4-cylinder engines: upgrades through the years

[Mr_Random]

I don't remember all the sensors, I just tried to grab everything attached to the harness when I bought it. Some things to remember:

• Speedometer? If you're converting the gauge cluster and all that, you'll also need the electronic speedometer thing that replaces the speedo cable in the transfer case or transmission housing.

• Temperature sending unit at the back of the head. Not sure if it's a different plug or not. I had to get a new one cause the top is plastic and breaks easily when trying to get to the valve cover bolts, fuel rail, etc.

• If you want to hook up the funky sensor in the power steering line, make sure you get the right line from a 4-banger with the threaded part.

I figured out why I wasn't getting fuel pressure. I had the lines switched . Now fuel is leaking out through the fuel pressure regulator o-ring. Gotta love junkyard builds. Time for a new o-ring kit on that. I still need the 91+ fuel pump too. It sounds like it's going to start now but doesn't quite make it. Maybe due to not enough fuel pressure? I haven't checked anything electrically yet to make sure I have spark, etc.

I wasn't going to get a wiring harness (let alone ECU and body harness) around here for the price I got it shipped, so I unfortunately don't know the locations of everything.

Did you not have power steering before? I have the sensor already, I'll just swap it over.

I plan to use the old guage cluster, because I don't think the NP231 speedo sensor can be swapped into the 207. For now I hope the tach will still work (it'll be the only one running directly from the ICU, Ignition control unit), every other guage has it's own separate sender that isn't affected by the computer, except the speedo which uses the cable.

Even if the whole cluster doesn't work, all I'll need for now is the speedo.

In the future I'll need a new tranny and I'll get an NP231 with it. I'm thinking I'll try to do the ax-15 and dakota/novak bellhousing thing too. That will lead to me getting a new guage cluster for sure...

My main concern right now is which connectors to swap over and how I'll get A/C to work (it doesn't right now anyways, the heater valve opens with it so it's just a waste).

The jeep is dead, probably due to a bad fuel filter, but I'll be riding my bike to work and investing extra time and money into research and parts instead of taking the time (20 minutes including the bike ride to the parts place) to change it.

 

[FlexdXJ]

the best upgrade for that pukey ass 4 banger is a 4.0

 

[xj92]

I didn't have power steering before, I added that on too. My A/C will need a lot of work too, but my primary focus is just to get it running. Since I put in a 4.0 radiator, and have a '93 compressor, I'm going to need some custom stuff to fit it all together with the 2.5L.

I'm planning a tranny upgrade (NV3550) and a rear axle upgrade, but not for quite a while. I just need to drive it for a while first.

I have a 4.0 in my '93 XJ. Good motor and I've done lots of mods to it too, but nobody likes 14mpg right now.

 

[Mr_Random]

the best upgrade for that pukey ass 4 banger is a 4.0

You'll be puking when you see how much better my mileage is than yours once I fix this thing! :clap:

And hey, if the original Jeeps used a 2.2L 4cylinder, and survived WWII, then I'm sure my 2.5L will survive right now!

Plus, the 4.0 was never meant for the XJ frame, see how much they had to cut up in order to fit it? Yeah, I'd have to do the same, I could fit a v8 as easily!

 

[xj92]

Talk about slow progress, maybe you guys can help me get it running. Here's a recap of what I have and what's going on.

'88 Comanche 2.5L with:
'93 harmonic balancer, A/C Compressor, Power Steering Pump, Alternator, Distributor & sensor, engine wiring harness & computer, chassis harness, fuel pump & sending unit, intake manifold, fuel rail, injectors, etc. etc.
'93 4.0 throttle body
91+ 4.0 62mm tb spacer (I know people say it is faster with a smaller bore, I plan on playing with this once it is running by testing it with and without the spacer).

When I try to start it, it just won't run. If I hold the throttle wide open, it might stay running for a few seconds, but still doesn't sound right and will die immediately after letting off the throttle. It won't even do that all the time with wide open throttle, sometimes it won't catch at all. I think I read somewhere that if the sensor at the back of the engine/front of the transmission bellhousing is bad it wouldn't run. Any other ideas? I pulled the boot off each spark plug and checked to make sure they were sparking, which they are. The plugs are new, but are the ones spec'd for the '88 engine if that makes a difference. The cap & rotor are new, and spec'd for the '93 distributor I put on it. It has fuel pressure at the fuel rail. Even if an injector was clogged, I think it would take at least 2 clogged injectors to make it not run, not sure. All the stuff I've thrown on is from the junkyard, so it is all suspect.

 

[FlexdXJ]

You'll be puking when you see how much better my mileage is than yours once I fix this thing! :clap:

And hey, if the original Jeeps used a 2.2L 4cylinder, and survived WWII, then I'm sure my 2.5L will survive right now!

Plus, the 4.0 was never meant for the XJ frame, see how much they had to cut up in order to fit it? Yeah, I'd have to do the same, I could fit a v8 as easily!

