Yet another Engine Swap

Good luck!! It sounds like you have a great donor motor for the transplant.

elafilos said:

Quick update if anyone is interested:

Found a donor car finally with 120.000 km in a pretty good condition. Used as a grocery getter since 2003.

We will be swapping the engines next week. Fingers crossed the jeep would be up and running by the end of June.

Since we will be having the engine on the bench, any recommendations of preventative maintenance in difficult to reach areas? Thinking of replacing the oil pan gaskets since it's a pain in the @@@ to remove once the engine is on.

Wish me luck

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Not a petrol driver so I can't add a lot other than a reminder to use HOAT coolant.

elafilos said:

Quick update if anyone is interested:

Found a donor car finally with 120.000 km in a pretty good condition. Used as a grocery getter since 2003.

We will be swapping the engines next week. Fingers crossed the jeep would be up and running by the end of June.

Since we will be having the engine on the bench, any recommendations of preventative maintenance in difficult to reach areas? Thinking of replacing the oil pan gaskets since it's a pain in the @@@ to remove once the engine is on.

Wish me luck

Click to expand...

Also the valve cover gasket.
The harness is in the way and the screws are far away.
And oil tends to leak.

Good Luck! Check everything in the engine before putting it in, and perform all necessary service to it. I know it would cost more this way, but it is good to know that you will not have any issues after 20.000km...

Quick and sad update. Donor decided to keep the car and the engine so he pulled off the deal the minute I was arranging the tow truck.

Took some hard decisions. Pulling engine out tomorrow and we'll see how it goes.

Get's harder and harder to justify keeping my KJ cost-wise, but I love this car.

It would have been wiser to just get another KJ and swap some of my parts on it, but the problem is that I love MY KJ, since it's tied to so many memories. Every scratch and bump reminds me of a story and can't get over it. I am pretty sure most of you understand what I am talking about..

And another update.

The moment we pulled the engine out of my KJ just got a call from a company dealing second hand jeep parts saying the found an engine from a car. It's from a 133.000km 2003 KJ which got bad roof rust, since it was used in a coastal area.

Price was a bit over budget, but decided to pull the trigger and pray. The engine arrives tomorrow evening.

Let's hope I am going to have a car by the end of the week.

elafilos said:

And another update.

The moment we pulled the engine out of my KJ just got a call from a company dealing second hand jeep parts saying the found an engine from a car. It's from a 133.000km 2003 KJ which got bad roof rust, since it was used in a coastal area.

Price was a bit over budget, but decided to pull the trigger and pray. The engine arrives tomorrow evening.

Let's hope I am going to have a car by the end of the week.

Click to expand...

Fingers crossed

Engine finally arrived. Quite expensive, but at least it's a low mileage (given it's age) and stock engine. No LPG conversions etc so it should be fine.

There is some surface rust given the fact that it was used in a coastal area of Crete, however nothing major that some good scrub and paint can't fix.

Nothing seems to be leaking, and all gaskets seem to be stock and solid.

I have ordered the following parts brand new from MOPAR:

1. Oil Filter
2. Air Filter
3. Coil Packs
4. Water Pump
5. Acc Belt
6. 8 engine seals (don't know the exact terminology, however these are the metallic seals meant to explode before the block does).
7. 2 Header seals (the exact same thing, but smaller).
8. Thermostat
9. OEM plugs

Also bought some steering rack bushings, since mine are shot - and some sway bar bushings.

Any ideas/suggestions what else to replace since the engine is currently on the bench?

6 - core plugs I guess?

Can't suggest anything else, I've never seen a V6! Sounds like you have got most of the stuff covered though. Good luck.

Almost there. Got the bust engine out today - I was a real nightmare due to it not being able to turn.

Bought brand new engine mounts since we are already there, and a brand new original water pump. Fingers crossed it would be done by tomorrow.

KJowner said:

6 - core plugs I guess?

