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-   -   My Engine Swap "build thread" 4.0 - 5.2 (

redhatman 11-09-2009 12:15 PM

My Engine Swap "build thread" 4.0 - 5.2
Ok, first off I know you are saying why would you go from a 4.0 to a 5.2, and not a 5.9? Well the answer is because I already had a 5.2 Jeep and had been trying to hunt down a wrecked 5.9 for the past 6 months.

I am already pretty far into this but there is some question with what people are getting into when doing a swap like this.

So I have two completely running Jeeps. My built 98 ZJ with a 4.0 and the donor 5.2 stock. Objective, tear out necessary components, redo parts of motor and put in mine.

Compression tested out well, so I did not replace any rings.
Heads were tested for cracks and warpage, all systems go.
The following parts have been replaced so far.

-Rear Main Seal
-Intake Manifold Bolts (One broke inside one of the heads)
-Oil Pan gasket
-Lower intake
-Upper intake
-Head Gaskets
-Thermostat gasket
-Waterpump hoses
-Spark Plugs
-Distributor Cap
-Distributor Rotor
-Fuel injector O-Rings
-Exhaust manifold gaskets

All rusty parts, like valve covers and oil pan were wire wheeled down, and repainted with high temp paint.

redhatman 11-09-2009 12:19 PM

Going to get some new exhaust manifold bolts tonight, the plan is to get the transmission up on the engine stand to change the pan and gasket, and get the engine and trans bolted back together tonight. Then...time to start tearing apart my ZJ.

chevyman840 11-10-2009 10:54 AM

Keep it coming i just found a 5.2 grand for 200 that runs a drives no title so im doing the same as soon as the 4.0 or tranny gives me any hint of trouble i will be keeping an eye on this thread yours is looking good so far

tirus89 11-10-2009 11:59 AM

Theres always something with you! Didnt do any mods while the engine was out?

blackjack12982 11-10-2009 04:44 PM

Have you thought of doing the plenum gasket while the 5.2 is out, it'd be alot easier than later on with it installed.

Hughes Engines

redhatman 11-10-2009 10:34 PM


Originally Posted by tirus89 (Post 8266316)
Theres always something with you! Didnt do any mods while the engine was out?

Phahahha yeah man just too busy to even post on JF anymore! I have no time to sit down and relax... relaxing is for Sally little B***'s! Hahah

I posted what all I did to it, I did do all gaskets. I was thinking of doing some mods but I dont have much money for that, its all going to tools for school (going to be a technician).

redhatman 11-11-2009 01:07 AM

Just got in for the night.... The first part of the night I spent using my new Power Probe III to test it out. I made the mistake of putting down the windows when I started the project, and with all the wiring and battery out I could not roll them back up before parking it back outside. So I took off both front door panels and powered up just the window motors with 12 volts.

Other than that, I got pretty much everything I think and hope I will Need for mine when putting it in. I am praying I do not need to rip out the dash for wiring or anything. Fuse boxes looked the same, so I think those will carry over. I finished taking out the A/C, and took out the engine mounts.

Here are some updated pictures, now its time to start tearing apart my Lifted ZJ. And I think anyone that knows me can tell you that as soon as that first bolt comes out there will be a rush to get the very last bolt back in.

JFox21 11-13-2009 12:01 AM

Always adding on to the Jeep. That's what I like to see! Looking good dude!

MudPit 11-13-2009 10:11 AM

Always better to practice on your own car. Good luck!

redhatman 11-13-2009 07:24 PM

Last night I started tearing apart "Sir Flexalot", what a sad day. Hopefully I will have those guts out by the end of saturday, so I can put the new one in on sunday and start bolting it all back together.

Does anyone know if I can get away with just switching the engine computer, and not mess with the dash or BCM (Body Control Module)?

redhatman 11-14-2009 12:14 AM

Here is last nights status

I made more progress tonight. The 4.slow will be pulled tomorrow along with the 42re. Tonight I got the main things out, t-case, rest of a/c, some random wires and such. I loosened up the engine mounts and now literally a jack stand and two engine mounts are holding it all up. I still have one transmission cable going to it now but that will come off tomorrow. I want to have the 5.2 + 44re in tomorrow and at least be able to hold its own and no more jack stand crap.

aircruiser 11-14-2009 12:57 AM

dude lemme know if you need help. i work 8-6 every day next week but i could probably come over and lend a hand..what are you gonna run for exhaust?

Greengc4x4 11-14-2009 01:41 AM

Dude, you trashed a TSi? Why didnt you swap everything over to it?!

redhatman 11-14-2009 12:03 PM


Originally Posted by Greengc4x4 (Post 8288691)
Dude, you trashed a TSi? Why didnt you swap everything over to it?!

Who ever said anything about a TSI?
Its just a regular 1997 Jeep Grand Cherokee Laredo.

Greengc4x4 11-14-2009 02:48 PM

oh, i didnt look at it close enough then. lol. it has tsi rims on it though

The time now is 10:17 PM.

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