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92 Stroked XJ - "The Punisher"

Old 07-31-2015, 11:37 AM
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Year: 1992
Model: Cherokee
Engine: 4.6L Stroker
Default 92 Stroked XJ - "The Punisher"

Going to log my progress here on the XJ I'm building up now. I'll have to migrate over from the Introduction section some of the stuff I did already.

Originally Posted by USNavyOrdnance View Post
Morning ya'll from SoCal. XJ noob here but have had other jeeps in the past. 56 Willyz(M38 A1), 85 Woody Waggy and a 07 Grand Cherokee. Just recently acquired a very cherry, unmolested 92 Cherokee Laredo 4x4 with 230k miles. Has original owners manual with maintenance records since brand new. I'm the third owner (second owner got it estate sale). Runs and drives good. Hasn't been used much in the past several years so it needs a good look thru. Been parked for a few years. Already swapped in new high octane gas and SeaFoam in the tank. As stated before she fired right up and is running decent.

I already started my process of identifying potential worn/wearing parts that haven't been already changed. It has the usual leak trail on the undercarriage for a 23 year old rig. Luckily no ticking, valve noise, bearing noise or CEL. Fluids look good. Will obviously get a SeaFoam flush in the engine, trans and fuel system. I already pulled the throttle body off for inspection and cleaning. The AIC was filthy. All cleaned up and everything looks good. Pulled the valve cover to inspect and clean the top end. All looks good. I'm going to verify/re-torque the head and rocker assembly. Pulled fuel rail and injectors for inspection and cleaning. Nothing abnormal found. Cleaned fuel injector ports on intake manifold and cleaned up top of the manifold. Exhaust manifold looks good, no signs/sounds of cracks. I think I'm going to pull the intake manifold and exhaust manifold off anyways since I'm replacing the exhaust. Exhaust tubing is rusted pretty well after the flange. Pretty sure cat is shot either way and muffler has a hole so I might as well pull the whole thing. New gaskets and O2 sensors will be installed too. That's as far as I'll get today. I'll do trans fluid and filter tomorrow along with t-case and diffs servicing/inspection. Gonna focus on the mechanical first then get to the fun stuff of lift, building bumpers and roof rack! Looking forward to being part of this forum.

SEMPER FORTIS
Attached Thumbnails 92 Stroked XJ - "The Punisher"-img_20150724_172338_5dd8a193e8001116479c1a53c4f15934fbce729f.jpg   92 Stroked XJ - "The Punisher"-img_20150724_172319_a52645b410c4bf056834c648587d8b028022073d.jpg   92 Stroked XJ - "The Punisher"-img_20150724_172753_61c6cbe9677546ce29490ff862cd1dd5cac589a0.jpg  
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Old 07-31-2015, 11:44 AM
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Decided to go with poor mans Stroker.

Originally Posted by USNavyOrdnance View Post
Made some headway. New fuel rail, new fpr, and "higher flow injectors". These are stock 4.0 injectors that came with the Jeep. Look to have been replaced in the past as they flowed decently and weren't as filthy as everything else. Soaked them is fuel for a day, cleaned them up really good and flow checked them(hooked them back up but not into intake manifold). They sprayed great(made a mess) but I want more... Lol. Took my scribe to them and punched the hole out a little more on all of them as even as humanly possible. Night and day difference on how they spray. Power wise and actually spray dispersion. Glad it worked out, don't have to buy new ones. Disassembled the throttle body, cleaned it up, bored out the inner, outer ports and IAC ports. Cleaned up the filthy IAC, looks new. TPS wasn't too dirty. Lets see how that changes things. Head, intake and exhaust manifold are off. Old rad and front clip is off. Got a new replacement OEM rad with tranny cooler built in. Water pump look good near new(fresh RTV) and so does the power steering system. Both look like they've been replaced very recently. All accessories pulled or moved outta the way, oil pan dropped(had to disconnect a few things to finagle it out) in anticipation for Stroker kit I'm dropping in. Going with the poor man stroker. 4.2 crank and rods. Reusing everything else I already have minus seals, gaskets etc. Obviously new bearing and piston rings. Reusing my pistons and cam. I've seen it done before and worked out great. If it doesn't, I'll shell out $ for a cam and pistons. Gonna port and polish head and intake while I'm at it. Wasn't going this far with the rebuild but its so simple to stroke these 4.0's out... Lol. Almost done, wish me luck!
Attached Thumbnails 92 Stroked XJ - "The Punisher"-11059525_10203181974710515_7164064745358349455_o.jpg   92 Stroked XJ - "The Punisher"-11753706_10203181974910520_8055792773278605826_n.jpg   92 Stroked XJ - "The Punisher"-11755638_10203181976070549_8879010757494182868_n.jpg  
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Old 07-31-2015, 12:05 PM
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These are the tires I'll be running once I give her her 4-5 inch lift. Nitto Trail Grapplers in 285/75/16. 4 + the spare with 90% tread left. Pulled them off my old Disco before I sold her.

This is also the rack I will be running on my XJ. I had originally built it for my old Disco. I'll more than likely have to modify the final dimensions some as I made it to be full length on my old Disco. The gutter mount will definitely have to be shortened. Made it from a small truck bed rack. These are older pics, most of it is just tacked in. Did all the final burns and paint already. I also added some other stuff that aren't in the pics. I'll post some updated ones soon.







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Old 07-31-2015, 12:22 PM
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Since last week I've accomplished quite a bit. On top of the Stroker I also added a toggle switch to turn on the fan manually, added a restrictor plate in the t-stat hose, pulled the restrictor from the airbox, added a throttle body spacer but then removed it, fixed my faulty fuel gauge and speedometer, pulled the gauge cluster and cleaned it up and all the contacts, inspected and fixed any shotty wiring, pulled all sensors and inspected/tested(ohm meter)/cleaned them, replaced all faulty vacuum lines and pulled the smelly headliner.

Btw, I found my exhaust rattle. I initially thought it was my cat but ended up being the stock muffler. Had a piece of itself rattling on the inside and the output was completely cracked. The cat and O2 sensor looked to have been recently replaced. Sweet! Lol. I have a thrush glasspack sitting on my parts shelf that was leftover from another build. Will run that and see how it sounds/performs.


Originally Posted by USNavyOrdnance View Post
Finished my 92's poor man stroker this week and in the process of fine tuning her. I posted some pics in the intro section.

Anyways, was wondering what gap you guys are running the have also done the 4.6L poor man stroker? I gapped the cheapo autolites at. 038(calls for. 035 stock) but seems like she doesn't like it too much. She stutters a very minut bit on deceleration in the 1k-800 rpms range. Pulled the tb spacer and she seemed to like that better but still not perfect so I set the gap to .035. She loves the stock gapping! Anyone else have this happen? I will upgrade plugs once I run a few tanks of gas thru her and change the break in oil. So far have done 2 cycles of SeaFoam in the fuel(91 octane). Yes I changed the filter, has a new for and cleaned up rail and injectors. Lol. I plan on to also SeaFoam flush the engine right before changing the oil to get anything I missed or couldn't get to. Same goes for tranny. Tia.
Attached Thumbnails 92 Stroked XJ - "The Punisher"-img_20150730_153334_6f831754397fdd1fe6c3dbfcdbbe1c6f5019e675.jpg   92 Stroked XJ - "The Punisher"-img_20150730_163610_ec298fb7b60e117164b1c29c6f1eee51f3d0dc45.jpg   92 Stroked XJ - "The Punisher"-img_20150724_193717_c7b604922893f067edb05a86a4624973266744fd.jpg  
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