I have a stock 91 with a 2.5 inline 4 cyl. I would rather not have to swap the engine is there any other way to affordably produce more power?
OK, I got the exact same thing. And I got ZERO money. Now I've been around the car scene a long time (mostly big chevys, I'm 44 yrs) but here is some advice:
Speed costs. How fast do you want to go?
Yeah you can hop up the 2.5 probably for a grand or so, depending if your motor is in good shape at all to begin with. You're probably better off with a motor swap tho if you're going to get into it that deep. One thing that is real popular is the chevy S-10 Blazer with the 4.3 liter.
If you can't do that then there are a few tricks but be aware that its never gonna be a barn burner. It just wasn't made to do that. One trick is to get the throttle body out of a 4.0 and put that on. Another trick is to get bigger fuel injectors out of a Ford Mustang 5.0. Third trick is to get some roller rockers (about $400) from Quadratec. Fourth trick is a hotter ignition system, a couple hundred from Firepower.
You might get another 20 HP after doing all that. Prolly run a bunch smoother and cooler. And eat your gas mileage too.
I've been out Iowa, how much time do you spend on the highway and around town as opposed to actually wheeling? You might want to re-gear to 4.56 but I wouldn't go much deeper than that unless you have crazy tires. Mainly because everybody goes like 100 out there.
Nope I'm not trying to be a jerk. But the fact is that I've been thru that and I'm trying to save you a bunch.