1989 YJ 2.5L - Not running - sitting 8 years.... - Jeep Wrangler Forum
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Old 01-23-2017, 10:11 AM
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1989 YJ 2.5L - Not running - sitting 8 years....

My father in law finally got the warning from the HOA to get the jeep out from under the deck its been under for the last 8 years. I had asked him for it several years ago, but he said no. Finally its mine. It does not run yet, but I'll get it there. I started by putting in the obvious battery. cranked and did not start. banged on the tank. no start. changed plugs, fuel filter, put in fresh gas, starting fluid. no start.




Finally got it towed back to my house Saturday and began the tear down. One of the reasons I took this jeep (BTW I paid nothing for it) was the frame, body and top have somehow remained

almost rust free, despite being stored outside in Virginia for 8 years with no cover.






The r/f wheel was going flat. it had sank into the mud 8 inches and dirt was inside the bead. Tires are horribly dry rotted but appear to the be only thing in that condition.




I normally wouldn't take on such a heap but the frame and body for some unfathomable reason has almost no rust. In addition to that the reason he stopped driving it was because he had a huge oil leak that was spraying (misting) from somewhere under the hood. I suspect it was either the valve cover gaskets (which are the plastic ones that tend to leak at the rear) or part of the pvc system. Well this oil leak put a layer of oil on everything under the hood before storage so it somewhat preserved all the rubber and plastic. There is very little dry rot. The top was green with algae/moss but power washed right off and kept it from dry rotting. floor pans are solid.





I ordered a bunch of parts. some of which still aren't here. I have a 15 gallon tank in this which is proving hard to find diagrams for and parts. quadretech had the sending unit, which was supposed to arrive Saturday but has not. I pulled the tank down, which i can see now why it didn't start.





I cant figure out where to get the vent lines marked in red to the right and the lines coming off the sending unit. Can i just get generic lines and cut. The lines to the right went up into compartment behind the passenger tail light. I had to take a small rubber panel off to get to them. The lines converged to a metal line that had nothing attached. just loose!!!! There was also a line that was connected to nothing going up into that area that is very long and runs back over the fuel tank and all the way to the front of the jeep. see the one hanging indicated by red. looks like it is a vacuum assist. guessing it was supposed to plug into whatever those to lines are supposed to go to.




while waiting for the parts i put the pads, rotors and new calipers on. one caliper was mislabeled on the box from autozone, so i have to get get another on.


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Old 01-23-2017, 10:26 AM
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not sure why my pics didnt come through. they worked on another forum i post on. they are from imgur.

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Old 01-23-2017, 10:36 AM
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pics not sure why the others dont show.




got these seats used. will need to modify the tracks though to get to work.


new brakes


oil soaked motor


this is the worst rust on the whole thing!



no rust on floor pans


i sanded and painted frame around tank. gonna just do it as i go since its not a frame off resto.



skid pan looked good


got the new tank mounted up to skid and ready to go when pump gets here
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Old 01-23-2017, 12:53 PM   #4
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Wow what an great and lucky find. What are you plans? Are you going for a stock look or are you going to build it up some? Might be had to tell from the pictures but the front springs looked pretty flat. Good luck with it and have fun!
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Old 01-23-2017, 02:08 PM
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Wow what an great and lucky find. What are you plans? Are you going for a stock look or are you going to build it up some? Might be had to tell from the pictures but the front springs looked pretty flat. Good luck with it and have fun!

Right now just to get it running. I am praying that the oil leak is from an overlooked item. I bought valve cover gaskets, PCV parts, oil pressure sensor and am hoping its one of them spewing. It possible though that it might be coming from all of those from blow buy. We will see. If the motor is shot I have a big decision. My wife will be driving this as well. I have kept too many toys/rooms/guns/tvs/ from her in the past, so i have to share this new toy. I have grandios dreams of having a small block in this, but two things would prevent me from doing so. 1) I just am not sure that I have the mechanical know how to do it. the wiring and fabrication part scares me. 2) I wouldnt want to put my wife behind the wheel of that.

