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Go Back JeepForum.com > Models > Jeep Wrangler Forums > TJ Wrangler Technical Forum > 2.5-4.0 swap is underway!!

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Unread 07-08-2008, 05:18 PM   #16
Black Hills TJ
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1997 TJ Wrangler 
 
Join Date: Dec 2005
Location: Black Hills, SD
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Any updates?

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Unread 07-16-2008, 08:07 PM   #17
RnEmOvr
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1999 TJ Wrangler 
 
Join Date: Mar 2005
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ok so finally was able to start working on it again, so far we got the old mounts cut out and the new ones welded in, will have pics later



to those who have done this what site did you use for the wiring? i am using the motor from a 95 yj
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-17-2008, 04:09 AM   #18
dodgetk81
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1997 TJ Wrangler 
 
Join Date: Mar 2004
Location: PA
Posts: 550
I used a 4.0 TJ harness, it was plug and play.
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97 TJ 4.0, auto, 4.5" RE long arm, 33 " MT/R's on Moabs, 4.10's, 8.8 w/Aussie locker, A to Z rockers, A/A SYE, Warn M8000, Vanco
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Unread 07-17-2008, 09:46 AM   #19
RnEmOvr
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Join Date: Mar 2005
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Quote:
Originally Posted by dodgetk81 View Post
I used a 4.0 TJ harness, it was plug and play.
so should i get a harness from a 99? the computer that was in my jeep has 3 plugs the one thats going in has one big one
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-17-2008, 10:11 AM   #20
RnEmOvr
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1999 TJ Wrangler 
 
Join Date: Mar 2005
Location: Ft Stewart, Ga
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here is list of things needed to do the swap,

*motor (duh) try to stay with your year group (the year of your jeep), 97-99 and 00+ although my swap is from a YJ
*trans, the AX-5 will not bolt to the 4.0 plus it will not hold the
power either ( i dunno about autos)
*t/c the 4cyl has less splines then the 6cyl so it wont work either
*computer, must be year/motor/trans/model specific
*harness (for most its plug and play, for some reason mine was not) XJ harness will not work, this is where year specific comes in play the most
*Upper left motor mount 52058865 (dealer part) (welds to frame, is what mounts bolt to)
*Upper right motor mount 52058864 (dealer part)(welds to frame, is what mounts bolt to)
*Reinforcement left motor mount 52058845 (i am making these though)
(dealer part)
*Reinforcement right motor mount 52058846 (i am making these though)
(dealer part)
*Exhaust need re done from header to cat (the cat is same and so is rest of exhaust)
*Drive shafts (front is now longer, rear is now shorter, doing a belly up is good idea at this time)
*Fuel lines from frame to fuel rail, you may be able to make the 4cyl ones
work, but mine didn't have enough play in them, $50~ from dealer part # is
52100272AH
*wiring diagram (you may or may not need it but still nice) http://www.ahdol.com/
*Vacuum lines the goto intake manifold, dealer only parts, 53030615 (valve
cover to intake tube), 4854265 (valve cover to intake manifold) and 4854163
(evap canister lines) all rang in at <$30 from dealer so no to bad, although yours may be different this is what worked for me
*Power steering lines, the 4cyl ones are longer, they will work but you risk them getting into the belt/fan, KOI has the pressure line at $15 but they do not have the return (they show it as bulk hose, the bulk hose works from the reservoir to pump but you need line with fitting from box to reservoir) advanced has the return for $25~ both were next day items
*Radiator hoses (upper and lower)
*Intake tube, the filter box fits but the tube is different, I found someone who did a CAI and bought theirs. Or you may do a CAI. I chose not to for i play in mud and the filter clog up to easy when open like a CAI filter is.
*Fan shroud, you may trim the one from the 4cyl


these are different from the YJ motor, and the TJ harness, if using TJ motor you will be fine
*sensor in thermostat housing, (the one from 4cyl will work)
*O2 sensor in intake, (the one from 4cyl will work)
*O2 sensor in exhaust manifold, (the one from 4cyl isn't long enough)
*throttle body (TJ has extra sensors)
*crank position sensor (the one from 4cyl will work)



things i bought since i had it all out anyway
*Brown dog mml and HD motor mounts
*SYE/CV shaft
*Belly up skid
*New belt
*Complete tune up from ignition coil to the plugs



The following parts will interchange from your 2.5 to the 4.0;
*Power steering pump
*Alternator
*Fan
*Radiator (mine wored for 2 weeks even without a fan, although fan is now in)
*I do not know about A/C but i believe it will
*Evap canister, although none of the lines will

If you have any questions send me a PM
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.

