Engine swap possibilities?
 

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A customer gave us a 2002 Grand Cherokee Laredo with a broken piston/bent rod 4.0.
i have a 86K mile 2001 5.9 magnum and a recently rebuilt 46RE plus the ecm and wiring from our 99 ram 2500 4x4 we scrapped
can the 5.9 magnum and 46re be swapped into the WJ body without major surgery or hacking up a nice clean GC?

Thanks Everyone!

Unless you can fab a lot of parts and motor mounts and enjoy a wiring nightmare its not a good idea.

I also have a complete 258 out of our 80 eagle, how different are 258 short blocks from 4.0 Engines?
moving motor mounts are not a problem as one there are aftermarket mounts in addition to cutting and moving the stock ones around and re welding them in or cannibalize mounts out of the scrapyard.
just trying to throw out ideas before spending more $$$$ to keep the wife happy

Okay, after a little research, the 258 (4.2) was used in CJs and XJs until 87 so I'm assuming it would have the same block and motor mounts as the early 4.0s.

"before spending more $$$$" and "engine swap" are not often complimentary concepts lol

After a lot of research about converting the 4.0 efi system to a 258 I abandoned that idea for the 258’s little brother the 232..Today while delivering a months worth of scrap they offered me a 232 out of a 74 Hornet in excjhange for a be scap and will be delivering it tomorrow to our shop.
I’m thinking of having it bored .040-.060. over,adding a Lunati Vodoo efi cam with Crower cam saver lifters, Lunati valve springs, good Cloyes double roller timing chain, Clevite Tri metal bearing and the machinist roccommends the dish pistons from the ag use 232 with 8.0/1 compression and Crome moly rings set. When the machinist regrinds the crank he’s going to shorten the snout to the 4-0 crank length and re bore and re thread the end for the 4.0 balancer
On top end will be the original 4.0 TUPY Head completely rebuilt with the extra cooling holes welded up by the machine shop. He figures with the dish pistons and the ,043 Fel Pro head gasket should be roughly 8.85 to 1 for reg grade fuel. I’m keeping the stock efi intake manifold and changing the exhaust to a tuned header and free flowing exhaust to round it out.
Yes, I need to move the motor mounts around a possibly a remote oil filer and if I have to remote the oil filter I will add on oil cooler from our parts overstock to round to add durability. Will keep every one posted as we make progress.

That sounds like an awful lot of money to spend on a swap job and you're still not addressing the electronics. In my opinion, you'd be much better off spending all that cash on a 4.0 that's designed with the electronics in mind. Remember it has to pass emissions inspection.

I'd be spending that money on a 4.6L stroker!

It’s not utterly horrible money wise, the Jeep was basically free, the old rotors/drums/exhaust/batteries etc netted me 1974 232 and I have to run the shop anyhow money wise so that’s a wash also. Robbie at the machine shop said no more than $1400 for his part which is rebuild short block and re do the head and a bit of welding so that’s not bad either. It should run on the stock 4.0 efi system seeing it will be around 2 cid less so that’s good for my wife Lisa who has a love/hate thing with modified stuff like our 2004 Suburban with a 2005 Escalade driveline, 496 tall block Dually, 383 tbi plow truck, 440 powered D350 dump truck.etc It snows here and that is her problem with high powered stuff.
Nearest stock 99 and newer 4.0 is $1650 with 164K mi, there is one with 101K mi for $1150 but you need to re weld some mount bosses on the block due to accident damage. Stroked 4.6 will not run the stock efi and the budget builds I see go $3000 or greater and I get the I won’t drive that today problem.
$1400 and change, exhaust about $450.00 with All incidentals like oil/coolant spark plugs and the like call it sub $2000.00 for a Completely rebuilt 239.5 cid engine in the GC that will not leak oil/coolant, or any of the problems a high mileage 4.0
And I have no IM or emissions here yet and with stock efi I am not sure it wouldn’t pass, .1 increase in stroke and .1 decrease in bore or 2 cid less doesn’t have much effect.

Okay guy! You look like you're got the situation well in hand. It also sounds like you're a gearhead with many swaps in your lexicon. I grew up with the any-car-any-engine-stick-a-4bbl-on-it-and-go bunch! My first car was a 37 Dodge with a 315 Red Ram Hemi in it. I blew the rear end because it was designed for 36 hp! You forget to think about stuff like that when you're 18 years old!

I still like to play with engines, but on the bench. I'm 73 years old and I'm done crawling around in engine compartments and underneath.

First gen Hemi in 37 Dodge coupe sounds like a ton of fun! Your knowledge and expertise in doing something like that when V8’s were more the exception than the norm is huge.
I was just letting everyone know that we thought it through, it wasn’t expensive and it should be able to work without a lot of aftermarket stuff and why that would keep the wife happy which was the goal in the end. Let the fun begin

Ya know? I think too many guys try to soup up the 4.0 because they think it's got no power. It IS a 4 liter after all and it's pulling 2 tons of metal around. You take a small sedan with a 4 liter engine in it and it's the next best thing to a supercar. The 4.0 is a torquer and develops max torque at 3000 rpm. It's not designed for high revs. The only time I find my WJ a little sluggish is with 1000lbs in the back!

Since my wife wanted the Jeep I looked up plenty of sites on the 4.0, how to interchange them over the model yrs, how much you can go over bore them safely and of course many of the stoker articles with how to set them up, tune them and get them to run and cool correctly. I thought why? For around $2700 you can get a bolt on supercharger kit and almost double the power and torque.
And if you want to see how that works take a ride in my kids BMW 325I with the centrifugal supercharger that eats his friends 6.0 SS Camaro for lunch, All with a 2.5 I6 engine.
I didn’t want to dial to much power in the GC, Was thinking of using up the good 5.9/46RE I have laying around but as it’s for the wife stock performance is okay.
Update-boneyard 232 had a crack in the block under the exhaust manifold so that’s out. Was down at machine shop to get 318 mopar pushrods and mentioned it. He said since I talked to him they picked up a few 4.0 blocks/cranks/heads and rods and he SHOULD have what we need to but a 4.0 together for the same money $1400 we talked about.
Back to page I I guess so do 232 and 258 cams fit the 4.0?