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Unread 11-09-2009, 11:15 AM   #1
redhatman
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1998 ZJ 
 
Join Date: Jul 2007
Location: Minnesota
Posts: 2,388
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
-Waterpump
-Intake Manifold Bolts (One broke inside one of the heads)
-Oil Pan gasket
-Lower intake
-Upper intake
-Head Gaskets
-Thermostat
-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.













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I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
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Unread 11-09-2009, 11:19 AM   #2
redhatman
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1998 ZJ 
 
Join Date: Jul 2007
Location: Minnesota
Posts: 2,388
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.
__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
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Unread 11-10-2009, 09:54 AM   #3
chevyman840
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1994 ZJ 
 
Join Date: Mar 2009
Location: locust grove, va
Posts: 26
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
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Unread 11-10-2009, 10:59 AM   #4
tirus89
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1993 ZJ 
 
Join Date: Sep 2007
Location: Boise, Idaho
Posts: 1,219
Theres always something with you! Didnt do any mods while the engine was out?
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Unread 11-10-2009, 03:44 PM   #5
blackjack12982
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1994 ZJ 
 
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Location: Cunningham, TN, Tennessee
Posts: 1,879
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
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Unread 11-10-2009, 09:34 PM   #6
redhatman
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1998 ZJ 
 
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Quote:
Originally Posted by tirus89 View Post
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).
__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
redhatman is offline   Reply With Quote
Unread 11-11-2009, 12:07 AM   #7
redhatman
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1998 ZJ 
 
Join Date: Jul 2007
Location: Minnesota
Posts: 2,388
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.










__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
redhatman is offline   Reply With Quote
Unread 11-12-2009, 11:01 PM   #8
JFox21
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Join Date: Aug 2007
Location: Lafayette, California
Posts: 1,527
Always adding on to the Jeep. That's what I like to see! Looking good dude!
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Unread 11-13-2009, 09:11 AM   #9
MudPit
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Posts: 348
Always better to practice on your own car. Good luck!
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Unread 11-13-2009, 06:24 PM   #10
redhatman
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1998 ZJ 
 
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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)?
__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
redhatman is offline   Reply With Quote
Unread 11-13-2009, 11:14 PM   #11
redhatman
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1998 ZJ 
 
Join Date: Jul 2007
Location: Minnesota
Posts: 2,388
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.
__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
redhatman is offline   Reply With Quote
Unread 11-13-2009, 11:57 PM   #12
aircruiser
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1996 XJ Cherokee 
 
Join Date: Jun 2006
Location: minnesota
Posts: 9,676
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?
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Unread 11-14-2009, 12:41 AM   #13
Greengc4x4
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1998 ZJ 
 
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Location: Ohio
Posts: 4,001
Dude, you trashed a TSi? Why didnt you swap everything over to it?!
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Unread 11-14-2009, 11:03 AM   #14
redhatman
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1998 ZJ 
 
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Posts: 2,388
Quote:
Originally Posted by Greengc4x4 View Post
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.
__________________
-Pat

I am now a dealer for Iron Rock Off Road
I offer the same great products you already know about,
the same low prices you have been seeing, and with
the same experienced customer support, but I can offer it nearly 24/7

"Project Dirty Princess"
5.9 ZJ 7" IRO, 35s, 8.8, hp30, locked, blah blah

"Project Grow A Set"

Quote:
Originally Posted by CMARJEEP View Post
Those tires look freakin awesome Redhat... took the ZJ up a notch in my book. Now you're at notch 2.
redhatman is offline   Reply With Quote
Unread 11-14-2009, 01:48 PM   #15
Greengc4x4
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1998 ZJ 
 
Join Date: Jun 2008
Location: Ohio
Posts: 4,001
oh, i didnt look at it close enough then. lol. it has tsi rims on it though
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