Topic: Questions: 2.5L Engine Replacement

[RockyMtnYJ]

This is my first post here.  I found this BBS recently when I was looking for info on the Internet.  It would appear that this is a place where the regulars are very knowledgeable.  I hope nobody minds me jumping right in with my questions and concerns.  I am NOT a mechanic, but I enjoy doing all things mechanical - and learning.

I've been thinking about replacing my tired 2.5L in the 95 YJ.   As it stands right now, I'm thinking about getting a long block from Hiperformer and adding top quality accessories to it, ie - headers, ignition, water pump, etc etc.

They said they can port and polish the remanufactured engine for me.  Should I have this done?  How can they do this properly without having my headers on hand to match things up?  In addition to that question, is there much point in porting the intakes without doing something to my intake manifold?  I've never done a project like this before, and I'm learning as I go.  In the end, I hope to have a good engine on a stand in about 6-12 months that I can just swap out.  In other words, I am going to do all the prep over months.

Any guidance or suggestions would be appreciated greatly!  I am on a very limited budget, so I'm thinking I'll just spend about $300 a month prepping the replacement engine until I've got all the stuff attached to it that I want.  I've already gotten an oil pan and aluminum valve cover.  Which are soon to be painted Chevy orange.

1995 YJ "Rio Grande"|2.5L|5sp|Everything stock right now.

[chrisfranklin]

Replace with another 4 immediately!  :shock:

[RockyMtnYJ]

Replace with another 4 immediately!  :shock:

Okayeeee???

[Jeffy]

You can have the head ported but you'll probably want to match the intake.  It doesn't require that much work though.  Take a gasket and line it up in the intake.  Then use a Sharpie and mark the opening of the gasket.  Then feather the opening with a dremel tool or tool grinder.  You'll also want to match the TB with the intake.  You might also consider a 4.0L TB. (Check the How-To's for details.)

Problem with rebuilds is that you need to take special care when choosing one.  You don't really know how many times the block has been rebuilt so find a relyable company.  This take a bit of research.  How much do they bore the block, etc...  You might also check some local engine rebuilders.  If you're engine is apart then you can have them work on it.

Another option is to go to a salvage yard and look for another engine.  Some people feel that a OEM block will last longer then a rebuild.  If the rebuild is done right it should last a long time.

If I was going to go cheap, I'd probably look at a low mileage TJ or late model XJ.  The salvage yard should have the keys and if you take a battery to it you should be able to being up the mileage.  The salvage yard should have done this when it was brought in though.

That's not really a limited budget if you're considering $300 for a 12mo project.  You could look into cams, headers, 5 angle valve job, roller rockers, gear drive for the cam, a turbo or supercharger...

[chrisfranklin]

Before you start thinking, "you know, my YJ could do with an LS1, an Atlas Transfer case and axle upgrades."  

(Or, hell, maybe, that's what I'm thinking)

[RockyMtnYJ]

Thanks Jeff!   The reason I was thinking "hiperformer" is because they warranty their remanufactured engines for 70,000 miles.  Now I realize that I'll void that warranty somehow - since I'm not a ASE mechanic, but if they're willing to warranty their engine for that long, I'm guessing it's probably a good engine?

I also looked into Jasper because they have a good reputation, but they want 2 grand for a long block.  That seems a bit outrageous to me.  I haven't really considered getting a used engine and rebuilding it because of the hassles.  First hassle would be getting it home.

Gosh, I wish I had nothing but time to work on this project.  The $300 a month is a loose estimate.  I've noticed that just about everything I would want to add to the engine is going to cost me at least $100.00.  From distributor, to water pump, starter, etc etc etc.

Wouldn't it be great if someone made a complete crate engine in 2.5???

I guess I need to keep doing my homework.  Please keep the recommendations coming on this.  I need all the help I can get.

[rooster]

I found a Brand new 96 Cherokee 2.5 complete engine with everything including MPI for $1700.   This guy has about 20 more.  They are surplus engines from a cherokee plant in Malaysia that closed down.  They shipped all the engines back to the states.

Ask for Scott at www.highpeaksauto.com

I am still figuring out all the wiring harness and ECM stuff so I don't have to put my TBI back on a brand new engine.  If you guys have any pointers it would be grand.  I found a 94 ECM from an XJ.

[montanajeep]

wondering for the 200+ bills I will be spending, what kind of gains, if any will I get.  I understand better burn, however will I even notice an increase in power?  Like I said earlier, I have installed factory (new) plug wires, plugs, rotor, and cap..

[RockyMtnYJ]

Well, I've come to, what I think, is a sound plan.  Now that I've replaced the lifters on the old engine, and it's running like a champ, I can relax and think more clearly.

I've deciding that getting a long block and tossing a bunch of accessories on it is going to give me huge headaches.  The reason:  Take an almost stock long block, and insert lots of variables all at once.

I think I'll still get the long block, but I'm going to test the accessories on the old engine first.  Like a TB swap to a 4.0, a new ignition system, headers, cold air intake, etc.  One at a time.  The one's that work out will go to the new engine when it's time to swap, etc etc.

I tell ya guys, for an inexperienced person like myself, it's a great relief to learn that my current engine probably won't throw a rod now on the way to work tomorrow and I can take my time planning the engine swap without any pressures.  Whewwwwww!