humblexy

Hi all. Ignore the words "block" in subject. This is for a complete engine. Question for you wise people who may have done a heart transplant on a 1999 XJ. I have a 1999 4.0L XJ manual 5 speed. Getting ready to swap a rebuilt 1995 4.0L from an automatic XJ into mine and will rebuild my original motor at a later time. Besides adding the pilot bushing, I'm hungry for any words of advice: Do you have any words-of-wisdom or tales-of-woe about 1995 engine swaps (fitment/mounts, electrical, otherwise) into a 1999? I'm not experienced, but I have a brother who is experienced mechanic and recently graduated from mechanic school who will be the main guy on this.

Thanks for anything you have, and wish me luck.

cruiser54

Yes. Use your intake, sensors, manifolds etc. Like you're doing a longblock swap.

• XJ Cherokee and ZJ Grand Cherokee 4.0L engine blocks interchange.
• 2000+ TJ Wrangler and WJ Grand Cherokee 4.0L engine blocks interchange.
• YJ and 1997-1999 4.0L TJ blocks will interchange in XJ/ZJ
• XJ/ZJ blocks, and the 2000+ TJ/WJ blocks do not interchange without significant modifications.

Jim Malcolm

Luckily for you, it's a 99. Treat the 95 engine as a long block you'd get from a parts store. Swap all of the electrical parts off the 99 engine onto the 95 engine, making sure you install the distributor correctly. You can use the alternator and A/C compressor brackets from the 95 if you want; you won't use the idler pulley on the compressor bracket if you do. Or use the brackets parts from the 99, same difference, just no idler pulley. Pretty easy swap. The "long block" is the same externally. I've always removed the driveshafts and transfer case and then pull the engine and transmission as one. An old tire works well enough for supporting the transmission will unbolting/reassembling it outside the vehicle.

While you have it out of a vehicle, however is a different story. The Freeze Plugs , particularly the ones on the back of the head and block, are a MUST DO in my opinion. Next up as "you'd be really smart to do" would be Rear Main Seal and Oil Filter Adapter O-Rings, which can be a bear if never broken loose previously. Depending on how long you intend to run this motor, the list can keep on going from there. I've never put a new motor into a vehicle, nor helped anyone else do it, it's always been one out of a JY refreshed with a few new parts. More JY motors into my brother's 85 Mustang GT w/ Centerforce clutch, gears, huge rear tires, ported heads, lumpy camp, victor jr intake, etc than I care to count... I replace Rod Bearings in any motor at every reasonable opportunity, but I have an engine stand, which makes all of this a whole lot easier. Oil Pump, Timing Chain, Valve Stems Seals, the list goes on, each with their own list of associated "while I'm here" mini-projects adding to the list. Then again could probably rationalize doing a complete stroker rebuild without one bit of machine work, depending on the cost of the pistons... But I have another beater that I should be my DD...

The other thing I'd look at while you're there is the steel brake lines, primarily over to the PS and to the rear, but even the DS sure is easier with all that stuff out of the way... The "easy bend" tubing they have now a day's is practically fool-proof. I bend the lines and take it to my buddy's shop and have him use his quality hydraulic crimper. Makes the whole conversation easier if you can drop them up and pick them up in a day or two... Also a good time to clean that dirty beast, assuming it's anything like mine...

humblexy

beautiful, thanks
yep that’s the plan for sure 👍

thanks for the swap list. Surprisingly difficult to distill all that from my searches. Valuable list.

humblexy

thanks a bunch
I’ll make sure all these are on our list of things to discuss doing at the same time, or consciously deferring. I want to strike a balance between 1) having it good to go soon, and 2) getting hard to access things done now, for efficiency’s sake. Your list helps!