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Unread 10-08-2013, 07:17 PM   #1
jafjap
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2002 TJ Wrangler 
 
Join Date: Mar 2013
Location: Virginia Beach, Va
Posts: 16
99 4.0L engine swap into an 02 2.5L

So if I can get some help and guidance from a few of you more experienced guys who have done an engine swap before, here is my project; I've got an 02 2.5l wrangler and am getting a 4.0l engine out of a 99 wrangler from a buddy. I want to swap the engines out and am curious how possible this is...if the harness are compatible and what all needs to be done, I know its a laundry list and quite an undertaking. I've got a buddy helping ,but having an idea of what all need to be done would make it a lot less overwhelming and costly. Thanks guys!

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Unread 10-15-2013, 06:50 PM   #2
2000GrayTJ
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1999 TJ Wrangler 
 
Join Date: Sep 2009
Location: Winnipeg, Canada
Posts: 658
We did one at work last year, from what I can remember you need:
1) cut/weld new motor mounts (obvious)
2) 4.0 tranny
3) 23 spline input for t-case (or 4.0 tc)
4) 4.0 fan shroud and possibly power steering reservoir, among other accessories like air intake
5) 4.0 ecm (watch out for SKIM)

As far as wiring goes it was basically as simple as adding 2 injector wires to the harness IIRC, since your 2.5 uses a distributor you should be fine in that department (wiring wise). HOWEVER, a couple years ago I was wanting to do the swap on my '00 4 cyl and ended up just buying a cheap 4.0 truck. I personally wouldn't waste my time doing the swap when a v8 is not much more difficult and certainly not any worse on fuel than the 4.0 (plus more power). No matter which swap you choose I would highly recommend having a complete donor for the swap, not piecing **** together.

Good luck
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'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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Unread 10-15-2013, 07:38 PM   #3
jafjap
Registered User
2002 TJ Wrangler 
 
Join Date: Mar 2013
Location: Virginia Beach, Va
Posts: 16
definitely thanks for the info and yeah that's why I'm ding it my buddy its giving me his 4.0 cause he did a 5.3l diesel swap and now the 4.0 is sitting in his garage!
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Unread 10-16-2013, 08:11 AM   #4
2000GrayTJ
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1999 TJ Wrangler 
 
Join Date: Sep 2009
Location: Winnipeg, Canada
Posts: 658
Nice I think you'll appreciate the extra power, at the end of the day it's still much easier than any other swap because the wiring is very minimal. Only downside is she'll be thirsty!
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'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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