Jeep Cherokee Closed to Open Cooling System How-To - Part 1 of 3

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Part 1 of 3: In this video I'll show you how to convert the older XJ Jeep Cherokee closed style cooling system to the newer open style cooling system. I believe Jeep made the switch in late 1991 so If you have a later model Jeep Cherokee this upgrade doesn't apply to you. This is quite extensive and I'll cover it in three videos. First we'll take out the old radiator and and coolant bottle along with the hoses, thermostat housing and replace it with a new radiator with a cap, a new open style coolant bottle, and some new hoses and new thermostat housing. I'll also show you 3 ways you can hook up your auxiliary fan to still work with the new cooling system. By the time were done you will have an entirely new and updated cooling system and hopefully keep your XJ running cool.

**UPDATE 05/25/2013 - It appears they now make a radiator that has a radiator cap and the hole for the older XJ stock temp sensor. So if you are buying a new radiator then you might want to get this one and you wont have to fool with the wiring mess I dealt with in the 3rd video. It is made by Spectra and the Part # is: cu1193. If anyone knows of other radiators that fit please let me know in the comments. UPDATE***

Do not Try this at home

Parts list:
newer XJ radiator or 3 core XJ radiator
radiator cap
newer XJ thermostat housing
newer XJ overflow bottle
Optional - Newer XJ heater control valve
3' of 3/4" heater hose
3' of 5/8" heater hose
6' of 5/16" hose
2 - 5/8"-3/4" hose adapters - Help part #47080
2 gallons antifreeze
2 gallons distilled water
1 quart transmission fluid (for automatics)
1/8" vacuum caps
extra hose clamps
3/8" -18 NPT Switch - Part # Borg Warner TFS8 OR Wells SW555
Pigtail for switch - Part # Dorman85140
5 Gallon Bucket
zip ties
electrical connectors
have I missed anything?


Part 2:    • Jeep Cherokee Closed to Open Cooling Syste...  
Part 3:    • Jeep Cherokee Closed to Open Cooling Syste...  


Disclaimer - This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee, wrangler, or any jeep vehicle. May be too intense for some viewers and children under 30 years of age. Please remain seated until the ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in jeep mirrors may be farther than they appear.