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Unread 08-27-2008, 07:17 AM   #166
Rezneck
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Here's a quote from sevenandeights on cjoffroad. (can I do that?)
Helpful when you're using the donor harness.




"If you can I would wait until you get the FSM. This way you can check out the wiring diagrams and the schematics that show the locations of most of the major connectors. At the very least study your current harness and maybe even take it with you for comparison.

This is from memory so don't take it as gospel:

Starting at the front driver's side . . .
1.) The harness terminates at the PCM (I would ask the yard for a "complete harness" and definitely try to get the PCM as a back-up. The front light bundle and electric fan lead are here also.

2.) Going back toward the firewall should be the diagnostic port and then some ABS stuff that hooks into the proportioning valve

3.) Next up is the firewall bulkhead connector. Definitely get this - you most likely will not use it but it helps when it comes to wiring because the pin outs are in the FSM. It allows you to test your wiring by just crimping on some female spade terminals to plug into the connector.

4.) Going along the firewall toward the passenger side will be a grommet that leads to the gauges. If the XJ is pretty torn apart you can go behind the dash and unplug the connectors and pull these wires out for completeness but you should not need any of this stuff and could cut it off.

5.) Next is the MAP sensor on the firewall.

6.) Then comes the fuel rail harness and CPS. This harness is kinda a pain to get off because it uses plastic connectors with teeth that fit over the valve cover bolts. The injectors themselves are a pain too. You will need a small flat head screw driver to pop the retaining rings off. MAKE SURE TO LABEL THE INJECTORS AS THEY COME OFF! You can disconnect the CPS unless they want to give to you (I told my yard that it was part the "complete harness" just like the PCM).

7.) I think the next thing should be the tranny wiring. My donor had an AW4 auto so there was a harness that went through the firewall to the backside of the passenger's dash where it hooked up to the auto computer (again, part of the "complete harness"). There should also be a connector for the VSS here.

8.) The next thing should be a ground at the engine block near the oil dipstick tube and a connector to the distributor.

9.) You should now be to the passenger side fender and there will be a connector to the wiper pump and maybe the cruise control and A/C. My memory is fading!

10.) AT LAST THE PDC! The PDC has been described above and will have a 6 G red wire attached to it from the battery. Right before the PDC there are a bunch of wires that go to the alternator, starter, and coil.

That's all I can remember. I think you will be safe if you cut every wire that goes through the firewall. Take your time and label everything or take pictures. I had never seen a 4.0L engine when I pulled my harness so I was pretty meticulous with the disassembly.

Don't forget the accelerator cable if you haven't got one yet."

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Unread 08-27-2008, 01:32 PM   #167
BioTex
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I decided to NOT do the 4.0 head swap!

I'm probably nuts, but have decided to stay carburated. I have posted my parts for sale or trade in this forums classified section, but wanted to briefly mention it here. Hope you all don't mind. I just want this stuff to go to a more needy person. I will trade all parts needed except CPS kit for a new carburator solution. My BBD is shot, so prefer Webber. I said I would keep it brief, so there you go.
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Unread 08-29-2008, 08:50 AM   #168
Kman1983
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I'm looking at a pile of Cherokee components and trying to identify the wiring as usable. If the o2 sensor is in the header is it the earlier(Renix) system and harness?? If I'm correct the '91 and later 4.0 systems have the o2 sensor in the head pipe between the factory header and catalytic convertor. I don't want to get the wrong parts...
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Unread 08-29-2008, 12:24 PM   #169
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you are correct.
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Unread 08-31-2008, 07:39 PM   #170
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4.0L Swap into '84 CJ7

Just bought a 4.0 from a '99 Cherokee with 105k miles on it that I plan to swap into my '84 CJ7. Currently I'm running the 2.5L. The engine came from a Cherokee with an automatic transmission.

I'll post pictures as I rebuild it this winter and swap this spring.

I do have some questions about transmission options....

I've got the stock 4-speed manual, what are my options for easily upgrading the tranny without a lot of modifications and possibly get a 5th gear?
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Unread 09-01-2008, 06:33 AM   #171
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Quote:
Originally Posted by kanute View Post

I've got the stock 4-speed manual, what are my options for easily upgrading the tranny without a lot of modifications and possibly get a 5th gear?
AX15. I used the one that came with the XJ donor.
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48 CJ-2A, Bone stock except it has Allstate locking hubs.
86 CJ-7, 4.0 HO, AX-15, D-30, AMC-20
84 CJ-7, YJ tub and fenders, 258 ci, T-176, D-30, D-44 Trutracs F/R, 4.27s, 33s
77-90ish Wagoneer/TJ/CJ Yard Sale Special, 360AMC, TH400, Quadratrac, D-44s F/R, 3.07s, 34" LTBs.
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Unread 09-03-2008, 09:19 AM   #172
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check www.novak.com for tranny options. they have a knowledge base you can read through.
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Unread 09-03-2008, 02:08 PM   #173
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Yeah, I agree that the fuel injected 4.0 beats the 4.2 anyday. My wife's 86 CJ threw a rod on the 4.2, and the shop that sent me a reman motor sent me a 4.0 instead. I bit the bullet and ripped everything I could get my hands on out of a 92 Cherokee (since there is no such thing as a totaled Wrangler!) and other than working through a few bugs, it runs better and gets much better gas mileage. Thanks for the new thread - I'll be following along as well.

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Unread 09-03-2008, 02:11 PM   #174
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Yes, the 91 and later have one O2 sensor mounted between the exhaust manifold and the converter. I believe some of the other models used two O2 sensor - one in the manifold and one in the converter.

Joe
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Unread 09-03-2008, 05:14 PM   #175
kanute
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I'm picking up my 4.0 block tommorow from the yard. Came out of a 99 Cherokee with 105k miles on it, got it for $300.

In your opinions...what is the best book to get when looking to rebuild this engine. I've rebuilt a couple of engines in the past, mostly air-cooled VW's.

I've never been a fan of the Haynes manuals.

Any advice?
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Unread 09-03-2008, 05:16 PM   #176
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Quote:
Originally Posted by Last Boyscout View Post
check www.novak.com for tranny options. they have a knowledge base you can read through.
Thanks! The Novak site is great and cleared things up for me considerably. I'm definately going to buy a reman AX15 or find one in a yard to have rebuilt.
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Unread 09-04-2008, 06:26 AM   #177
Last Boyscout
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i have Haynes manuals for my xj and cj. they suck for the most part. order a FSM (Full Service Manual.) for wiring it's the only way to go and should cover the engine rebuild better than any part store repair manual.
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Unread 09-06-2008, 06:34 PM   #178
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I got a question about passing the smog test in California. I have an 83 CJ7 that I am planning on converting to a 4.0 head with MPFI from a 91 Cherokee. I will have all of the parts from the Cherokee. My question is what problems will I face in trying to get it to pass smog in California? I live in Nevada and they don't care, just as long as the sniffer test is OK. I searched on the California DMV web site but it was useless. Any info is appreciated. Thanks. Dustin.
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Unread 09-07-2008, 07:58 AM   #179
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it seems like half of my answers are go to www.cjoffroad.com . go to their 4.0 swap forum. 80% of the people on it are in Cali. if anyone can answer your Cali smog question they can. i'm not trying to run everyone off but reading that forum is where i got all my answers.
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Unread 09-07-2008, 07:25 PM   #180
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OK. I tried going to their website a few days ago and it was down. I will try again. Thanks.
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