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Postal going 4.0/AW4

I have the same swap in my 84 Scrambler. I used a 99 TJ 4.0 motor, 95 XJ aw4, the novak adapter/clocking ring that they worked with me to make. I used OBD1 since it was easier to swap in. I put my fuel pump in the tank and used the two wire speed sensor. Everything has worked out very well. I blow away the yearly emissions test and get about 21 MPG on the highway. I used a 93 XJ wiring harness under the hood and a blended cj/xj harness inside the cab since I used the XJ steering column. The XJ column gave me tilt, delay wipers, light switching on the column, and cruise control.
 
DaveB said:
I have the same swap in my 84 Scrambler. I used a 99 TJ 4.0 motor, 95 XJ aw4, the novak adapter/clocking ring that they worked with me to make. I used OBD1 since it was easier to swap in. I put my fuel pump in the tank and used the two wire speed sensor. Everything has worked out very well. I blow away the yearly emissions test and get about 21 MPG on the highway. I used a 93 XJ wiring harness under the hood and a blended cj/xj harness inside the cab since I used the XJ steering column. The XJ column gave me tilt, delay wipers, light switching on the column, and cruise control.
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Nice, what size tires and what gears are you running? I won't know what to do if I were able to get 20+ MPG... that's more range than our 05 or 08 Wranglers!! (I have the large tank)

I have a 95 harness and computer sitting on the shelf (that will be for sale if I don't use it), and I've thought about using it to go OBD1. I assume you swapped out most of the sensors to work with the 93 harness?
 
Engine, tranny and tcase all pulled, she's empty. Pics tomorrow. Haven't gotten to bed before 2 AM since last weekend...:ZZZ::ZZZ::ZZZ:
 
Today was insane getting things done on the honey do list before I'm out of town for a week. Just got in from getting the tranny separated and loaded in my trailer for the ride to Toby's tomorrow.

One thing for certain: I'm really loving the epoxy coating on the garage floor. Boatloads of all kinds of fluids all over the place...
 
bigwalton said:
Nice, what size tires and what gears are you running? I won't know what to do if I were able to get 20+ MPG... that's more range than our 05 or 08 Wranglers!! (I have the large tank)

I have a 95 harness and computer sitting on the shelf (that will be for sale if I don't use it), and I've thought about using it to go OBD1. I assume you swapped out most of the sensors to work with the 93 harness?
Click to expand...

I run 32s on it with 4.56 gears. I used all of the OBD1 sensors and injectors with the 93 harness that I used. The oil pressure sensor was from a CJ so that the dash gauge worked properly. On the OBD1 motors there are two temp sensors, one in the thermostat housing and one on the back of the head. You can use a CJ sensor on the rear sensor so your temp gauge works properly. The OBD1 ECM doesn't use the oil pressure or rear temp sensor so you won't mess up anything using the CJ sensors. The OBD2 ECMs run all of the gauges and the rear temp sensor isn't in the motor anymore so you have to find some other spot to put it in. On my cj8 the 93 XJ harness fit quite well and the fuse block firewall connector bolted right up to the original holes.
 
Mr. Beep is the best!

Huge thanks to Toby for doing all the work needed to pull the engine and tranny and almost all the little bits before I even got there. Was a nice day hanging out with him pulling the last things and some stuff for him.

With more work than I wanted to cause, we got it in my trailer. I'm in a hotel in OH because I have to do a work trip to KY from our main office tomorrow. I'll take it home tomorrow after my trip.

I figured I had the evening here in the hotel and there's a Home Depot across the street from the hotel, so I got a razor knife and cut off all the loom and tape in the hotel room bathtub. Only managed to cut one wire in the process!

Sleep now.
 
bigwalton said:
I figured I had the evening here in the hotel and there's a Home Depot across the street from the hotel, so I got a razor knife and cut off all the loom and tape in the hotel room bathtub. Only managed to cut one wire in the process!
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And that, my friends, is the definition of a "Jeepaholic". :thumbsup:
 
Scramblerman84 said:
Man everyone is doing swaps!! Lets see the pics!! when is this...



