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one more 4.0L engine swap

  • Thread starter Thread starter scramcraz
  • Start date Start date
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scramcraz

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Yes, after salivating for a year over all the good things that happen when you ditch the old 258, creeping incrementalism has struck me [6 months after my ground-up redo, the only thing left is the mill]. I found a complete engine from a 95 cherokee with all the goodies[starter, alt, ac &ps pumps, harness, computer, all sensors, bell hsg] delivered for cheap. Boy, do I have alot of questions. I'm putting this in front of a t999 automatic that came in my scrambler.
1) Has anyone done this & not used the wiring harness from hesco, in other words, wired it yourself?
2) Can anyone help me on spotting the cps sensor in my transmission housing so I don't have to buy the kit from hesco?
3) Can I use the vehicle speed sensor from the cherokee on my scrambler? I assume it screws into the transfer case.
4) The donor engine (95 cherokee) was a standard shift so I need a flex plate from an automatic. There seem to be several different flex plates. What is the difference in the plates & which one do I need to bolt up the old auto tranny to the 4.0L & use the speed sensor located in the tranny housing?
5) Which fuel pump (part #, make) would be best for a frame mount? Don't really want to drop the tank, but I will if it is best option.
Thanks for any and all input; I'm sure as I get into this I will have more questions!
Bob
 
I can help you on maybe one of your 5 issues.

In regards to #5, I used the Airtex E8248 (actually the Autozone look alike made by Airtex with the same number) for the frame mounted fuel pump. I went with it after reading a very lengthy email forwarded to me from Jefe who frequently posts to this BB. I think any one contemplating this swap or the EFI conversion should read this email and I will be happy to forward it to you if you provide your email address. I checked your profile and it is not there.

I can not answer any of your other issues because I did not do my own wiring and did not use the transmission you are using. I swapped in the AW4 from the XJ.

You have not mentioned it but by using an XJ engine, you are also going to have to change the water pump and fan blade also. The water pump can be either the YJ or ZJ. The fan blade will need to be from the YJ.

Later, Ken
 
Re: 4.0L

I am about 97% done with my 4.0L swap. My scrambler now runs like a champ! I can help you with a couple of your questions.
1) I belive the guys working at Hesco are the same ones in the movie Deliverance! I didn't buy their harness. From your harness, you only need three wires to make the new engine run, but you'll want to use most of them if you plan on using your old gauges. I couldn't have done it without both service manuals.

2) My CPS was on the top of the bellhousing. you can't miss it.

3)The VSS from a 99, 231 X-Fer, will not work with a Dana 300 and the spedo cable. This is where I discovered the guys from Hesco were country bumkins. My VSS had three wires, and the one they sent had two, they knew this but sent it anyway. The part has flimsy aluminum threads and is made of plastic (I am waiting for it to melt and fall off). They also did not include the connecting harness with lead wires- extra $ and time. Finally, after I got that they did not include the wiring diagram - their VSS works differently than the one that came with the 99, but they claim it is good to go-.

If anyone is still reading this, Why do you need a VSS if you aren't using the odometer/speedometer?

can I get a copy of the e-mail?
s_s_mac@yahoo.com
 
I put a 93 4.0 in my Scrambler, while I used the Mopar Hesco kit, I have had to replace things over the years.

The Vehicle Speed Sensor I used is Chrysler part #56027015. The Fuel pump is Chrysler Part # P4532709.


-Norman-
 
Relating to Kens input on the water pump and the fan.

My 4.0 came out of a 93 GRAND Cherokee and we did not change the water pump and used the fan from the 258 along with the shroud from the GC. I have read in other posts that you must change the water pump and all but I have had no problem with it at all.

Dan
 
There is a difference between a Cherokee and a Grand Cherokee. The Cherokee's fan is not mounted on the water pump, it is mounted off-set to the passenger side of the engine and the radiator also had an electric fan.

