a easy swap. and the jeep is now pretty quiet
Next I got my Idle surging under control. There was a bit of slack in one of the ball joints on the throttle linkage. So the modified governor spring was not the problem.
I got the aircon hooked back up. I increased the size of the retainer bolt for the harmonic balancer to 5/16, and used some of the Loctite sleeve retainer 680 suggested by JesterGrin. I still need to road test the aircon.
All in all the jeep is running really well.
I am starting on the next engine for the Dakota. I am looking for a T56 transmission, and another TD04L-10KYRC-5 turbo. if anyone has a spare of either of those they want to get rid of send me a PM.

 

Good to hear the progress. I am hopefully dropping my motor in tomorrow. Love the Dakota idea.

 

The Aircon was a bit more work than I thought. I was pretty rough on it the past few months, So I guess I jostled something to make it leak. But that was not the only problem. Back lots of months ago when I had the Harmonic balancer pulley failure. I did some electric work on the engine start stop.
The problem ended up being I had jumped into the Jeeps Aircon circuit to get some power for the start run stop. Well I guess the load was enough to keep the compressor from starting. So after re-locating the engine run stop to a the NON used fuel pump circuit, and about 10oz of r134, I have nice cold air.
I had to up the idle quite a bit now that the aircon is loaded. I am idling at about 820rpm aircon on, and 1050rpm aircon off. Interesting is that EGT went from 200F aircon off to 235F aircon on. The aircon is a pretty big load.
I thought I had the idle surge figured out, but it still hunts around a fair amount. I am pretty stumped on that.
Also I am going to try and look for some sort of Idle bump solenoid I can hook up that will raise the idle while the aircon is on. It will most likely be a huge PIA to set up. I think the aircon will just stay on pretty much all summer

 

I want revive the dead here as I have just acquired a 99 GC with 4.0. The grand is about 500Lbs heavier than your Cherokee. Knowing what you do now, do you think the V2203 can push the GC? It has a few electrical issues that I could fix and sell to get a square body. By the way your build has been inspiring to watch, along with red and fte and rangmar...you guys rock!