4.0 Swap, a continuing thread.

[Nunner]

**** When I started this thread it was going to be a 4.0 head swap and Chevy TBI, then changed to a 4.0L swap and finally became a 4.6L Golen Stroker swap so that is why the thread switches around a few times.******


After much debating I decided to do a 4.0 swap on the YJ, when I began the teardown it was going to be a 4.0 head swap and Chevy TBI conversion but I just decided to go all the way. I'll probably be pulling the motor this weekend but here are a few pictures from when I was planning on doing the other swaps:

This was for the head swap:

First off with the valve cover:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix241.jpg

Now working on a couple of the head bolts:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix243.jpg

I'm sure this wasnt impairing my cooling system at all:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix244.jpg

Intake and exhaust manifolds off:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix245.jpg

The ever important parts table:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix247.jpg

And the head off:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix249.jpg

[Nunner]

Wiring for the Chevy TBI and the TBI:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix250.jpg

Working on getting everything separated:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix251.jpg
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix252.jpg

I hate wires, but everything ready to be torn down:
http://i13.photobucket.com/albums/a291/mattanunn/WeekendFix254.jpg

[RescueJP]

hay if your doin a full 4.0 swap. I will buy the chevy TBI off of you if you have the ecm for it still

[Nunner]

I sure do, but I don't know for a fact that the ECM works.

[RescueJP]

do you have the write up for the head swap and chevy tbi addon. Could u pm me a price for the tbi. as well as the write up linkl

[Nunner]

PM sent!

[Nunner]

UPDATE: I decided against both the head swap/EFI and a standard 4.0 swap so here's the new build: 4.6 Golen Stroker and NV-3550 Swap:

T-Case out:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker001.jpg

Drive shafts:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker002.jpg

Bay getting empty:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker006.jpg

Support the Tranny:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker007.jpg

Pulled the shifter:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker008.jpg

Getting ready to pick it:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker009.jpg

I think somethings missing...:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker010.jpg

In the air:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker011.jpg

Ready to be rebuilt:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker013.jpg

[Nunner]

Scotty likes the new stroker:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker014.jpg

A lot:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker015.jpg

Tip of the day, don't assume that your doner tranny is empty:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker016.jpg

Engine and tranny mounted:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker017.jpg

Everything mounted:
http://i13.photobucket.com/albums/a291/mattanunn/Stroker019.jpg

Next wiring......#@$@%@!!!

[RescueJP]

So im assuming you have the tbi harness and computer for sale now? Nice pics i will be following this.

[Nunner]

The harness is a MESS but yeah I don't need em!

[RescueJP]

Hmm hmmm im wondering if i should do that route ur tbi or if i should do the 4.0 head swap and MPI have u found any really good write ups. on the MPI?

[Nunner]

I never looked into the MPI, when I began this project is was supposed to stay as cheap as possible......now I have 4.6 Stroker.

[RescueJP]

ok what write up were u usin for the head swap tbi install

[BrockGrimes]

http://jeep.off-road.com/jeep/article/articleDetail.jsp?id=277013

[Nunner]

Well I'm back from Iraq so its time to finish up this writeup, we ended up having to get the wiring professionally done, but it came out a lot cleaner that way.

Since we no longer had the 4.2Ls manual fuel pump we needed to pick up a aftermarket inline fuel pump, I just looked up what flow we would need (I can’t remember where at this point, but it wasn’t hard) and went down to Kragen and picked one up for about $40 if I remember correctly. The new pump came with everything that was needed except for some mounting brackets and fuel line, the zip ties shown next were just for a temporary basis for test fitting. While you’re at the auto parts store you might as well pick up some fuel injection hose to run from the pump to the intake. (The pump is now in a permanent welded in bracket, I will get a picture of it as soon as I get the chance.)

http://i13.photobucket.com/albums/a291/mattanunn/Stroker007-1.jpg

After the fuel pump was mounted with fuel lines routed I began the tear down of the transfer case, because the B/A 105 has a 21 spline output shaft and the NV3550 has a 23 spline shaft I had to change the input shaft on my 231. I had torn down a few transfer cases before so I wasn’t to worried and this one was not different, pretty easy.

http://i13.photobucket.com/albums/a291/mattanunn/Stroker008_2.jpg

Here it is with everything torn apart, its really not as bad as it might look. Just take a good look at it and when you do put it all back together run it through all the gears a few times to make sure everything shifts right.

http://i13.photobucket.com/albums/a291/mattanunn/Stroker009-1.jpg

The 21 spline (left) and the new 23 spline input shaft. We went to a junkyard looked through their selection of transfer cases and found one with a 23 spline shaft pretty quickly, tore it down to get it out and paid $30, you can also buy them online, but the junkyard is the best choice in my opinion. After we had it reassembled we just bolted it back up to the NV3550 put up the skid and connected the driveshafts. Everything was looking good until we ran the case through its gears and found out that it was contacting the floorboard, not allowing it to fully shift. The fix was easy enough though, just cut out what was hitting

http://i13.photobucket.com/albums/a291/mattanunn/P5252147.jpg

After it was all cut and cleared we just cleaned up the cuts and called it good. Also one of the bolt holes for the transfer case shifter wont line up with the NV3550 but with the remaining bolts it was still very tight, hopefully it doesn't become a issue. The only thing left to do besides wiring was hooking up the old master cylinder to the new slave on the NV3550, the only thing that had to be done was to buy a line adapter from Kragen to hook it up.

The end was in sight! Then.... came wiring, after a week of failed attempts I had to go on deployment and the Jeep went to the shop to get wired, the only thing I can tell you about the wiring is that it is no joke, if you don’t know what you’re doing don’t start, the entire Jeep needed to be re-wired between the new engine harness and the fact that the old chassis harness was on its last leg anyway it made for bad times, but in the end it came out clean.

http://i13.photobucket.com/albums/a291/mattanunn/PC110007.jpg

http://i13.photobucket.com/albums/a291/mattanunn/PC110006.jpg

http://i13.photobucket.com/albums/a291/mattanunn/PC110004.jpg