My XJ 4.0 rebuild - JeepForum.com

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post #1 of 38 Old 01-02-2014, 05:14 PM Thread Starter
kcirwilliams
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2001 XJ Cherokee 
 
Join Date: Dec 2013
Location: Neosho
Posts: 58
My XJ 4.0 rebuild

Should be getting donor 4.0 from a 98 XJ next week. I've started a parts list knowing that I won't be able to order some until machine work is done. List as of now is as follows:
Pistons
Piston Rings
Rod Bearings
Main Bearings
Cam Bearings
Camshaft
Lifters
Timing set
Oil Pump
Expansion Plugs
Block heater - Mopar #82201506
Push Rods
Cylinder Head - haven't decided on converting old style or going with new casting
Water Pump - Gates #42004
Thermostat - 195f Stant Superstat #45359
Gasket set
Serpentine Belt
Oil filter - Wix #51515

I will be posting pictures and updates as everything progresses. Any input on best parts to go with will be greatly appreciated. I've got the 2000 cherokee fsm. Not sure how different it will be for the 98 motor but I guess we'll see.

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2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)

Last edited by kcirwilliams; 01-02-2014 at 05:25 PM.
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post #2 of 38 Old 01-02-2014, 05:28 PM
Xride
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I'd recommend some poly over that carpet there. lol

You should keep a running cost, I'd love to do this myself some day.

99 XJ, black, 4x4, NP231, 8.25 rear. Fully locked.
5.5" long arm lift, 35x12.5x15 Kumo KL71MT
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post #3 of 38 Old 01-02-2014, 05:33 PM Thread Starter
kcirwilliams
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2001 XJ Cherokee 
 
Join Date: Dec 2013
Location: Neosho
Posts: 58
I plan on keeping track of everything I spend on it throughout the process.

It was much warmer in my house assembing the stand. I tried to convince the wife it was a great spot for it but she wasn't having it

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)

Last edited by kcirwilliams; 01-03-2014 at 06:05 PM.
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post #4 of 38 Old 01-04-2014, 12:15 AM Thread Starter
kcirwilliams
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2001 XJ Cherokee 
 
Join Date: Dec 2013
Location: Neosho
Posts: 58
I checked local hardware stores today and the 7/16 14x2-1/2 bolt must be the unicorn of bolts around here. I ordered a pair of ASMC grade 9 7/16 x 2-1/2 bolts and 4 grade 8 3/8 x 2-1/2 bolts for the engine stand. I've read that grade 5 will get the job done and I know there is no standard for grade 9 bolts. It may be a bit overkill and this isn't really update worthy but that's all I've got as I patiently wait for next weekend when I should be picking up the 4.0

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #5 of 38 Old 01-04-2014, 07:58 PM Thread Starter
kcirwilliams
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2001 XJ Cherokee 
 
Join Date: Dec 2013
Location: Neosho
Posts: 58
Price List - I will edit this post as the build goes on with prices and where parts were purchased.

$150.00 96 XJ Block, crank and 0630 Cylinder Head (craigslist)
$146.08 BP753 Connecting Rods (ebay)
$155.86 Sealed Power 802cp .030 Pistons and Mahle Rings
$33.81 Clevite 77 Cam Bearings #SH1980s(ebay)
$28.25 Ebay timing set
$7.97 Victor timing cover gasket set (ebay)
$24.95 Water Pump - Gates #42004 (rockauto)
$10.75 Dorman 902-306 Thermostat Housing(ebay)
$10.08 195f Stant Superstat T-stat #45359 (rockauto)
$49.26 Victor gasket set - valve cover, head, 0630 exhaust/intake (ebay)
$12.71 Valve cover grommets for CCV elbows (ebay)
$8.90 CCV elbow (ebay)
$15.00 Rear main seal (ebay)
$20.99 Goodyear Serpentine Belt #4060950 (ebay)
$13.95 Oil filter adapter o-rings (ebay)
$19.15 Oil pan gasket (ebay)
$6.98 Crown Auto J3173076 Oil Slinger(quadratec)
$36.65 Harmonic Balancer (ebay)
$24.54 Victor GS33414 Head Bolt set (ebay)