I am still considering buying a professionally rebuilt 2.5l if the engine is no good. They come with a 3 year unlimited mileage warranty. Im sure it will be a little more peppy too, I know this will limit me to what I can do with the vehicle. There are a lot of people on here, who paint the 2.5l as barely able to get up the driveway, but then there are other people who seem to get around no problem.
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Old 01-24-2017, 06:58 AM
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Fuel line issue

Ran into a bit of an issue last night. I got the sending unit in yesterday. Got it in the tank. I had planned on replacing the lines up to the hard lines. I cut them off the old tank because they were so seized. I did cut them close but it didnt really matter because I planned to replace. Of course with jeeps nothing works the way you intend. The lines are wedged between the frame and the body. it appears they are supposed to be there from the pictures Ive seen online. How does one get these out. They are wedged tight. It looks like i will have to loose the body from the frame to get them out. Is this right? Is there a trick? I just want to get it running to make sure the engine and fuel system are good. I will probably replace the hard lines later on.


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Old 01-24-2017, 11:13 AM   #7
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Nice find!
The 2.5 is a sufficient engine if you stay with the stock configuration, but so many lift & toss 33" tires and wonder why it doesn't agree with them.

I Actually found my Jeep in Virginia that hadn't been used for many years, spent the last 2 years replacing parts a little bit at a time like your doing.

Keep the photos coming!
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Old 01-24-2017, 09:28 PM
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So I half assed the fuel lines just to get this sh#t running. I put the fuel lines in using two in line fuel filters and connected secondary lines to them. pumped some fuel in and......no start.....I checked and the pump is now working which is great. can hear it doing its thing which it wasnt before. I am getting fuel, air but no spark. I have already changed the spark plugs so i decided to change the cap rotor and wires. The rotor would not come off and for a while I thought i was missing something. After determining it has no "release" I smacked it with my fist and got it to come free. The shaft was rusted and had seized. The cap and rotor were corroded inside as well.
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Old 01-24-2017, 09:29 PM
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So after that..... Eureka. Ignition, spark, combustion!!!!
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Old 01-25-2017, 06:54 AM
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Heres a better video. that photobucket one comes through juttery

https://www.youtube.com/watch?v=8f7IcOtiZFM
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Old 01-25-2017, 06:54 AM
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it came out smokey like this for about 5 minutes and then cleared up.
https://www.youtube.com/watch?v=pEJUlgm8pww
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Old 01-25-2017, 09:26 AM   #12
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Cool build! As for the fuel hoses, they *should* slide out. The previous owner of my Jeep ran new hoses through the frame. One day I smelled gas and lost a lot of fuel pressure... Yeah...

I was able to get the rubber block out with needle nose pliers and 45 degree pliers. Silicone spray is all you really need. Just clean up the rubber, sandwich the new hoses in the block, and slide it underneath the frame. It may help to sand the rust down on the frame and body, then put some oil on it.

I think I wrapped the block with cheap electrical tape just to keep it together. I was then able to pull the tape out while the block was in.
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Build thread for OJ, my YJ. 1993 Wrangler S 2.5L/AX-5/NP231 with SYE, Spartan locked Dana 30/Aussie locked Ford 8.8 @ 4.88, SOA lift with 2.5" OME HD springs and front Bilstein/rear Rancho shocks, Barricade 9500 winch, custom front and rear bumpers, 136 amp alternator, 35" Super Swamper LTBs.
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Old 01-25-2017, 10:19 AM
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Cool build! As for the fuel hoses, they *should* slide out. The previous owner of my Jeep ran new hoses through the frame. One day I smelled gas and lost a lot of fuel pressure... Yeah...

I was able to get the rubber block out with needle nose pliers and 45 degree pliers. Silicone spray is all you really need. Just clean up the rubber, sandwich the new hoses in the block, and slide it underneath the frame. It may help to sand the rust down on the frame and body, then put some oil on it.

I think I wrapped the block with cheap electrical tape just to keep it together. I was then able to pull the tape out while the block was in.
Thanks. I think I will get some other stuff done on vehicle to get it going and then go back and revisit the lines and do the hard lines as well. Good to know that someone else experienced the same problem as well.

Just curious how does your jeep get around with the 35" tires
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Old 01-25-2017, 11:23 AM   #14
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Thanks. I think I will get some other stuff done on vehicle to get it going and then go back and revisit the lines and do the hard lines as well. Good to know that someone else experienced the same problem as well.

Just curious how does your jeep get around with the 35" tires
I have 30s. Not putting on 35s until my 8.8 is done. And I'm doing it right by regearing to 4.88. I like to use 50th gear.
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Build thread for OJ, my YJ. 1993 Wrangler S 2.5L/AX-5/NP231 with SYE, Spartan locked Dana 30/Aussie locked Ford 8.8 @ 4.88, SOA lift with 2.5" OME HD springs and front Bilstein/rear Rancho shocks, Barricade 9500 winch, custom front and rear bumpers, 136 amp alternator, 35" Super Swamper LTBs.
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Old 01-25-2017, 12:49 PM
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well went home at lunch to put in some marvel mystery oil and let it run for a little while before i change the oil out tonight.

