Ok well since I last updated I have torqued on the intake and the exhaust and installed the serpentine.
Torqing theintake bolts was pretty easy to do. All i did was but the front and rear studs to line the exhaust up and then the intake has alignment studs built into the head. I hand tightened all the studs and then followed the torque sequence on jeepoffroad.com's write up on the 4.0 swap. Torqued all the bolts to 23 pounds.
The serpentine was relatively easy. I pulled everything from a pre 94 HO xj. I want to say it was a 93 but I dont recall. I am going back to the boneyard to get the Powersteering lines from it so I will confirm the year then. I was told not to go with the xj setup as I have mentioned before because XJs have an offset fan and running it will conflict with your front clip. I have contour fans so no biggie, I am estimating I will have about an 1'' of clearence at the tip of the bolts for the fan(that is the furthest point of the setup).
I had posted alot of ?'s on cjoffroad about this and was told the serp should go in with no mods. This is not true. the alternator bracket on mounts to the 4.0 in 4 places, 2 to the block and 2 to the timing cover. The two block mounts are not on the
AMC 258 i6 / 4.2l but the 2 timing cover slots are. The upper one is just bored straight through and the bolt slide through and threads into the bracket no problem. the bottom position is bored half way through on the
AMC 258 i6 / 4.2l and then has a smaller taped hole for a bolt the rest of the way. What I did was took a drill and widened the back half to the same size as the front and slide the bolt through
(NOTE-patience is a virtue here I didn't want to take the time to do it right and remove stuff off the front clip so i could come at the hole even and I came at it from behind. My drill is too large and I still couldnt get a straight shot at it. My hole went in at an angle. Luckily It was just enough that I couldt thread the bolt through but it was a close call.)
Also my
AMC 258 i6 / 4.2l had an eyelet at the bottom of my block. I am not sure why its there, maybe the factory used it to hoist the engine? It was preventing the alty bracket from falling in place so I cut a v out of it and eveything mounted up.
The AC mounts in the same holes as the original,3 in the block and 1 in the timing cover. and then the PS bracket mounts to the water pump and the intake. I did't take the time to measure but there may be a chance that the PS braket will fit the original intake if someone wants to upgrade to serp but keep the carb and stuff.
Also (and I did know this) the
AMC 258 i6 / 4.2l 's crankshaft is longer in the front so you need to buy a spacer. HEsco has it for 35 bucks.
Hesco Inc. - High Performance Engine Service Fortunately I have a guy locally that needed the tilt column out of a parts car I am scraping and he had made one of these before and so he made me one as payment. What he did was took an old v-belt crank and cut the center out then turned it to even it out and used a micrometer to make sure it was the correct size. Not a bad deal for me.
This week I have got to go back and get the line that screws into the top of the PS pump. I thought I could use the CJ one but not the case. WHat I will have to do is take the line off the PS box and then take the part that mounts to the pump and take them to a shop and have them join the lines. It will probably cost more than it should but it shouldn't be too hard to do and after that it will be plug and play. The return line slides on no problem BTW.
Felpro Gasket
Torqued on
Serpentine goodness
By the way I am pretty sure the serp is not necessary for a 4.0 head or 4.0 injection swap. I just figured while I was at it may as well. And it is releatively easy to pull and install. This serp cost me 60 bucks and I got everything except the harmonic balancer, I even got the belt because it was visually in decent condition and i figured it has some life left. The only reason that wasn't incleded for 60 bucks was because I didnt have a puller with me. Also for that same price I got an ECM and a Zj valvecover.