Danno, if you are using the 258 fan blade, the pitch of the blades may possibly be wrong for that engine unless you had a 258 with a serpentine belt system. The 4.0 uses a reverse rotation water pump and most 258's used a forward rotation water pump.

I will get those emails sent out later today from home. Am having to work today. Bummer!

Ken
 
4.0

I don't know what is up with my cheesy service provider but it seems you have the address correct: wdidiesel@computron.net
I get plenty of spam daily... maybe they filter out the good stuff. Jefe, thanks for your link, & to everyone else who has posted. At this point, I believe I can tackle the wiring harness & put the CPS in the auto tranny(with the correct flex plate & some precise drilling). The water pump/fan is still a mystery that I have to hash out. Right now I have a shroud, fan clutch, & v-belts but that will change to something. What do you do with the brackett that holds the offset fan on the cherokee? Is it integral with the alt or ac compressor, or can you just shuck it? I have not received my transplant yet, just wondering & trying to work out as many bear traps as possible before I get started.
Thanks to all!
Bob Williams
 
Re: 4.0

I originally used the fan clutch that came with the XJ engine and got a used fan blade from a YJ and mounted it to a water pump from a ZJ. I just removed the XJ fan blade from the A/C and alternator mount. I also used the original CJ shroud.

However, I did have some overheating problems. So I went to a 3 core radiator and chucked the fan clutch and YJ fan blade. I went to a 17" flex fan and cut the 2" spacer down to 1 3/8". Then I fabbed a 1" spacer to move the shroud 1" closer to the engine. I did grind off about 1/4" of the old XJ fan shaft for more fan blade clearance.

I also added a piece of flat expanded metal snug against the radiator between it and the fan blade. This is a precautionary measure so that if I get into some deep water the fan blade will not imbed itsell into the radiator core.

No more overheating problems.

Later, Ken
 
4.0

Ken,
Do you have auto trans & air on your rig like me or manual & no air? I have a 6 blade(I think) fan, shroud, & 3 core radiator now & it just runs against the therm(195). Guess all that xtra hp is going to be more of a load. What therm are you running?

Bob
 
Re: 4.0

Ken,

Yes my 258 was born in So.Cal and had the Serp belt system. Thanks for that tid bit I didnt know they were that different all I know is that it works fine. Although mine runs great now I'm disapointed in the power differance. Yes it runs better, yes starts better, yes a little more power, but I was expecting some Ummmpf and its just not there. I wish I had spent my money on a V-8.

Dan
 
Re: 4.0

Bob, with the 258, I had the T5 and and not A/C but had the York A/C pump for an OBA system. I used a 180 thermostat with the original 2 core radiator and 7 blade fan.

With the 4.0, I swapped in the AW4 which is the auto out of the XJ. It is built by Toyota and is a 4 speed overdrive. I really like it but it took a while to get it wired correctly - there was not any help available on the net for this swap. I also run the 195 thermostat on this engine. I also use the A/C pump on the 4.0 for OBA after adding a pre-oiler.

Dan, what gears are you running? Most CJ's that are of our vintage that have not been regeared are 2:73's. I went to 4:10/4:11 a couple of years before my 4.0 swap. Could not believe the power gain. The gear change was the best money I ever spent on my Scrambler for performance. It made a lot more difference in power than the 4.0 swap. The 4.0 swap gave me reliability that was really missing with the Carter BBD besides I was down to about 400 miles per quart of oil on the old 258.

Later, Ken
 
Re: 4.0

Ken,

I have the 4.10's also. I go thru 1st, 2nd and 3rd fairly quick and then 4th pulls ok. Off road I almost NEVER use 1st, its way low. In 5th on flat ground is awesome 70 mph no problem. Its when I hit the hills, I live in the mountains as you know, that it really bogs down and is a down right wimp. Between Denver and home (Idaho Springs) there are two major hills (mini Passes) and I have to 3rd gear both of them, it sucks. But my 258 was the same way.

Dan
 
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