NO START......

I lost spark. Going to order a coil and crank sensor and see if that it.
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Old 01-25-2017, 11:28 PM
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Cool is on orde, but I did get a crank sensor. Put it in and we're good started up. Sensor was really dirty.
I put some marvel mystery oil in and let it run for a while and then changed the oil. Tomorrow I'm
Going to changed the transfer case and transmission fluid and then take it on its maiden voyage. I got a little worn out on the mechanical work tonight so I cleaned and waxed the hood. Still have to wax the sides and back but shined up nice.


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Old 01-26-2017, 07:01 PM   #17
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Great work - keep it up.
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Old 01-27-2017, 07:03 AM
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Replaced valve cover gasket an valve cover last night.
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Old 01-27-2017, 07:19 AM
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photobucket sucks. such a glitchy site. sorry for the repetitive pics.
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Old 01-27-2017, 10:38 AM   #20
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When you get tired of wrenching on yours you can come and wax mine for me with all your spare time. Lol It seems like a never ending battle sometimes but keep the Faith Brother. Nice job so far.
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Old 01-27-2017, 11:47 AM
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thanks it is a lot of work....
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Old 01-27-2017, 11:54 AM
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Did a brake flush. first i sucked all the fluid out of the reservoir. Nasty sh*t at the bottom.


Ran EPR through the engine for 30 minutes and then did an induction service with BG stuff. Oil came back out black.



took for its first drive after that. It runs pretty well. Transmission feels a little loose. still need to do the service to that though. TIRES ARE HORRIBLE. ordered for khumo ATs today. will be here Monday.

The engine is doing a new thing now. At start up its reving immediately to 2k RPM and then comes back down. I am going to replace the idle control valve and see if that fixes it.
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Old 01-27-2017, 04:13 PM   #23
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You should really be playing the lottery !��
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Old 01-28-2017, 04:37 PM   #24
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I like to use 50th gear.
50th gear! Wow, my Jeep must be a racecar!!!

Anyway this Jeep is going to be really cool in a couple of weeks.
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Build thread for OJ, my YJ. 1993 Wrangler S 2.5L/AX-5/NP231 with SYE, Spartan locked Dana 30/Aussie locked Ford 8.8 @ 4.88, SOA lift with 2.5" OME HD springs and front Bilstein/rear Rancho shocks, Barricade 9500 winch, custom front and rear bumpers, 136 amp alternator, 35" Super Swamper LTBs.
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Old 01-29-2017, 06:38 PM
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Replaced the EGR valve and the rev up at start up was fixed by the idle control motor. EGR valve was really clogged. Got the seats going in now. Got the old ones out. Painted the frames. Floor pans look good. Figured I'd put a coat of paint one while I have the carpet pulled up. Unfortunately. A bolt broke coming out. Had to drop it out. Will finish tomorrow. Decided to paint the hinges on the hood too.








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Old 01-30-2017, 06:41 PM   #26
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Thanks for the inspiration. I've got a 95 that I picked up in October that had some major issues, but I'm slowly getting it back. I actually moved it recently which is something that I was unable to do when I got it because the rear-end was frozen solid. thanks again...great work.
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Old 02-01-2017, 03:13 PM   #27
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Great start to saving the old girl! Glad that its coming along well for ya! Good luck keep it up!
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Old 02-02-2017, 06:45 AM
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new tires are on. looks good. took it for a short drive. very smooth now.


unfortunaley, the 30 year old drag link did not want to adjust, even with torch and hammer and eventually split. so have a new one coming today.
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Old 02-02-2017, 08:16 PM   #29
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You know the trick for those? Hit where the taper is. Pickle fork is also good when they're trashed anyway, and being replaced.
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Build thread for OJ, my YJ. 1993 Wrangler S 2.5L/AX-5/NP231 with SYE, Spartan locked Dana 30/Aussie locked Ford 8.8 @ 4.88, SOA lift with 2.5" OME HD springs and front Bilstein/rear Rancho shocks, Barricade 9500 winch, custom front and rear bumpers, 136 amp alternator, 35" Super Swamper LTBs.
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Old 02-03-2017, 12:05 PM   #30
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At this rate, you'll have a new jeep in no time lol. Looking great!

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