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Old 12-14-2013, 08:53 PM   #1
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2.5 to 4.0 swap

I am looking to swap the 2.5 in my 97 TJ and i was wondering what all is needed to do the swap.

From what i already understand it is not a direct swap or a bolt in job.

has anyone done this and can you give me any pointers and or advice?

Thanks

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Old 12-14-2013, 08:57 PM   #2
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I plan to just buy a lightly wrecked 4.0 tj and transfer parts from the 2.5L tj over to it.. My 2.5L tj is a 97 so hope to upgrade years too! Lol seems easier to just buy a tj with a 4 liter already in it, or so I'm told..

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Old 12-14-2013, 09:38 PM   #3
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I looked into it too when I bought a 97 SE cheap. Was going to change it over. I sold it.
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Old 12-14-2013, 10:18 PM   #4
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You'll have to cut different spots for it to fit. Some of the mounts won't line up to.
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Old 12-14-2013, 10:20 PM   #5
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Old 12-14-2013, 10:24 PM   #6
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I've done it, as have several others here in the forum. If you are dead set on doing this, here's the good news..the '97 is the easiest to do of the TJ's as long as you use the 97 electronics: 4.0 PCM and engine harness.

Different components are as follows:
Fan shroud
Obviously the engine
Engine mounts and location
Transmission
Transfer Case
Rear drive shaft

That's a very basic list, and some components can be modified rather than total replacement. This is a swap that can be done, but rarely is it of any financial advantage. It's usually a better idea to sell what you have and buy what you really want.
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Old 12-14-2013, 11:20 PM   #7
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What might I be looking at financially? My car already has a 4 inch lift, snorkel, winch, 33s, a CB and the paint scheme that I want so I would REALLY prefer to not sell it.
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Old 12-15-2013, 08:08 AM   #8
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Figure $1500-$2000 in round numbers if you're doing it yourself. More if you find someone to do it for you.
The real stumbling blocks are the "I might as well" issues. Such as "since I'm taking this all apart, I might as well_________" fill in the blank.
In my case I rebuilt the engine, changed to a D44 and HP D30, used NV3550 instead of an AX-15, a new radiator and heater core, all new clutch assembly with master and slave setup, and my list goes on.
You'll need welding skills or someone to do it for you, along with cutting and grinding. Figure that in, too.
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Old 05-12-2014, 01:59 PM   #9
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Honeslty 1500 to 2000 doesn't seem that bad..the prices of wrecked 4.0 TJ's even are higher than that and you still have to replace what's broken..sure you have the labor of doing the swap but still if you do it all yourself..
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Old 05-12-2014, 03:39 PM   #10
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when you swap the ECU (PCM) as you have to you may have issues with match up of cluster and ECU regarding odometer ect

At least with 97 no sentry key issues assuming donor is a TJ

if you get a donor cherokee there may be some other issues but it is doable although the sell and buy another is usually more economical

Also unless your current TJ is basically rust free and no sig collision damage don't even consider going down this road as you will regret spending the time and effort on a substandard platform

Try very hard to stay same year for harness and PCM and all the stuff bolted to engine but for the long block itself you can go back a few years and forward to 99

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