Last edited by RnEmOvr; 07-02-2009 at 09:50 PM..
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Unread 07-20-2008, 08:51 PM   #21
RnEmOvr
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finally stole the ex GFs phone and uploaded the pics here you go, sorry they quality isn't that good its from a camera phone

cut old mounts off, gotta love plasma cutters!!




all gone



well remember my engine hoist? well it wouldn't work due to bumper sticking out so far, so instead of taking bumper off, we pulled out dads F550 work truck with hoist




getting motor in place



checking for clearance



we then marked mounts, pulled motor, tacked mounts and tested motor again, mounts were to far back,



so moved them up little bit and tried again

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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.

Last edited by RnEmOvr; 10-11-2008 at 02:19 PM..
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Unread 07-20-2008, 08:52 PM   #22
RnEmOvr
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1999 TJ Wrangler 
 
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they fit so dad fully burnt them in





his welds are getting better, i dont think these are going anywhere, but just to be on safe side be are making braces this week,






that is all for now, once we make the supports i will bring the jeep home and things will fly then, also if anyone has a truck and would be kind enough to tow my jeep home that would help alot, i will give you money plus gas, i have trailer
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-20-2008, 09:04 PM   #23
Zoom By You
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Location: Long Island, NY
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Looks good, it's great that your father is so handy....
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2001 TJ Sport Amber Fire, Dual Tops/Dual Doors, 4.0, Banks Ram-Air, Banks S.S. Monster exhaust, five speed, NV3550, A.A. SYE/Tom Woods, 4:56 D30/D35, Detroit Truetrac at both ends, Solid diff covers, 4.5 R.E. Super Flex W/3.5 springs, adjustable upper and lower control arms, adjustable front and rear R.E. track bars, TeraFlex shock relocation brackets, R.E. Mono tube shocks, R.E. front stabilizer, R.E. 3/4" front spacer, 33 X 12.5 TrXus STS, M/T Classic-locks, ShrockWorks Rock Rails, Hanson 52" front bumper, EPi9.0 Superwinch with wireless control, Olympic rear bumper, Olympic Mountaineer rack, Bushwacker 6" Pocket Flares, Optima yellow top, IPF headlights W/ Fatboys, upgraded relay/wiring harness, KC Slims, Bosch rear lights, Garmin c550 GPS, Garmin 76S GPS, Cobra CB 148GTL W/Astatic Mic, Pioneer Sound, 3A Racing fire extinguishers. Manhattan Rated....
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Unread 07-22-2008, 11:22 PM   #24
RnEmOvr
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finished the mount supports, the ex GF even helped again

all cut out,


cleaning them up some




welding them in,





all done, motor going in tomorrow


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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.

Last edited by RnEmOvr; 10-11-2008 at 02:19 PM..
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Unread 07-22-2008, 11:27 PM   #25
bubbaj27
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2003 TJ Wrangler 
 
Join Date: Jun 2008
Location: Texas
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I agree. That's cool. Enjoy that 4.0. My brother-in-law has the 2.5 liter is his, I've got the 4.0. You're gonna fall in love with your Jeep all over again when you get the install complete.

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Unread 07-22-2008, 11:37 PM   #26
RnEmOvr
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1999 TJ Wrangler 
 
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my buddy has a YJ w/4.0 so i know the 4.0 all to well
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-23-2008, 11:00 PM   #27
RnEmOvr
Have Cummins, Will tow.
 
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1999 TJ Wrangler 
 
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well i got the motor and trans bolted in today, but got so excited i forgot to get pics, i will get them tomorrow, but here is pics of us redoing the steering bracket



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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-25-2008, 12:05 AM   #28
RnEmOvr
Have Cummins, Will tow.
 
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1999 TJ Wrangler 
 
Join Date: Mar 2005
Location: Ft Stewart, Ga
Posts: 10,589
motor is in!!! will start wiring tomorrow





new brown dog MML and engine side mounts



and trans

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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-25-2008, 12:47 PM   #29
RnEmOvr
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1999 TJ Wrangler 
 
Join Date: Mar 2005
Location: Ft Stewart, Ga
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ill ask again, to those who did this swap what did you use for wiring diagrams? my computer had 3 plugs but the new one from the 95 YJ only has one big plug, i need to know what to do,
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My Jeep 2.5-4.0 Motor Swap, Very detailed Military Jeepers

Looking to swap my 4" springs for your 2-3" springs. PM for details.
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Unread 07-25-2008, 03:01 PM   #30
dodgetk81
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1997 TJ Wrangler 
 
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Posts: 550
I got an engine harness and computer from a TJ. I'm pretty sure your old computer will not work with the new engine. I would think you need at least a TJ 4.0 manual computer.
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97 TJ 4.0, auto, 4.5" RE long arm, 33 " MT/R's on Moabs, 4.10's, 8.8 w/Aussie locker, A to Z rockers, A/A SYE, Warn M8000, Vanco
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