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Unread 03-25-2008, 11:33 PM   #1
Blazin Den
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1995 YJ Wrangler 
 
Join Date: Nov 2007
Location: Delaware County,PA
Posts: 313
4.0 Swap Information

i have seen alot of people posting about how to put a 4.0 in the YJ. So i have done the best i could at 1:30 am to help some people out. here is a list of sites that will help you do the 4.0 swap.

General Info on the 4.0 swap
http://www.cjoffroad.com/forums/topic.asp?TOPIC_ID=1097
http://jeep.off-road.com/jeep/articl....jsp?id=277042 (bottom has link to wiring information)

2.5 to 4.0/AW4/242 using 1992 XJ Donor into 1995 (Tomb Raiders Swap)
http://jeepforum.com/forum/showthread.php?t=514821

2.5 to 4.0/AW4 into 1989 YJ ( Big N Brokes Swap )
http://www.jeepforum.com/forum/f12/finally-my-turn-4-0-aw4-swap-my-89-yj-good-bye-2-5-a-462517/
http://www.jeepforum.com/forum/f12/time-change-everything-low-center-gravity-makeover-yj-updated-w-pic-461242/

4.0 Renix Swap
http://www.freewebs.com/billsbuckets/pastprojects.htm

1987 YJ 2.5 to 4.0
http://www.4wdandsportutility.com/te...wap/index.html

1987-1990 2.5 TBI 5spd wrangler using 4.0 OBD1 1994 Cherokee with automatic Transmission
http://cjoffroad.com/forums/topic.asp?TOPIC_ID=14839

90 YJ 2.5/ax-5 using a 93 YJ 4.0L and TF999 automatic transmission
http://www.bc4x4.com/tech/2003/jeep25-40/

93 2.5 using 93 xj 4.0/ax-15 (Leans93 Swap)
http://www.jeepforum.com/forum/f12/leans-4-0l-swap-complete-pics-668796/

94 YJ 2.5 to YJ 4.0 using a 92 YJ with the 4.0L HO motor and AX15
http://www.jeepaholics.com/tech/25to40/25to40.htm

2.5 to 4.0 using 94 HO
http://www.jeeps-offroad.com/f40/engine-swap-31795/

OBD2 Info

2.5 to 4.0 using 98 OBD2/AX 15 from 93 into 91 YJ (roccomonte swap)
http://www.jeepforum.com/forum/f12/4...thread-899497/

4.0 Swap using OBD2 information along with other links to other swaps
http://wilhelm-tech.com/jeep/mods/40EngineSwap.htm

4.0 Swap using OBD2 with donor being 98 XJ 4.0/aw-4/np-231
http://www.madois.com/html/tech/40swap.html ( need to find the new link doesnt work right now)

4.0 Swap using OBD2 1999 TJ 4.0L OBD2 engine into a 1994 XJ 4.0L HO
http://bb.bc4x4.com/showthread.php?t=132488

4.0 from 2000 TJ into 89 YJ
http://www.cjoffroad.com/forums/topi...s=evap%2Cpurge

97 XJ wire harness and splicing info
http://wilhelm-tech.com/jeep/mods/WiringConnectors.htm
http://wilhelm-tech.com/jeep/mods/HarnessSplicing.htm

99 TJ 2.5 to 4.0 swap using 6cyl/5spd trans/t-case/computer/harness (RnEmOvr swap)
http://www.jeepforum.com/forum/f9/2-5-4-0-swap-underway-576008/
http://www.jeepforum.com/forum/showp...3&postcount=20


4.2 to 4.0 using 95 xj (yjcrawlr swap)
http://www.jeepforum.com/forum/f12/90-4-2-95xj-4-0-swap-build-thread-681707/

4.2 to 4.0 (cevans87 swap)
http://www.jeepforum.com/forum/f12/4...build-1114875/

4.2 to 4.0(Fenix85182 swap)
http://www.jeepforum.com/forum/f12/4...years-1136267/

4.2 to 4.0L
http://www.rockcrawler.com/ // go to the tech section,look under motor section for YJ 258 to 4.0L Motor Swap
http://www.bc4x4.com/faqs/yj.cfm?cat=5&faqid=138
http://www.coldspeed.net/forums/showthread.php?t=4372
http://jeepforum.com/forum/showthread.php?t=455084
http://www.4x4wire.com/jeep/tech/engine/fi40swap01/

