Does anyone have a comprehensive guide to removing an inline 6 from a 91 Cherokee. I am fairly certain I can do without, but it will take me longer and I will likely remove more than is necessary.

I need to pull the engine from a '95 cherokee (automatic), remove the engine from my '91 manual, then put the '95 engine in to my '91 preferably retaining the manual transmission.

Any help or comprehensive guides would be helpful as I am looking for a streamlined process

 

The XJ engine swap is probably one of the easiest I have ever done. There isn't a whole lot to it, especially in the older models. Key things are:

• Before you even get started, look at both vehicles and be sure of what you will need from one for the other. Are they both federal emissions vehicles? Or is one a Cali emissions? I have a 2000 that I swapped with another 2000 so most things matched besides the emissions, so I just converted it to a federal emissions
• I believe that even though there is a 4 year gap, not much changed in the motor between the two. Both have a cap and rotor set up, should have all the same wiring, etc.
• The header panel, radiator, AC condenser all must come off. This will make it easier to pull the motor out. Also, if you have a lift on either of them, pull the front tires and put it on jacks, this will drop the front end and make it a lot easier
• I didn't pull my intake or exhaust before I pulled the motor, it's not necessary but it does give you more room to work if you pull them. It also make things easier if you pull the front drive shaft.
• Be sure to properly label EVERYTHING you pull apart or off. Color coded electrical tape is a good idea. For example: pull a vacuum line and label the line and the port it plugs into with the same color
• The top bolts on the tranny are a *****. Seeing as you are leaving the tranny you won't want to pull it with the motor. Before you pull the motor mounts, drop the cross member and keep the trans supported. To undo the top bolts on both transmissions you will need an E12 star socket. Once you undo the top bolts, jack the cross member back up and bolt it back in place. You want the tranny stationary. A trans jack isn't a bad idea, because you will need to support it once you remove the motor
• Once all the trans bolts have been removed, be sure to pull the motor out as straight as possible from the trans. If you yank up on it or drop it down too low while the shaft is still in the motor it can put too much stress on the pump (for the auto)
• While you have the motor out this is a perfect time to look over everything. Change any gaskets that are bad, swap worn parts, give it the ol once over. I changed every gasket, threw a header on, new timing cover, and just for good measure upgraded my injectors. Before I had wrecked my old one and pulled the motor I had just overhauled the cooling system, but if you haven't looked at it in a while this is a perfect time to consider swapping the water pump, thermostat, hoses, radiator, heater core. It is an almost 30 yo vehicle after all
• This is also a perfect time to look at other things in the engine bay that could need attention while the motor is out. How is the steering gear box spacer? Brake lines? Any worn wiring harnesses? rusty spots on the frame that could use some love? Do it while it's easy is my philosophy
• The removal is the hardest part, because if you label everything properly it should go together pretty easily

Have fun and good luck!

 

Did you end up making the swap? How'd it go?