My XJ 4.0 rebuild - Page 2 - JeepForum.com

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post #16 of 38 Old 01-21-2014, 01:05 AM Thread Starter
kcirwilliams
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Some of the goodies that have come in so far. Connecting rods came in today and 5 of them are 691s and 1 is a 544. There's a few little differences between them but they should balance out to the same weight when I take them to the machine shop. The gaskets that have come with the water pump and thermostat housing will get replaced with the felpro gasket material I ordered.

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post #17 of 38 Old 01-22-2014, 04:14 PM Thread Starter
kcirwilliams
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Picked up the "block and crank" today. It turned out to be block, crank, rods and pistons. Not bad for $60
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post #18 of 38 Old 01-23-2014, 10:01 AM
brian0128
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I'll be watching this to get an idea of cost.
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post #19 of 38 Old 01-23-2014, 05:42 PM
landude
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Yep, same here..
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post #20 of 38 Old 01-24-2014, 04:06 PM Thread Starter
kcirwilliams
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Removed the pistons, main caps and crankshaft today. Put the caps back on so they stay in order and don't get lost somehow. Cam bearings arrived a couple days ago. Just waiting on pistons and then we should be ready for the machine shop
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post #21 of 38 Old 02-20-2014, 08:10 PM Thread Starter
kcirwilliams
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post #22 of 38 Old 02-12-2015, 10:39 AM Thread Starter
kcirwilliams
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Updated price list on post #5

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post #23 of 38 Old 02-12-2015, 11:08 AM
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What pistons did you get?

Generally a .020" overbore is standard to clean up the bores. The pistons should match the bores. It is a good idea to let the shop that's doing the boring to size the pistons to the bore.

The shop that did my engine screwed up. They went .020 over and bought .020 over pistons but the ******* that did the honing went to far so the piston/bore clearance was too great. They had to buy another set of .020 +.001 pistons and rings to make the proper fit.

Avoid .030" if possible. You're getting close to thinning out the block walls at .030". .040" is out of the question on the 4.0.
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post #24 of 38 Old 02-12-2015, 11:32 AM Thread Starter
kcirwilliams
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I've got .030" pistons. There's plenty of people that have been fine with a .040" overbore and I've even heard of people having success with an overbore as big as .060" so I'm not worried. The pistons, rings, rods, block, cam bearings, crank and head is all going to the machine shop together. They will have the pistons there so they'll be able to match the bore to them.

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post #25 of 38 Old 02-12-2015, 12:25 PM
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Quote:
Originally Posted by kcirwilliams View Post
I've got .030" pistons. There's plenty of people that have been fine with a .040" overbore and I've even heard of people having success with an overbore as big as .060" so I'm not worried. The pistons, rings, rods, block, cam bearings, crank and head is all going to the machine shop together. They will have the pistons there so they'll be able to match the bore to them.
You'll probably be okay with .030 over but .040 & .060 over.....

Read this, it's from the Mopar Jeep Engines, 3rd Edition, manual, part number P5007161, page 134:

Boring and Milling Specifications

Because it is a thin wall casting design, the 4.0L can only
be over-bored .030" (maximum), although .020"
(maximum) is preferred. Regardless of the amount of
overbore, if the engine is to be used for high output racing
purposes, the cylinder wall thickness should be checked to
be sure the block doesn't have a bad case of core shift. The
cylinder wall thickness should be the same all the way
around or thicker on the major thrust side of the cylinder
bore; that is, passenger side (as installed in the vehicle).
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post #26 of 38 Old 02-12-2015, 02:47 PM
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post #27 of 38 Old 02-12-2015, 05:00 PM
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Would love to learn how to do a rebuild. Subscribed.
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post #28 of 38 Old 02-25-2015, 10:35 PM Thread Starter
kcirwilliams
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Here's a shot of one of the work areas

forumrunner_20150225_233427.jpg

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post #29 of 38 Old 02-25-2015, 10:37 PM
Trainhop91
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Hope to get a 4.0 and rebuild it as well! Going to be watching this. Good work!
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post #30 of 38 Old 02-26-2015, 07:06 PM Thread Starter
kcirwilliams
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Valve cover all cleaned up and painted

forumrunner_20150226_200504.jpg

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