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Old 03-15-2015, 07:31 PM
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2.5L to 4.0L swap

Hey everyone. I have a 99 tj with a 2.5l engine in it. It is still drive able but it's on its last leg. I have a 4.0l engine from my previous 2000 wrangler that I took out. I was wondering what needs to be done to swap the engines out.
What kind of wiring can I use from the 2.5l if any?
Do I need to change the motor mount location?
The 4.0l has A/C and I plan on just taking that out.
And since I live in California am I going to have any problems with smog?

Right now I have the 4.0 engine, trans, and transfer case hooked up and on a stand.

I'm sure I have more questions but I can't think right now. Thanks guys

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Old 03-15-2015, 07:43 PM   #2
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What happened to the 2000 body and frame

Yes you been computer also as well as harness and new welded in motor mounts

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Old 03-16-2015, 12:21 AM
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The jeep was involved in a hit and run so I dismantled the whole body but kept the drive train attached to the frame and welded some wheels on it to wheel it around.
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Old 03-16-2015, 02:32 AM   #4
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For smog you will have to go to the smog ref. he will inspect it and if its ok he will put a ref sticker saying what was done. Also, you will be held to 2000 year model smog standards. If i remember right. Ill have to check my smog manual to be sure.
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Old 03-16-2015, 08:40 PM   #5
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Sell all of it and buy a 4.0 factory equipped TJ. You'll be time and $$ ahead. I've done a conversion in Ca. and have a 50 state legal rig in my garage. You'll have to jump through some pretty serious hoops to make the referee happy. All the same rules apply no matter what you swap...4.0, Magnum, LS, Hemi, etc. Everything that was OEM on the 2000 engine will have to be there and fully functional to get a CARB approval sticker. So once again, if you are not set up and have the resources and $$$ to do this, refer to my first sentence.
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Old 03-16-2015, 09:16 PM   #6
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Move to Florida and you can put whatever engine you want in it! LOL But I agree, you'll spend a ton on that swap to make the state of California happy..
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Old 03-17-2015, 12:03 AM   #7
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The biggest thing that stops me from doing a swap from a 350 vortec to a LS in my chevy is the money needed for the evap system. Thats where it really hurts! So i am just gonna rebuild my ol faithful.
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Old 03-17-2015, 01:59 AM
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By what you said about putting everything from the 2000 wrangler on the 99 wrangler. Do you mean EVERYTHING? Cause I wanted to leave off the AC, but include everything else. I literally have all the wiring for the 4.0l but if worse comes to worse I can have it registered in my grandparents name in Oregon. But as far as money spent...I have everything except maybe aftermarket motor mounts and some small things. I don't want to sell this jeep because the previous owner did everything I wanted to do to my old jeep like ford axle, 4.88 gears, lockers, long arm lift, and some other stuff. It's a solid rock crawling rig minus the engine.
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Old 03-17-2015, 02:01 AM
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But I should also add...I would be willing to kind of do whatever I can to the 4 banger to give it a little more umph. The previous owner did do engine work to it like throttle body and what not but that's about it
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Old 03-17-2015, 09:55 AM   #10
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Yes if you have everything from the 2000 including exhaust with cats and sensors and evap system and PCM and complete wiring harness and all sensors
Just move everything including inst cluster over to older than and weld in new motor mounts
The key is discard nothing from 2000 until project is complete and regestered
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Old 03-17-2015, 10:42 AM
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Okay, so are you saying to leave the a/C on? Is there anyway I can not do that haha. I'd rather not create extra work for something I don't want to swap over
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Old 03-17-2015, 12:18 PM   #12
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Sure you can skip the AC or better yet to avoid belt issues just leave the compressor but don't bother with any other ac components and use the compressor as an air compressor as on board air to air up tires and such
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Old 03-18-2015, 12:51 PM   #13
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Quote:
Originally Posted by Digger84 View Post
Sure you can skip the AC or better yet to avoid belt issues just leave the compressor but don't bother with any other ac components and use the compressor as an air compressor as on board air to air up tires and such
That's a awsome idea!
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Old 03-18-2015, 01:50 PM   #14
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Old 01-21-2016, 02:18 PM
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Just a little update since I got it running with the swapped 4.0L. Everything is working as it should. Took it to get examined by a BAR referree and it all passed. He was surprised because he said I am the first one since April to have passed on the first try. Pretty damn stoked
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Old 01-21-2016, 06:08 PM   #16
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So what did you have to do to shoehorn in a 4,0 where a 2.5 used to live?
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Old 01-21-2016, 11:36 PM
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So what did you have to do to shoehorn in a 4,0 where a 2.5 used to live?
Honestly it was a direct swap. Just have to relocate the engine mounts. Also watch out for SKIM if your jeep is equipped with it. I had to send my PCM out to get it cleared so I could actually start the jeep. I also took out non essential stuff off of the 4.0L like all of the A/C. I left the compressor on, made a plate to cover the ports, and bought a non-AC serpentine belt.
I also took out the windshield wiper fluid container for more room. Left everything else stock.
So nice to be able to n pass people on the highway and actually do the speed limit haha
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Old 01-22-2016, 12:11 AM
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Digger84 helped me out a lot. That and YouTube haha

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