I used to have an 03 Wrangler, Freedom Edition. 3 budget lift and 33's. I sold it and moved on with a family. My kids are older now and the have been successfully brainwashed into wanting a Wrangler. I got a descent deal on a rust free 97 TJ with a knocking 2.5L, 5 speed about 2 weeks ago. I also got a good deal on a 96 Cherokee with a 4.0L 5 speed($400).
I spent the last few days pulling the 25 eng/trans/tcase and the 4.0 eng/trans/tcase. The TJ was a nice easy pull, the XJ on the other hand can kiss my @ss. That thing was the biggest PITA to pull out. Anything that could get hung up, did. I ended grabbing the torch and cutting everything out of the way.
The TJ has a 3.5" suspension lift, 1" body lift, custom front/rear bumpers, swing out tire carrier, bushwacker flat fender flares, and 33x12.5 BFG M/Ts.
The plan is to use the XJ computer, TJ wiring harness but adding 2 fuel injectors to the computer pins and make my own motor mounts. After I puled the 4.0 I puta few new parts on just because it was out. I put all new gaskets, including the head gasket and head bolts. I also put in a new oil pan (I may have popped a hole in the XJ one when I dropped the motor on the front diff), a new stainless steel header, a quick paint job and put in a new Melling oil pump.
Wish me luck on the rest of this headache
This is my replacement, It is a starting point an unbelievable cheap price for what it is. I am finishing up the motor swap in the TJ and it is already sold.
The XJ is crusher bound with no floorboards, rear frame rotted, and only glass being a usable part left on it.
I figured that I would still finish the motor swap on here so people can use it for a reference. As far as the wiring goes, I got a print out of the Jeep 2.5 harness and the 4.0 harness. The wiring colors are all the same and the harnesses are all the same except the 4.0 had two extra fuel injectors that get wired into the harness where the pins go into the computer. The problem that I found from the 6 cylinder to the 4 cylinder is that just about all the plug ins are shaped different. Yes I could cut and splice, but I have a friend with an extra 1999 4.0 Jeep for parts, so I am pulling the harness off from that. Here are a couple pics of the motor mounts and engine in the Jeep
The drivers side motor mount, modified to fit without changing any steering brackets. These are the 2.5, 4cylinder cut off with a plasma cutter and welding back were I need them. I was also able to use the 4 cyl drive shafts.
Not sure if anyone is reading... or cares, but I figured I would finish this up in case somebody out there is looking at this for reference. I got a wiring harness from a 97-98 Sahara. Had a few different extras on it that caused me to have to also change the body wiring harness also. Not an issue at all, took 15 minutes. I had to change the wire connector for the distributor to the 4 cylinder one because the 96 Cherokee one was different. Also had to put in the oil pressure switch, by the filter, from the 2.5 in. As well as the idle air control motor and the coil, plugs were different on both but the 4 cylinder ones matched the TJ harness and the Cherokee ones did not.
Tried to fire it up on the 96 XJ 4.0 5-speed computer, no fire at all. Put in the 97 TJ 2.5 5-speed computer and it fired up and ran on4 cylinders (as expected). I knew these two would not work, but wanted to try this just to post the info.
Finally, plugged in the 99 TJ 4.9 auto computer. It fired right and ran perfect, no issues. I have read that a check engine light will come on because the computer is looking for a torque converter lock up, with my manual trans will not give it.
I also position the engine/trans where it needed to be to reuse the 4 cyl front and rear drive shafts. I have read they were different, but I did not have a 6 cylinder one to compare. Have any questions, feel free to ask. I will let you know what I have discovered and I am not afraid to tell you that I don't know to the answers that I don't know.