4.0 Swap

O.K. it's my late(1983) CJ5 but I wanted to share swapping in the fuel injected 4.0. I bought a rolled '95 XJ with a good running 4.0 for $200. I used the XJ 4.0 but swapped on the YJ waterpump,and alternator brackets along with a YJ 4.0 flywheel. I grafted in the engine harness out of a '93 YJ and used the '95 XJ computer.

 

I modified my T176 bellhousing so I could mount the Crank Positioning Sensor(CPS) Another view, the bracket is 1/8" thick steel and the spacers between the bellhousing and the CPS bracket are 258 exhaust manifold washers. I ended up trimming off the ends of the CPS. The end of the CPS is approx. .020 from the flywheel. Centerline from the sensor is 2.425" from the center of the upper drivers side bellhousing bolt. I used a piece of roofing rubber to make a seal and used silicone between the bellhousing and rubber.The 6 holes are tapped 8-32. I will be using silcone between the rubber and the bellhousing.

 

I istalled the Hesco pilot bushing that is on the right in the picture. On the left is the standard 2 piece oilot bushing I pulled from a '93 4.0(that was to be the 4.0 for my swap but it had an accident)

 

Heres my '83 CJ5 looking at its 4.0 thats soon to be in its engine bay.

 

I ended up using an airbox and tube from a '97 TJ. Rather than mount the fuel pump in the tank I mounted the NAPA P74155 fuel pump on the frame cross member. I ran new fuel line from the tank to a universal 5/16" NAPA #3002 fuel filter then stepped up to the fuel pump.Out of the fuel pump I used the 5/16" NAPA high pressure rated fuel line and stepped it up to 3/8" going into a NAPA high pressure fuel filter #FIL3486 (standard replacement for a '93 YJ and I mounted it with a YJ fuel filter bracket) from there I connected to the CJ's steel fuel line to the engine bay. I bent some 5/16" steel line around the front of the frame to the drivers side and used the high pressure hose to connect to the 4.0's fuel line. I also used NAPA 1/4" high pressure hose for the return line, I don't think I really needed high pressure hose on the return side but better safe than sorry for the small investment. Grafting the '93 Wrangler wiring harness into the CJ engine bay was pretty simple. I used a Factory Service Manual to figure out what wires to connect.

 

On to the wiring: Red and black wire(10 ga) from YJ harness to Red wire(10 ga) on CJ bulkhead(this is the wire that originally picked up power from the solenoid on the CJ), yellow and white wire(about 16 ga) from the YJ harness to the red(about 14 ga) on the CJ bulkhead(switched power). Yellow wire(16ga) from the YJ harness-wasn't in the harness where the FSM said it was, turned out they moved the wire, due to a salt issue,to the harness going into the firewall to the left of the master cylinder as you stand at the radiator('93 specific, was in the supplement manual I didn't buy-I wouldn't have looked if I did buy it) to the light blue wire(14 ga) on the CJ bulkhead(crank-to-start). I pulled the brown/white wire from the YJ harness where it goes to a plug for the tranny and grounded it(nuetral safety switch). I swapped the CJ oil pressure switch with the XJ one. The tach wire is grey/light blue and the MIL(check engine) wire is black/pink.

 

I used a speed sensor for a '91 Wrangler. This has the provision for the mechanical speedo and hook up for the 'puter. Good luck in finding the speedo cable adapter, Chrysler discontinued it. You have to find one off an XJ cruise control under dash module...I searched and gave up and bought one online for more than I'd like to admit to....

 

Looking good!

Cant wait to see how it turns out. A 4.0 swap may be in my postals future. Going to try and ware the 258 out first.

 

Cool, I'm in the middle of a similar swap for my 84 CJ7. It's getting a 4.0 from a 93 XJ. I have all the wiring from the said XJ to blend in with the CJ harness.

I did similar mod work a T-150 bell housing to fit the stock CPS. Mine was a 1 bolt CPS though. I'm not sure why, maybe because the motor was paired with an auto trans initially?