Hi all, just a quick introduction: I've been an MJ guy for a long time. I currently own 3 and half Comanches. I've also owned a Canadian-import 2-door XJ in the past, but never got around to making an account here. However, the girlfriend and I just picked up a '96 export XJ in Italy for a road trip around the country, so I figured this merits a build thread, because it's a bit of a novelty.

Its got a 2.5L VM Motori turbo diesel, AX-15, NP231, dana 30/35 with 3.73 gears, and a limited slip rear. It also came with every option available besides cruise/auto--because Europe. Most options still work. all the power locks and windows needed a little lube, but they're working. Some other knickknacks will need attention.

I forgot to snap a pic when we bought it, but here it is on the way back to her family's house.



That light bar didn't work, and the wiring for this and more turned out to be a complete disaster. I probably spent a full day just stripping out all of the PO's electrical "modifications" I was lucky to find these screw terminals, because most of his splices were twisted wire with tape.


He had a lot of other professional repairs like this door hinge



But we made the ~10hr drive back to her parents place, and I spent about a week and half prepping it for our trip. We'll be heading from her folks' place in Turin, to Palermo, with many stops in between. I'll update this thread with the repairs/mods we did to get ready for the trip.

Also, any info anybody has on this engine would be amazing, FSMs etc. I'm pretty familiar with this vehicle platform, but the engine is a new one for me. I know there are a few international users on here, so if you have anything to share, please let me know. Thanks!

 

The original headliner was totally destroyed, so we had to reskin it.



she picked the fabric, and I think it really turned out alright. We might do the visors and overhead console to match at some point, but this was good enough for the time being. I know these illuminated visors can be tricky to open without snapping tabs. We also stripped the interior while we we were at it, and deep cleaned everything.

 

At some point a PO had put in a 1.5” puck and add-a-leaf lift. The add-a-leaf had brought the saggy springs to roughly stock height, and the pucks gave the vehicle a reverse rake, and destroyed the original track bar. There was a lot of steering rod end slop, and the sway bar bushings were shot, so I put in basically a whole new front end. Sourcing parts was a little challenging, not speaking the language, but we got it done. All new steering, shocks, track bar, and sway bar links. And I took out the pucks.

its got crisp handling now (for an XJ), and most of the highways noises have been cured.


I also took advantage of the EGR delete to install sensors for an external boost gauge and exhaust temp gauge. Update: they do not work. Don’t buy the cheapest ones on Amazon



we took it on a test drive straight up into the alps for two days, and it actually did ok.