4.0 Head Swap on 4.2
http://www.monsterslayer.com/pages/j...ead/40Head.htm Tim Weaver's swap
http://www.bustedjeep.com/projects/rebuild.asp
http://www.geocities.com/035jeep/40L.html
http://jeephorizons.com/phpbb/viewtopic.php?t=2542
http://www.northeastsurf.com/4.0%20head%20swap.htm
http://jeep.off-road.com/jeep/articl....jsp?id=277013
http://www.northjerseyjeepclub.org/m...ewtopic&t=2182
http://www.cjoffroad.com/forums/topi...50&whichpage=1
http://jeepsunlimited.com/forums/sho...68#post8138668
http://www.northjerseyjeepclub.org/m...ewtopic&t=2182

OBD2 to OBD1
http://www.cjoffroad.com/forums/topic.asp?TOPIC_ID=786

OBD1 to OBD2
http://bb.bc4x4.com/showthread.php?p=863296

Junkyard GM TBI Install on 4.2
http://www.bustedjeep.com/projects/junkyardtbi.asp
http://jeepforum.com/forum/showthread.php?t=676393
http://www.bustedjeep.com/projects/junkyardtbi.asp
http://www.justih.org/Binder-Bench/s...ead.php?t=6489


Stroker Info
http://www.angelfire.com/my/fan/stroker.html
http://www.jeep4.0performance.4mg.com/stroker.html
http://www.rockcrawler.com/techrepor...er40/index.asp

i am sure there are more write ups available and other people might post them up. These will hopefully help people that are trying to find information about different engine swaps.

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95 White YJ 2.5L/AX-5 Stock on 31s. Ground Pounder Fab (BESRK) Front Bumper, Herculined Interior, Windshield/Front Bumper Mounted Lights, Uniden PRO 520XL Cb,Hidden Hitch Trailer Hitch, Bestop Supertop, Modified CJ7 Hardtop and CJ7 Twist Handle Full Doors (winter)

Last edited by Blazin Den; 12-30-2009 at 08:50 PM.. Reason: add more info
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Unread 03-26-2008, 08:51 AM   #2
crb577
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1993 YJ Wrangler 
 
Join Date: May 2005
Location: Colchester, VT
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not a write up but i have a bunch of photos from when I did mine people can get the general idea that the mounts do have to be cut and new ones welded in at least.

http://rides.webshots.com/album/444691195crgxlO

hope that will help someone
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1993 Jeep Wrangler
4.0L Tom Woods rear HD shaft
D30 w/yukon alloys, lock right, jb4x4 bracket, Rusty's HD tie rod 8.8w/ LSD,SOA xj rear 100" wheelbase, homemade greasable boomerang shackles, SS braided lines, 1" prothane body lift, 35" TrXus M/T, smitty built XRC.
lots of gen right armor and rear stinger.
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Unread 08-16-2009, 12:07 PM   #3
paulzwieg
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Lots of good info on these links I'll be busy reading before I make the change.
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Unread 08-24-2009, 09:36 PM   #4
Hainze
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Lots of good info
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Unread 10-24-2009, 11:17 AM   #5
Blazin Den
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Location: Delaware County,PA
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some more people have been asking about a 4.0 swap so i thought i would bump this back to the top. let me know if any links do not work and i will fix them.
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95 White YJ 2.5L/AX-5 Stock on 31s. Ground Pounder Fab (BESRK) Front Bumper, Herculined Interior, Windshield/Front Bumper Mounted Lights, Uniden PRO 520XL Cb,Hidden Hitch Trailer Hitch, Bestop Supertop, Modified CJ7 Hardtop and CJ7 Twist Handle Full Doors (winter)
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Unread 11-12-2009, 11:10 AM   #6
Blazin Den
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i edited some stuff and added some new links. I will try and fix some of the headings for the links to make them easier to read and find.
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95 White YJ 2.5L/AX-5 Stock on 31s. Ground Pounder Fab (BESRK) Front Bumper, Herculined Interior, Windshield/Front Bumper Mounted Lights, Uniden PRO 520XL Cb,Hidden Hitch Trailer Hitch, Bestop Supertop, Modified CJ7 Hardtop and CJ7 Twist Handle Full Doors (winter)
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Unread 11-16-2009, 10:18 PM   #7
paulzwieg
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I'm in the process of putting a 2000 4.0 out a Cherokee in a CJ. Can't wait to do the wiring. LOL
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Unread 04-02-2010, 12:04 PM   #8
green89yj
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1989 YJ Wrangler 
 
