How To: Build your own 4.0L turbo Cummins (Beware...170+ pics)

[GrimmJeeper]

Set-up allowances. Each of you get 10% of your income to spend any way you wish. Save it up. That is how I pay for my fun stuff, but can't yet afford the entire turbo set-up.

That works even better if you work and she doesn't :roll:

 

[XJCasper]

That works even better if you work and she doesn't :roll:

Oh yes it does. She was working when we originally set it up.

 

[Mesh]

I like the v-bands. Since you solid mounted your exhaust where does it move with the engine?

 

[Boostwerks.com]

I like the v-bands. Since you solid mounted your exhaust where does it move with the engine?

I have a flex section in the down pipe right before the crossmember. Also with the brown dog motor mounts, the engine doesn't move much at all.

 

[xj9140]

When will we see complete turbo kits available for sale?

 

[urban yan]

When will we see complete turbo kits available for sale?

I've been asking him that for years.

 

[Boostwerks.com]

Currently I'm more concerned about getting a full shop going so making complete kits would actually be feasable. Right now they are simply beyond my scope of simply making turbo manifolds.

 

[yossarian19]

That sounds reasonable. Tellya what, give me a couple years to get out of debt first & then see where you are with the shop & a completed kit.
Till then... keep up the good work

 

[GrimmJeeper]

Any way to get one of them fancy manifolds built out of regular steel instead of stainless for a few less $$ ??

 

[Boostwerks.com]

Any way to get one of them fancy manifolds built out of regular steel instead of stainless for a few less $$ ??

whats funny though is mild steel schedule pipe costs almost as much as 304 stainless. Also the durability of a mild steel manifold would be much lower due to the heat cycles. 304+ stainless takes repeated heat cycles much better, while the mild steel gets very brittle and eventually cracks.

BTW, we still have 1 manifold available for $650 shipped! After that is sold, they are going back up to $750.

 

[Boostwerks.com]

Oh...Forgot to mention. The Jeep passed emissions here in Colorado (roller test) with all of the turbo setup intact. I know several people have been curious about it's ability to pass, and now it's been verified.

 

[h-townxj]

Now you just need to make is carb legal so I can build one lol

 

[Root Moose]

Could post the e-test numbers? It would be interesting to see what the tolerances are for those in other jurisdictions.

 

[Boostwerks.com]

Could post the e-test numbers? It would be interesting to see what the tolerances are for those in other jurisdictions.

Sorry it's taken me a while, but here they are:

Stats:
HC: .6636 of 4 Max
CO: 11.74 of 20 (not surprising since they let it so long)
CO2: 542.33 of (unlimited?)
NOX: 2.367 of 9

 

[Root Moose]

Interesting... Here are the values for the test I had done recently (stock 4.0). I'm guessing we are not using the same units here in Ontario.

               +--------------------------++--------------------------+
               |       ASM2525 Test       ||      Curb Idle Test      |
               |-------+---------+--------++-------+---------+--------+
               | Limit | Reading | Result || Limit | Reading | Result |
               |-------+---------+--------++-------+---------+--------+
        HC ppm |    58 |      5  |  PASS  ||  150  |     5   |  PASS  |
               |-------+---------+--------++-------+---------+--------+
           CO% |  0.32 |   0.01  |  PASS  || 0.70  |  0.00   |  PASS  |
               |-------+---------+--------++-------+---------+--------+
        NO ppm |   652 |    136  |  PASS  ||  N/A  |   N/A   |   N/A  |
               |-------+---------+--------++-------+---------+--------+
               |   RPM |   1674  |  VALID ||  RPM  |   747   |  VALID |
               |-------+---------+--------++-------+---------+--------+
               | Dilution | 15.6 |  VALID || Dilution | 15.5 |  VALID |
               |----------+------+--------++----------+------+--------+

Could you check what units your test was using?

 

[XJCasper]

Don't know what any of that stands for, but Canada numbers are most likely metric.

 

[Root Moose]

It's actually SAE/SI unit agnostic. ppm is parts per million, percent is percent.

 

[Boostwerks.com]

Bump for updates. My front D30 polish has been recently installed, and the rear 8.25 shall be thrown in soon as well. It's worth noting since I'll be off to the dyno as soon as it's in.

 

[mmag1982]

Excellent write up and build, couple of questions though:

1. I remember calling AEM specifically about their Fuel Ignition controller and they informed me that they have no specific plug in harness for the Jeep Cherokee!,, Did they issue this recently or something.? Can you share more details about how you hooked your unit up?

2. It might sound a little bit off, but why a turbo?. Wont a supercharger give you nearly the same gain with the added bonus of having to do nothing about the exhaust manifold? I'm not an expert but it seems that a supercharged system will involve much less fabrication?

 

[Boostwerks.com]

They don't have a direct plug in FIC for the cherokee. They do have a jumper harness however that allows you to make it plug and play. It's a little more work for you, but it's not hard at all.

Simply put... I love turbos. Super chargers are great and all, but they simply don't match a turbo in terms of efficiency and the overall fun factor. Also those of us that love turbos also love the fabrication involved to make it all work. If your looking for easy bolt on power, a supercharger might be best for you. However, if you like a challenge and the satisfaction you get from building your own system, a turbo is the only way to go. I could go on for days with the benefits a Turbo offer's over a supercharger but in the end, it's all up to you.