$775.88 total

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #6 of 38 Old 01-15-2014, 07:03 PM Thread Starter
kcirwilliams
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Location: Neosho
Posts: 58
Any recommendations on an overbore? I was planning on .020

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #7 of 38 Old 01-15-2014, 07:53 PM
uberxj92
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I'll get flamed for this but, any over bore if .030 or less won't give you any real noticeable performance gain. It will give you numbers on paper. You start feeling it at .040 up.
My dads machine shop builds performance engines. He always goes .040 up. We've built several 4.0 stroker's that way. No complaints yet.
If you punch it out use the over bore pistons not the cheater way with rings.

http://www.jeepforum.com/forum/f177/92-xj-sadness-2075657/index2.html
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post #8 of 38 Old 01-15-2014, 07:57 PM
uberxj92
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Have you looked into roller rockers? Good middle of the road upgrade.
Brass freeze plugs?
They sell a true zero degree timing gear set. I use them on both of my stroker's.

http://www.jeepforum.com/forum/f177/92-xj-sadness-2075657/index2.html
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post #9 of 38 Old 01-15-2014, 08:00 PM Thread Starter
kcirwilliams
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Location: Neosho
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I'm not really going for a big performance boost as much as I am longevity.

When I pull the current 4.0 and rebuild it after this one is done is another story though. It's more than likely going to get the 4.2 crank/rods, a larger overbore and hotter cam if it can be saved!

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #10 of 38 Old 01-15-2014, 08:03 PM Thread Starter
kcirwilliams
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Quote:
Originally Posted by uberxj92 View Post
Have you looked into roller rockers? Good middle of the road upgrade.
Brass freeze plugs?
They sell a true zero degree timing gear set. I use them on both of my stroker's.
Definately going with the brass freeze plugs(and a block heater). Plan is to go with a complete clearwater head. If I remember correctly it should have the complete valvetrain so I don't think roller rockers will happen.

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #11 of 38 Old 01-15-2014, 08:12 PM
Kalali
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Quote:
Originally Posted by kcirwilliams View Post
Definately going with the brass freeze plugs(and a block heater). Plan is to go with a complete clearwater head. If I remember correctly it should have the complete valvetrain so I don't think roller rockers will happen.
Clearwater head doesn't come with rockers and/or push rods. In your case you'll need to get new ones assuming you're going to use new lifters and cam.
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post #12 of 38 Old 01-15-2014, 08:15 PM Thread Starter
kcirwilliams
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Quote:
Originally Posted by Kalali View Post

Clearwater head doesn't come with rockers and/or push rods. In your case you'll need to get new ones assuming you're going to e new lifters and cam.

Yes I am. That's good to know! The reasons I started this thread is to give as much of a play-by-play on the rebuild as possible and get info like this

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #13 of 38 Old 01-16-2014, 09:14 PM Thread Starter
kcirwilliams
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Join Date: Dec 2013
Location: Neosho
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I've updated the price list on the first page. So far Ebay has been the best bet on parts because of free shipping. There's quite a bit more on my watch list so I'll continue to update as I buy.

It's looking like I'm going to pull the trigger on a +.030 Sealed Power pistons and rings set over the weekend and a Melling MC1377 cam. As soon as they gets here its off to the machine shop

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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post #14 of 38 Old 01-16-2014, 10:19 PM
jeepkid03
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Subscribed to this thread! I'm looking forward to the build! Which thermostat are you getting? I tried looking up the part number but couldn't find it. The Stant Superstat is a good one, I have the 195 degree (#45359) and it keeps my temps right at 197-202.

Good idea going with the new clearwater head, you won't be disappointed and it will go together much easier than modifying an older style head.
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post #15 of 38 Old 01-16-2014, 11:23 PM Thread Starter
kcirwilliams
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2001 XJ Cherokee 
 
Join Date: Dec 2013
Location: Neosho
Posts: 58
Fixed the typos. I'm using the superstat 45359. I've been reading reviews on just about evrything before I buy and it looked to be one of the better ones.

2001 Cherokee
2006 Liberty (wife's)
1998 Wrangler (sold)
1997 Cherokee (sold)
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