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Unread 03-13-2012, 10:09 PM   #1
4Slow9erHybrid
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1997 ZJ 
 
Join Date: May 2008
Location: Hopkinton, MA
Posts: 705
ZJ cabin air filter

Because our ZJs have just a very poor screen at the cabin air inlet, all sorts of debris gets to the evaporator core and it rots out with time. Mine was no exception. So I decided to retrofit a proper cabin air filter.

I started with a WJ cabin filter housing and modified it to fit my ZJ.



The area where the housing mounts to is pretty flat on the WJ, but on ZJ it's curved. There's also less room there, so I had to shorten the housing:



Redid the cut-off side:



Next I made the back surface from fiber glass cloth and resin. First I glued the precut cloth to all 4 sides with the resin and let it set. Sorry, no pic. Next I covered the firewall with masking tape and attached aluminum foil to it with double sticky tape, sprayed with WD 40 (to be able to separate the resin once it sets). Stuffed some aluminum foil to the other side of the cloth, WD40 and bunch of foam.




After release:



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1997 JGC Laredo 4.0 4x4 99900mi * 0W30 German Castrol since 75k * 225/75/R15 Firestone Destination AT on Ravine rims * winter 235/75/R15 Bridgestone Blizzak DM-V1 * UC suspension * Monroe Reflex Monotube shocks * factory skids * KOR steering brace * rear Addco SB * Magnaflow cat and cat back system * complete 5.9 interior
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Unread 03-13-2012, 10:22 PM   #2
4Slow9erHybrid
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1997 ZJ 
 
Join Date: May 2008
Location: Hopkinton, MA
Posts: 705
Added another layer of fiberglass cloth, let it set and then a layer of resin to both sides. Traced the hole outlines onto the fiberglass and cut them out with a dremel. Here is the finished housing:


Just for cosmetics, sprayed it with some black paint.
Next is the final installation, used a GENEROUS amount of RTV and had to plug a bunch of holes (circled with red) with duck tape and RTV.


Filter in place:

All finished:


Had to grind away a section of the cowl for the housing to fit here:


I'm happy with the result. The air flow did not change at all, but it's much quieter in the cabin.
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1997 JGC Laredo 4.0 4x4 99900mi * 0W30 German Castrol since 75k * 225/75/R15 Firestone Destination AT on Ravine rims * winter 235/75/R15 Bridgestone Blizzak DM-V1 * UC suspension * Monroe Reflex Monotube shocks * factory skids * KOR steering brace * rear Addco SB * Magnaflow cat and cat back system * complete 5.9 interior
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Unread 03-26-2012, 06:03 AM   #3
Ghaniba
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1999 XJ Cherokee 
 
Join Date: Sep 2008
Location: Northeast CT
Posts: 387
Awesome work, I love it!

Dave
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'98 TJ - Retired
'98 ZJ 5.9 Limited - Tow Rig
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Unread 03-26-2012, 11:26 AM   #4
sebian
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1995 ZJ 
 
Join Date: Sep 2009
Location: Austin, TX
Posts: 1,360
Subscribed so I can find it later
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1995 ZJ 5.2L V8 318. 220,000 miles and still rollin.

List of parts not replaced yet:
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Unread 03-26-2012, 11:30 AM   #5
torchd
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1998 ZJ 
 
Join Date: Jan 2010
Location: Chicago
Posts: 2,390
Looks nice. How much was the cabin air filter?
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[b]1998 Jeep Grand Cherokee Laredo[/b]
2" BB Pucks | SkyJacker Hydro Shocks | Rubicon Wheels | Cooper 245/75/16 Tires

[b][color=red]2002 Trans Am[/b][/color]
Cam, Full Exhaust, Stock Heads, Stock LS6 Intake and Stock 10 bolt with 3.42s
[b]420 RWHP and 382 RWHTQ[/b]
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Unread 03-26-2012, 11:43 AM   #6
4Slow9erHybrid
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1997 ZJ 
 
Join Date: May 2008
Location: Hopkinton, MA
Posts: 705
Thanks guys. I bought the housing and filter kit for $28.25 from filterheads.com

http://www.filterheads.com/product/single/AQ1097KIT

However, I'd suggest to buy just the housing from them ($21.50):

http://www.filterheads.com/product/single/82208300

Their filter is just a dust filter, while you can buy a Fram FreshBreeze filter which also gets rid of odors (activated carbon and baking soda). I'll get a FreshBreeze when it's time to replace the filter.
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1997 JGC Laredo 4.0 4x4 99900mi * 0W30 German Castrol since 75k * 225/75/R15 Firestone Destination AT on Ravine rims * winter 235/75/R15 Bridgestone Blizzak DM-V1 * UC suspension * Monroe Reflex Monotube shocks * factory skids * KOR steering brace * rear Addco SB * Magnaflow cat and cat back system * complete 5.9 interior
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