Can't suggest anything else, I've never seen a V6! Sounds like you have got most of the stuff covered though. Good luck.

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Core plugs indeed.

Read all of this...

https://www.jeepkj.com/threads/engine-replacement-checklist-kj-2002-2003-and-maybe-2004.80359/

dtennes said:

Read all of this...

https://www.jeepkj.com/threads/engine-replacement-checklist-kj-2002-2003-and-maybe-2004.80359/

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Thank you for the write up. I ll talk with the garage taking care of the installation to make sure we are up to spec.

I am wishing you the best! I just got my engine replaced with a rebuilt one, done by a retired mechanic who works solely on Liberties/KJs for a hobby. It looks amazing and is really running great, but did spring a small oil leak that I haven't been able to locate. It's not an alarming amount, but enough to frustrate me with my hopes for a like-new engine.

She fired up today! All good, drove a couple of kilometers around the city.

Some weird things happened though.

1 the oil sender had a different wiring, so I had to use the one from my own car. Thank god mine was almost new.
2 The flywheel didn't match my converter - it was like 10-12mm shorter. Had to use my own.
3. There is a slight vibration when firing her up, that goes away almost immediately. Probably due to the new engine mounts, mine where shot.

Other than that everything else was a direct fit. Now my old engine is on my bench ready to be disassembled to figure out what caused it's failure.

After 300km I noticed coolant smell.

Took me a couple of days to trace it down to a torn expansion tank return line which I replaced.

Currently I am facing a vibration on idle which disappears between 1000-3000 rpm and comes back a bit under 3500. We traced down a torn trans mount which is currently been sent to me and going to be replaced tomorrow morning.

I am hopping *fingers crossed* that this is due to my brand new engine mounts not aligning perfectly to my old beat down trans mount.

I'll keep you posted.

2k KM later update...

Bad news - got quite a lot of oil consumption already added 2.5 liters (3 quarts +-). The car smells bad, but there is no smoke. No external leaks at all.

The vibration is still there, yet haven't found out what's causing it. There is also a fluttering sound in low RPM that goes away almost instantly. Weird.

Called the scrap yard that sold me the engine which has 3 months warranty. They told me that the piston rings could be stuck and would eventually free themselves. This doesn't make any sense but there is not much else I could do right now. I might even try moving a grade up to 10w40 just to see how it works out.

On the Brightside the car runs, gas mileage is pretty standard and power is OK.

elafilos said:

2k KM later update...

Bad news - got quite a lot of oil consumption already added 2.5 liters (3 quarts +-). The car smells bad, but there is no smoke. No external leaks at all.

The vibration is still there, yet haven't found out what's causing it. There is also a fluttering sound in low RPM that goes away almost instantly. Weird.

Called the scrap yard that sold me the engine which has 3 months warranty. They told me that the piston rings could be stuck and would eventually free themselves. This doesn't make any sense but there is not much else I could do right now. I might even try moving a grade up to 10w40 just to see how it works out.

On the Brightside the car runs, gas mileage is pretty standard and power is OK.

Click to expand...

Compression check it, also watch the exhaust in your mirror when you pull away from lights or a junction, a puff of smoke would suggest valve stem seals.

KJowner said:

Compression check it, also watch the exhaust in your mirror when you pull away from lights or a junction, a puff of smoke would suggest valve stem seals.

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I really hope it's something that simple as valve stem seals, because piston rings is going to be a very expensive job to do.

I am seriously considering keeping it as is right now since it's my 3rd summer and weekend car. What's the worst case scenario?

elafilos said:

I really hope it's something that simple as valve stem seals, because piston rings is going to be a very expensive job to do.

I am seriously considering keeping it as is right now since it's my 3rd summer and weekend car. What's the worst case scenario?

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It will wreck the cats if it's burning oil, how long it will take is unknown. Have you checked to see if the oil is leaking underneath anywhere? You may be lucky (ish!) And have a small leak somewhere, but the bad smell isn't encouraging.