:):)
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I'm being horrible on the pics i know! It's killing me. I've just been on the run non-stop around this stuff... I hope to get them up tonight, another hotel in Kalamazoo for a work trip.

I don't know what we've got going on this weekend, but I was hoping to spend a bunch of time on it, though it may be late at night after Laura's asleep...
 
Pics

Before:

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Fenders and grille pulled:
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Loose and on the hoist:
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Empty:
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Out, dang it's filthy:
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Separated the tranny to get it to the new owner:
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The aftermath, along with a garage floor completely coated in ATF, oil, coolant and power steering fluid:
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Spent the night going through posts on cjoffroad and this article:

http://jeep.off-road.com/jeep/article/articleDetail.jsp?id=277043

and comparing them to the wiring diagrams and pin outs I have from the 97 FSM. No one seems to have posted the equivalent of the "5 to fire" from the OBDI computers, so maybe we can work that out in a simple fashion. I'm currently very confused about the fact that the connectors that they cite and say are the same in appearance from TJs to XJs to ZJs (just with different connector numbers) don't exist in my FSM. I think I've found most of the wires that are cited in what I believe are the equivalent plugs in the 97 XJ, but there's a BOATLOAD more wires in the three plugs that go to my PCM than they are showing...


I'm working on a nice PDF that will identify the connectors and wires for a 97 XJ and highlight the ones needed to: connect to the CJ harness, wire in resistors to fool the computer, grounded, etc. and to serve as the starting point for thinning the harness once things are running. I've got to find the wires first though...
 
Eric- when working out the wiring for my LS swap, I ordered a diagram for the donor vehicle from these guys- http://www2.wiring-diagram.com/ it came via e-mail the next day, and was extremely helpful. It had the PCM fully diagrammed with every wire, used factory color coded lines for the wiring, and actually had the wiring paths shown ( a line from component to component, not just "see a7 c101").

Sample page:http://www.wiring-diagram.com/samples/mricsample.htm
 
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Randyzzz said:
Eric- when working out the wiring for my LS swap, I ordered a diagram for the donor vehicle from these guys- http://www2.wiring-diagram.com/ it came via e-mail the next day, and was extremely helpful. It had the PCM fully diagrammed with every wire, used factory color coded lines for the wiring, and actually had the wiring paths shown ( a line from component to component, not just "see a7 c101").

Sample page:http://www.wiring-diagram.com/samples/mricsample.htm
Click to expand...

Thus far I've been really pleased with how easy the FSM diagrams/pinouts are. Having them in PDF is fantastic because I can just search on the wire code to jump from one to the other as needed (I pulled out just the wiring diagrams into their own PDF to make it easier to search). So it's not a mattter of being able to figure out the wiring diagrams, it's just that I'm not certain where I need to make the feeds to/from the CJ side of things. Nothing short of a diagram/table/listing of the wires where the splices should go will help.

Does that make sense? I may have to go off a best guess and work from there to just see what happens. I think I have most of them figured out from comparing the article I linked to to my FSM.

One thing that I will say. If I hadn't already done the HEI and MC2100 and done the resulting thinning of the CJ harness, I could EASILY see how this would overwhelm folks. Having the engine compartment so nice and tidy will REALLY help because there's no real work to do on that side. Getting the gages to work and figuring the check engine light will really be it for the CJ side. :thumbsup:
 
I see....

I made a listing of what was needed on the swap side...constant power, switched power, start feed, ect. Included amp ratings for compatability.

I then made a list of what I had on the Scrambler side.

From that point it was (almost) as simple as connecting from one list to the other. I found I needed more switched power feeds on the swap side than I had on the Scrambler side...that's when I started introducing relays and things got interesting....:eek:

I found it helpful to deal with only the engine side of the Scrambler wiring harness. You can also get male and female terminals for the bulkhead connector from Napa in case you need to add more wires.
 
bigwalton said:
think I've found most of the wires that are cited in what I believe are the equivalent plugs in the 97 XJ, but there's a BOATLOAD more wires in the three plugs that go to my PCM than they are showing...
Click to expand...


That's why I bought the online diagram. All the online sources left me with many "mystery" wires. The diagram told me exactly what each one was. From there, I could determine if they were necessary or not.
 
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