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Location: Georgia
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has anyone spelled out what the 5 to fire wires everyone is talking about are and how they are hooked up? I thought since this was already made, it would be a good place to have basic information like that.
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Herc.Custom Green paint. RC 4". 5 Goodyear 33X12.5 MT/R w/Kev. Cragar V5's. Corbeau Moab seats. Optima Yellow.XRC8 Comp Winch. XJ 4.0/AX15
WTT: 4" springs for 6"
WTS: 4.2 parts. Fuel lines, pump, block, head, accessories, just ask
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Unread 04-02-2010, 12:51 PM   #9
Bastidjeep
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Quote:
Originally Posted by green89yj View Post
has anyone spelled out what the 5 to fire wires everyone is talking about are and how they are hooked up? I thought since this was already made, it would be a good place to have basic information like that.
You need a constant 12v to the steering column. Key on 12v(ignition) Key on start (starter relay) The ignition should power your Power Distribution center relays such as the fuel pump relay which will be your 4th wire. Mine started with 4 unless I am forgetting something....I am not sure exactly how specific you need what you are asking?
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Unread 04-02-2010, 01:14 PM   #10
green89yj
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1989 YJ Wrangler 
 
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that helps. Mine is OBDII so the starter and fuel pump relays are actually grounded not energized to close but that helps. So you had to do what to send 12 volts to the steering column?
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Herc.Custom Green paint. RC 4". 5 Goodyear 33X12.5 MT/R w/Kev. Cragar V5's. Corbeau Moab seats. Optima Yellow.XRC8 Comp Winch. XJ 4.0/AX15
WTT: 4" springs for 6"
WTS: 4.2 parts. Fuel lines, pump, block, head, accessories, just ask
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Unread 04-02-2010, 03:40 PM   #11
green89yj
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1989 YJ Wrangler 
 
Join Date: Nov 2008
Location: Georgia
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hey. what if I used the cab and engine side of a cherokee bulkhead connector, would that make my life a little easier? Does anyone know how to remove the lock cylinder and could I replace it with my YJ one?
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Build
Herc.Custom Green paint. RC 4". 5 Goodyear 33X12.5 MT/R w/Kev. Cragar V5's. Corbeau Moab seats. Optima Yellow.XRC8 Comp Winch. XJ 4.0/AX15
WTT: 4" springs for 6"
WTS: 4.2 parts. Fuel lines, pump, block, head, accessories, just ask
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Unread 07-14-2010, 08:59 AM   #12
topgun6969
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1990 YJ Wrangler 
 
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Location: Madison, WI
Posts: 28
where would i find information on cross referencing different year jeeps and which parts work with what
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Unread 08-31-2010, 06:16 PM   #13
gf70sShow
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1987 YJ Wrangler 
 
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nice

Last edited by gf70sShow; 08-31-2010 at 06:18 PM.. Reason: wrong tab in browser- my bad
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Unread 09-01-2010, 06:30 PM   #14
papashaps1
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1987 YJ Wrangler 
 
Join Date: Jul 2007
Location: Carlisle Pennsylvania
Posts: 46
I looked at all the threads and have done some searching and I am not finding what I need. I swaped the origonal 4.2 in my 87 YJ for a rebuilt 4.2 from an either 89 or 90. I thought is would be an easy swap. I have hooked up all of the matching connections under the hood but now I have some "extra" wires that have no place to go on the new engine. Anyone have any idea were I can see a picture or diagram of what all the connections from my YJ go to? I really appreciate any help you all could give me. If you need pictures or more detail I will be back home on Saturday and can post them at that time. Thanks again.
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Unread 09-08-2010, 12:57 PM   #15
bword
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Location: Derby, Ct
Posts: 350
thanks for this
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