2003 TJ 4.0L into 1992 MJ

[ev700401]

I've been working with this swap for a bit and am getting hung up on engine block brackets.

Here is what I have:

1992 MJ originally had 4.0L in it.

2003 TJ 4.0 with all 3 d/s original block mounting location bosses broke off from accident in prior vehicle. I have MORE Bombproof engine mount block brackets for 2000-06 TJ/LJ (BBTJ0006).

I welded on a tab for an 8th mounting hole at the lower rear of the MORE d/s block bracket to compensate for not having any good mounting points at the 3 original block locations, so I have 5 good mounting points on d/s.

Yes I know the hole for the rubber engine mount is in a different spot on XJs/MJs compared to Wranglers. Since the MORE brackets have the hole in the Wrangler location I have relocated and slotted a hole on the d/s MORE bracket to fit into the MJ engine bay. I am currently using the OEM '03 TJ p/s block bracket and factory rubber mounts.

Here is my issue...the engine is not in straight. It is not noticable to the naked eye, but you notice it back at the transmission mount. I have modified the hole on the d/s mount side to side a couple times, but it only makes it a little better or a little worse depending, never right.

It seems to me that the engine mounting on the unibody are staggered different on XJ/MJ than they are on Wrangler which means that it isn't a matter of having my holes correct left to right, I need to move something front to back on one side, which I'm not sure I can.

I contacted MORE, but they do not know anything or make any suggestions on how to use their brackets in the vehicle. All they sell are brackets to fit the listed engine block and then their knowledge stops there.

I am using the OEM p/s bracket because I did not feel I have a need for the MORE bracket on p/s and the OEM bracket fits much better with ignition coil and distributor access (using all 1992 OBDI stuff on newer block). Plus the way I figure it, if the MORE block brackets are made off the dimensions of the Wrangler brackets then it should be the same anyway with the only difference MORE tying into more holes in the block.

So I ask, those who have put 2002 and newer 4.0Ls with the different engine mounting bosses into older XJs and MJs what brackets have you used? 01-earlier brackets will not bolt up to the new blocks. 2000-newer TJ block brackets are not correct.

Maybe I am missing something, but I worked with this for long enough and now turn for help.

 

[Tim_MN]

When Jeep startted using the new curved intake manifold, they had to move the engine slightly to the passenger side so the new mainfold would clear the suspension tower. The transmisson crossmember and mount were also offset.

See this thread -> http://www.naxja.org/forum/showthread.php?t=1071717

You can twist the engine/trans some to make the crossmember fit. That shouldn't hurt anything.

 

[ev700401]

Thank you.

That does help explain the issue I am having, my transmission mount is consistently shifted to the passenger side no matter where I move the engine within it's range of movement.

I was assuming that my transmission mount location would remain consistent and serve as a verification for my engine position.

Let me check some things and I will see.

 

[kastein]

I would find another engine... between the head, exhaust, and emissions system, and the broken off bosses, it may be better to do so. I don't know what the market is like out where you are, but here a 91-99 4.0 goes for $100-200 all day long on the classifieds and even at some you-pull junkyards.

Also, I want pics of your MJ! 92s are incredibly rare these days.

 

[ev700401]

The head is a TUPY casting. I'm using the 03 exhaust manifold with a 00 XJ downpipe (without precats) and 00 XJ crossover pipe (which I may change just this portion due to how much it hangs down). Bosses being broke do not matter any more since I am still bolted to 5 good block holes on D/S. I got the engine for free.

Here is a pic (edit I posted a pic then read we are not supposed to...I don't know...)

 

[ev700401]

I got the engine and transmission mounted up in a way I think I'm happy with finally.

No matter how I moved the engine or slotted the hole in my MORE D/S bracket I could not get my transmission mount to line up. Knowing that there was another trans crossmember out there that is 1" off (which is exactly what I ended up being) made me feel a little better and I went a ahead and modified my trans mount so everything should be good now. I split the difference on engine position from where the original 92 4L was to where an 01 XJ 4L sat left to right and made the transmission sit where everything was square.

I still do not fully understand why things did not line up perfectly without modification, but that part appears to be behind me now atleast.

 

[kastein]

ok, free is a good enough price to justify what you are doing IMO. Good luck!