JEEP ZJ by Goliath Off Road
 

Few weeks ago I realized that project GOLIAT XJ will be a long term build. It's time to build something else, something that will be a quite fast project.
The white jeep ZJ was sitting in our shop for months. Neglected and in not very good shape inside and out.
Well... I picked the ZJ for the next project! :thumbup:

Let's start from the beginning... This is how she looked like when I decided to start the build. A lot of surface rust ( jeep was sitting in fabrication shop )

https://cimg8.ibsrv.net/gimg/www.che...d6d667a86a.jpg

https://cimg5.ibsrv.net/gimg/www.che...afff15a89a.jpg

Time to clean this thing up a little bit.

https://cimg4.ibsrv.net/gimg/www.che...d8b483c358.jpg

https://cimg5.ibsrv.net/gimg/www.che...be40511df2.jpg

The interior was garbage

https://cimg1.ibsrv.net/gimg/www.che...de632651a0.jpg

Time to take everything out lol

https://cimg3.ibsrv.net/gimg/www.che...03902d9dcd.jpg

https://cimg4.ibsrv.net/gimg/www.che...77a1a8be64.jpg

Now I'm looking for some black interior.

Jeep has a bad plenum gasket and oil leak from valve covers.
First I rdered some plenum gasket repair kit from Dorman. ( package included: gasket for plenum and thermostat housing, all new hardware for intake manifold and throttle body, thermostat, and little rubber hose )
I took the intake manifold out and I saw a pool of oil.
I cleaned everything, put the new gaskets, and set everything in place.

https://cimg7.ibsrv.net/gimg/www.che...1523f4ad1d.jpg

https://cimg9.ibsrv.net/gimg/www.che...d7c8ba65e3.jpg

Plenum done, now time for the valve covers. I dedided while I have them out, It will be good to refresh them a little bit.
Sand blasted and ready for the powdercoat.

https://cimg1.ibsrv.net/gimg/www.che...bbf67abdef.jpg

I wanted something that will be looking a little different. I picked some " old mirror " powder. Very pleased with how it turned. It looks actually way better in person.

https://cimg4.ibsrv.net/gimg/www.che...662b2398ad.jpg

I went to the auto parts store today and picked up some goodies.

https://cimg5.ibsrv.net/gimg/www.che...a53596cd99.jpg

* project update *

So I fixed the plenum, but it was't the end of the problems with the engine.
Piston rings are worn out and the jeep is burning tons of oil.
Decided that faster way is to buy a different engine than fixing current one.
I found one on craigslist one hour drive from my location, with ( as the seller claimed ) 200k miles on it for $100. Seller said that the engine doesn't burn oil and there is no knocking. Finally bought the engine for $80 :thumbup:

When I was taking out parts from the engine I saw that it was SUPER clean inside, no oil / carbon build up or anything like that. After I took out the oil pan there were honing marks, pistons were almost new, new gaskets all around, new water pump, new injectors, new belt, new freeze plugs all around and no paint on the engine at all. I asked my buddy ( mechanic ) what he think about it. He said that the motor was rebuilt from top to bottom not that long ago! LUCKY! :thumbup:

Decide to just lay a fresh coat of paint, and put the new gaskets on.

Here's how the engine looks now. I didn't finish it yet ( lack of time )


https://cimg5.ibsrv.net/gimg/www.che...bcab1347b8.jpg


https://cimg6.ibsrv.net/gimg/www.che...36a0eab639.jpg

https://cimg8.ibsrv.net/gimg/www.che...04d149fee1.jpg

https://cimg9.ibsrv.net/gimg/www.che...6ceff8865f.jpg

* project update *

Went to the junk yard yesterday and bought some parts for the 4wd conversion.
Some transfercases ( 249 and 242 which I'll be using ), rear Dana 44A with Quadra-drive ( hydraulic lockers ), transmission for 4wd, and some other stuff like shifters etc. :icon_biggrin:


https://cimg4.ibsrv.net/gimg/www.che...6f03ba7e36.jpg

https://cimg5.ibsrv.net/gimg/www.che...303c72f9ca.jpg

This looks like a good time fixin' to happen.

yea, a lot of work to do in the next couple days :icon_cheesygrin:

:popcorn:

Following!

* QUICK UPDATE *

I wasn't at the shop long today, because I went to pick up my new, future project. :red_indian:

https://cimg4.ibsrv.net/gimg/www.che...e403728302.jpg

But I have a quick update on the engine build. Intake assembly is in place :thumbup1:

https://cimg0.ibsrv.net/gimg/www.che...6e4a724619.jpg

Well... it finally started to look like an engine

https://cimg3.ibsrv.net/gimg/www.che...c5005e5ac0.jpg

Well... During last few days I did some progress on the build.
New engine is ready to put in.
Old engine is out.
Now it's time to start cleaning undercarriage and engine bay. whole engine bay is covered with nasty, orange water stains.

off course I flooded the shop with tranny oil and coolant... :hang:
https://cimg9.ibsrv.net/gimg/www.che...a204978291.jpg

https://cimg0.ibsrv.net/gimg/www.che...930ffd04b0.jpg

Cleaned the engine bay today. It took about 8 passes to clean it from all this nasty stuff.
Well it didn't t turn out as good as I wanted it, so I think that I might buy some white chrysler paint and spray the whole engine bay with it to make it look fresh and ready for the new engine! :brows:

https://cimg1.ibsrv.net/gimg/www.che...3a0eadbeea.jpg

So the engine bay, after today, looks like this. Only few harnesses more to take out and I will start the "paint prep" process.

https://cimg4.ibsrv.net/gimg/www.che...b80084e854.jpg

Engine bay is stripped. I left the harnesses, because there is no way to take them out without removing the dashboard, and ABS pump, because I can't break the loose on the bolts, and don't want to strip them.

( you can clearly see whyI want to paint it )
https://cimg2.ibsrv.net/gimg/www.che...3152f8c875.jpg

My motor and transmission mouns are worn out. Actually the rubber inserts are separated from the housings.
I looked at the stronger motor mounts, because I want to upgrade from rubber to poly. The cheapest I found was $180 for the set of three ( 2 motor, 1 transmission ). Thought it is really pricey.
Well. I'm gonna make my own then.

https://cimg8.ibsrv.net/gimg/www.che...734ca95242.jpg

Why not delete the ABS?

The bolts on the break lines are super super tide. I tried to remove the ABS, but I don't want to strip the bolts, so I'm just gonna leave it there.