If you have a stick then you probably will get more gas mileage but I don't care. The 4.0 is a much better engine than a 2.5. How can you even compare a 2.5 XJ to a WWII era Jeep anyways. It was way lighter and smaller than an XJ. I guess if you have a 84-86 it wont fit didn't realize that. All i have to say is 4.0 FTW!!!!!!!!

 

[xj92]

You waited 3 weeks to reply with that? I guess I'll start a new thread for my issue since you want to turn this into a lame 2.5 vs 4.0 thread.

 

[Mr_Random]

You waited 3 weeks to reply with that? I guess I'll start a new thread for my issue since you want to turn this into a lame 2.5 vs 4.0 thread.

I KNOW! BTW, the original GPW was only seven hundred lbs less than the XJ... but add 3 plus men and lots of gear, I'm sure the original jeep, with a whole 85 HP, was much heavier...

Okay, back on topic! How is your conversion coming along? is it running yet?

I finally have everything in place, most of the parts are locked up outside, but still have some more coming.

I'm still fighting with myself on how to wire things, I'm tempted to just get one yanked from the JY, but I don't think the YJ engine harness I have will plug straight into an XJ interior. Either way I may be a little screwed, haha.

Edit: sorry, I meant willy's MB instead of ford GPW, which are pretty much the same anyways...

 

[xj92]

Still not running yet. Somebody over on comancheclub suggested that the 91+ flywheel is different and I'll need the newer one for the CPS to pick up the right signal. I got one from autozone but haven't put it in yet. I need to get a transmission jack first.

 

[Ghost]

Still not running yet. Somebody over on comancheclub suggested that the 91+ flywheel is different and I'll need the newer one for the CPS to pick up the right signal. I got one from autozone but haven't put it in yet. I need to get a transmission jack first.

Yea it is. You did nto change that? I did not think to ask either. Keep us posted!

 

[Mr_Random]

Yea it is. You did nto change that? I did not think to ask either. Keep us posted!

That throws a nice wrench in... how much will the new flywheel cost? Wait, I'll have the answer myself soon anyways... ah the wonders of the internet!

anything else that's gonna jump up and bite me in the butt?

Edit: yeah, we have the tranny jack and I think I'm gonna get new throwout and pilot bearings, I'm thinking the pilot is squealing, and the throwout is making a low hum/ not disengaging soon enough. We just replaced everything too! Ah...

 

[Ghost]

I just junked one too.

 

[Mr_Random]

Yeah... at any rate, I need to replace/ rebuild the tranny soon... ah...

So who thinks that the idiots at AZ will take a core exchange on a different flywheel? I'm thinking I'll buy the remanufactured, then swap it on and bring back the old one. I doubt they'll think anything of it... The flywheels have the same tooth count and all...

 

[xj92]

The old starter will work with the new flywheel, right.....?

 

[Mr_Random]

The old starter will work with the new flywheel, right.....?

That too! Ghost, do you know?

 

[Ghost]

The old starter will work with the new flywheel, right.....?

Not sure but I believe it will.

 

[Mr_Random]

Okay, new question, anyone know if the newer electronic speedo sensor from np231's can swap onto the 207? I want a cheap solution, hesco has a part that can convert the cable to an electronic AND cable output, but for the price I could buy a whole 231 with an SYE already installed (used of course).

also, hesco's part is for both the 207 and 231 cable driven speedo's, so could that mean interchangability of the electronic speedo? Or are the internal parts of a cable driven fundamentally different from the electronic?

 

[Ghost]

Okay, new question, anyone know if the newer electronic speedo sensor from np231's can swap onto the 207? I want a cheap solution, hesco has a part that can convert the cable to an electronic AND cable output, but for the price I could buy a whole 231 with an SYE already installed (used of course).

also, hesco's part is for both the 207 and 231 cable driven speedo's, so could that mean interchangability of the electronic speedo? Or are the internal parts of a cable driven fundamentally different from the electronic?

The sender for the 231 is bigger then the one for the 207. The 207 will not take the sender for the FI system.

 

[Mr_Random]

The sender for the 231 is bigger then the one for the 207. The 207 will not take the sender for the FI system.

okay, i shall keep that in mind, but the sender isn't necessary for now, right? I'll wait on the 231, because I'll have to get at least a different rear driveshaft, right? The front CV shaft flange may not bolt up either...

Yeah, but that'll be later... for now, how can I get a spreadsheet to display on here without converting it to an image file and uploading it to an image hosting site? I have a spreadsheet of expenses that I've put into this swap, I need to add the final parts to the list, but I'll try to post it when done...

thanks!

 

[Ghost]

The front yoke on a 231 bolts right up to the 207. The 231 rear shaft is shorter then the 207 IIRC so if it is going in a lifted xj the 207 shaft may be perfect.