Help with engine swap

Eastcoasteskimo

NAXJA Forum User
Location
Hampton, VA
Free beer and food for anyone willing to help swap out an engine. I bought my son the same xj I had when we first moved to hampton but had to sell it due to orders to England, which I lost. The xj has 230, 000 miles on it so we decided to buy another with 103, 000 on it but I am over my head. I live on bethal manor (Langley AFB). If willing to help my son is willing to pay in beer, food and or money. Thanks in advance. If no takers any helpful hints are welcomed.
 
I'd be happy to answer any questions you have, although I'm to far away to help in person. Easiest way to start is by pulling the front header panel and radiator. I've done both methods- just pulling the motor, or pulling the whole drivetrain-motor, Trans, and tease at one time, and that is fastest and easiest.
The hardest part if you just pull the motor is getting to the upper bellhousing bolts with it all in the jeep. I also suggest taking pictures of which electrical plugs to where, and labelling them if necessary. You'll be glad you did. From there it's no big feat. Several times I've had the whole shebang out, fixed, and back in in one day.
Still not as easy as an old VW, but still manageable for sure.
 
I'm too far away to help as well.

I will add on to what Chief said. I recommend removing both motor mounts off of the engine and drop the motor down until it bottoms on the axle, then you can easily get to the top bellhousing E-12 bolts. Then raise the motor back up and support the tranny and remove the lower two bolts(these will be the last four bolts you take out before pulling the motor.

Make sure you;

1)remove the inspection plate and all 4 torque converter bolts(15mm)
2)the starter
3)front fascia and upper radiator support
4)unbolt the condenser and swing it to the pass side and support it with a chair, do not disconnect
5)remove the radiator
all wire harness and label as you go
6)take the battery out and after you remove the AC compressor, just lay it over where the battery was, dont disconnect it-no need to.
7)remove air box
8)remove the power steering pump and lay it where the air box was, leave it connected
9)remove the motor mounts and brackets
10)drop the motor down and remove the upper bell housing bolts
11) raise the motor back up and remove the lower bell housing bolts and two bolts holding the rest of the flex plate on including the dip stick tube/grounds

Pull it!
 
Remember to remove the CPS, too, because it's in a pretty vulnerable spot to get smashed by the flexplate while you're attempting to remove/install the motor.

I pull the whole drivetrain as a unit like thechief86 does.

Like xjtrailrider, I generally don't disconnect the ac compressor or power steering pump from their hoses - I just unbolt them from the motor and lay them to the side. Easier than recharging/bleeding the darn things when they have to come off the motor anyways.

Rather than disconnecting the fuel line quick disconnects at the fuel rail, I just unplug the entire injector rail from the intake manifold and lay it aside still connected. You'll need new O-rings, but a box of them is like $5.

Gaskets you will want to have on hand:
exhaust manifold "donut"
maybe two new studs or through-bolts for the manifold to downpipe flange if yours look rusty
new exhaust/intake manifold studs for the cyl head, the bolts are usually fine to reuse but I had a stud break in half on me flush with the head surface at the back of the block while trying to reinstall, so I recommend replacing them now. It'd been 50% broken for years from the rust on the break.
manifold gasket - it's like $7 at the parts store
any gaskets that seem to be weeping on the donor motor, it's more fun to do them out of the car

Oh, and use a silver sharpie or masking tape and a marker to number the fuel injector plugs. Everything else is pretty self explanator/only goes on one way, but it's not always obvious which injector plug went on which injector.

Remember to disconnect the grounding strap from the rearmost head bolt before trying to pull the motor.
 
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