4.0 engine swap help!

[defibvt]

So I have a 74 CJ5 . I have a T-18 tranny and a Dana 300 Transfer Case . I am attempting to drop in an an XJ 4.0 from a 91 XJ. I don't know what I am doing wrong. My engine mount holes will not line up. I have about 2.5 inches until the valve cover hits the firewall. I am attaching images. I do have the XJ engine side motor mounts and the original AMC 232 i6 frame side motor mounts. I also have AMC 258 i6 / 4.2l motor side and frame side brackets.

 

[defibvt]

I hope the pics show what I am trying to express. I will take any advise. I am at a stand still until I figure this out. Thanks for looking and the advice.

 

[JpWanderlust]

I'm doing this same swap on my 77... I had to use the AMC 258 i6 / 4.2l motor mounts... I'll be out there in a few minutes I'll try to snap you a couple photos to show you how it's mounted

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[JpWanderlust]

The AMC 258 i6 / 4.2l mounts bolt on further back than the xj ones

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[defibvt]

The AMC 258 i6 / 4.2l mounts bolt on further back than the xj ones

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Do you have a pic of the driver's side?

 

[defibvt]

I'm doing this same swap on my 77... I had to use the AMC 258 i6 / 4.2l motor mounts... I'll be out there in a few minutes I'll try to snap you a couple photos to show you how it's mounted

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If it isn't to much trouble, could you post pics of the passenger and driver's side?

 

[defibvt]

What size bolts are holding the engine side brackets on? I need to chase some threads. Is one of the bolts on the driver's side a different size?

 

[JpWanderlust]

Yeah I used 5 of the original bolts from the AMC 258 i6 / 4.2l but for some reason the rear bolt holes on the driver side was larger... I can't remember exactly what size now... I'll try to get you a good pic of the drivers side when I get back to the shop

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[defibvt]

Yeah I used 5 of the original bolts from the AMC 258 i6 / 4.2l but for some reason the rear bolt holes on the driver side was larger... I can't remember exactly what size now... I'll try to get you a good pic of the drivers side when I get back to the shop

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Thanks. I am starting to get an idea how it goes together. Any pics you and possibly if someone or you know that bolt size it would be great. Saves me multiple trips to ACE Hardware.

 

[defibvt]

Thanks. I am starting to get an idea how it goes together. Any pics you and possibly if someone or you know that bolt size it would be great. Saves me multiple trips to ACE Hardware.

You are talking about the bolt closest to the firewall, correct?

 

[JpWanderlust]

Yep the one closest to the firewall... You can see it's a different bolt... I just found a bolt the right thread pattern but it was too long .. took it to the hardware store and matched it up

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[defibvt]

Thank you so much. I believe that will line every thing up. Unfortunately, I won't be to mess with it until Friday.

Hopefully, by then someone may have the bolt sizes. Got to chase those threads.

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[JpWanderlust]

Keep updating your thread... If you have any other questions I'll try to help you out... I'm nearly done with my swap finally

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[defibvt]

So, I took one of the five bolts that are the same to Ace Hardware. That bolt is 3/8 x 16 x 1 3/16. Need to replace all five due to their condition. Will also chase all the holes with a tap.

The oddall bolt is 7/16 x 20. Since Ace Hardware doesn't have bolts that are 1 3/16 in length, I am going to buy 1 1/4 length bolts.

Hope this info helps someone.

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[JpWanderlust]

Glad you found it... If you run into anything else just ask

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[defibvt]

Ok, since you asked. What motor mounts did you go with. I have these.

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[JpWanderlust]

I'm reusing the ones from my AMC 258 i6 / 4.2l so I'm not sure of a brand or anything but that looks pretty much like what I have

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[defibvt]

Thanks. I thought these were correct.

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[JpWanderlust]

Hey out of curiosity have you considered what fan setup you're going to use? I used a yj fan clutch and fan and it touches my rad so I have to go electric I guess

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[defibvt]

I read a write up that recommends dual pusher fans because of the issue are descrbing.

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