89 4.2 to 96 XJ 4.0 Swap Thread w/ wiring - JeepForum.com
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Unread 03-30-2010, 06:57 PM   #1
green89yj
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1989 YJ Wrangler 
 
Join Date: Nov 2008
Location: Georgia
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89 4.2 to 96 XJ 4.0 Swap Thread w/ wiring

Ok. I'm in the middle of a 4.0 swap into my 89 YJ and I have found a lack of actual "complete" wiring diagrams. I have a 97 XJ fsm but it's nothing I haven't found online. Basically at the end of this I want it to be the most complete swap thread anywhere with step by step instructions like move this pin to this location and splice this wire into this wire etc.
Anyone with information to share please post up and I will update as I make progress.
On the mechanical side I just want to remind everyone that they need:
4.0 starter
4.0 flywheel

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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 03-30-2010, 08:28 PM   #2
Douglas S.
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1991  
 
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Unless you feel like spending 300 on the CPS kit from Hesco. I just swapped my transmission and don't really want to do it again so it looks like that's what I'll be buying when I swap to injection this summer.
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Unread 03-31-2010, 05:28 AM   #3
green89yj
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1989 YJ Wrangler 
 
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yeah. I got the whole engine and transmission from a rolled 96 XJ so I'm good on the flywheel. I did have to covert my NP231 input from 21 to 23 spline though because I didn't feel like dropping to coin for a whole new transfer case.
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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 03-31-2010, 11:40 AM   #4
remmons
Some assembly required.
2002 KJ Liberty 
 
Join Date: Mar 2010
Location: Vernal, Utah
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I am glad that you started this thread, green89yj. You had an interest in my wiring conversion. I know I haven't been much help as of late with my build. I have had other issues that took precedence over my Jeep.

This is what I have done thus far. I have determined what components were needed under the hood, and taken note of what wires that were needed. I have also taken notes on what needs to run from under the dash to the engine compartment. I was not satidfied with just moving two wires while I had the fuse block apart. I should have a comprehensive converion chart within the next week or so, time and family permitting.

In the mean time, I will be watching your thread for progress made.
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Unread 03-31-2010, 04:39 PM   #5
green89yj
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Thanks remmons. I was tired of mooching off other people and decided I should start contributing some, as little as I do know haha. So far I have had the most problems with my ASD relay I think so I'm gonna try to start there and work backward.
Does anyone know what wire provides the main voltage to the PCM and which one signals the PCM which position the ignition switch is in, like to signal the starter, fuel pump, ASD, or whatever.



What are the 5 to fire that everyone is talking about all the time?
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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

Last edited by green89yj; 04-02-2010 at 07:00 AM..
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Unread 03-31-2010, 05:24 PM   #6
remmons
Some assembly required.
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@green89yj.
I had checked out your build thread a couple weeks ago. I meant to comment on it then but got sidetracked. That is a nice rig. What is that paint color? Looks like the color I painted my old CJ5A. (Deep Jewel Green).
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Unread 04-01-2010, 07:22 PM   #7
green89yj
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The paint is a mystery color that can probably never be created again. When I bought the paint based on a 1"x.5" color sample, it was way too light and they couldn't just add a little more pigment to darken it up because it was mixed already or something so I bought two cans of black with the same pearl flake and mixed it all together in a Home Depot 5 gal paint bucket and sprayed that mix.
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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 04-02-2010, 09:28 AM   #8
remmons
Some assembly required.
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Location: Vernal, Utah
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If I think about it, I will look for a snapshot of my old CJ and compare the paint colors. At this point they look very close.
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Unread 04-02-2010, 03:43 PM   #9
green89yj
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ok. Cool.
I just went to the junkyard and got a wiper stalk and ignition switch with lock cylinder but no key from a 96 xj. I basically have all the underdash wiring except the gauges and anything on the passenger side. I am just going to stick the bulkhead connector together and see what I can get.

Does anyone know how to remove the lock cylinder from a cherokee ignition switch and also do you know if I can put my YJ one in or if I will need to get a new lock and keys?
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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 04-02-2010, 04:30 PM   #10
remmons
Some assembly required.
2002 KJ Liberty 
 
Join Date: Mar 2010
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The ign lock cylinder is removed by removing everything on the column to gain access to the lock cyl. There will be one screw (located at the tail end of the lock cylinder) that needs to be pulled out. There is also a "tab" at the end of the lock cylinder that can be depressed by a narrow screw driver. I believe the key will need to be in place and at the off or on postion in order to be able to depress this tab. I never tried it with out a key.
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Unread 04-03-2010, 06:39 AM   #11
green89yj
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well I didn't have a key so i had to get a little more creative with it. I prefer to call it destructive testing of tamper proof abilities.
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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 04-03-2010, 07:12 AM   #12
Bastidjeep
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When I did my conversion all I did was that I left the original bulkhead plugs of the YJ on both sides. I labeled everything and left 1 ft long pigtails on the YJ wiring. I then soldered and heat shrank all the necessary wiring in the conversion. The only 2 wires I ran through the center bulkhead rubber plug was my check engine light wire and fuel pump wire. green89yj, somewhere along the line I think you are going to have to cut and splice wiring. I think if you can post some pictures it may give all of us a better understanding of exactly what you are doing and may be able to steer you in the right direction.
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Unread 04-03-2010, 07:43 AM   #13
green89yj
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I am fully prepared and expecting to cut and splice/solder wires. I'm just trying to make sure I isolate the right ones. What are you wanting pictures of?
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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 04-03-2010, 10:31 AM   #14
SkullTripper
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Posts: 305
Quote:
Originally Posted by green89yj View Post
Ok. I'm in the middle of a 4.0 swap into my 89 YJ and I have found a lack of actual "complete" wiring diagrams. I have a 97 XJ fsm but it's nothing I haven't found online. Basically at the end of this I want it to be the most complete swap thread anywhere with step by step instructions like move this pin to this location and splice this wire into this wire etc.
Anyone with information to share please post up and I will update as I make progress.
On the mechanical side I just want to remind everyone that they need:
4.0 starter
4.0 flywheel
If you kept the 4.2 trans.. you won't need a 4.0 starter and flywheel will you?
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Unread 04-03-2010, 11:53 AM   #15
Bastidjeep
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Quote:
Originally Posted by SkullTripper View Post
If you kept the 4.2 trans.. you won't need a 4.0 starter and flywheel will you?
The flywheel is different between the 4.0 and 4.2. The exciter ring for the crank position sensor is the difference.
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