1989 Jeep
February 22, 2004
We bought this Jeep for my wife Val in
October of 2003. We bought it with 62,000 original miles. The Jeep ran great.
It was clean. It has the
First things first, the wife wanted to be rid of the stock look. For an anniversary present, I got a Rough Country 4" Lift off of eBay. After finding a buy on 2 like new BFG Mud Terrains and one really good tire, we headed to Discount Tire to buy 2 new matching BFG's and 5 new wheels. It all sat until I had a buyer for our original leaf springs. (He was going to use them in a Suzuki Samurai). My father-in-law and I completed the lift and new tire install in a bit better than a half a day. (See pictures below)
I figured the best thing to do was sell the engine/trans and do a Chevy Vortec 4.3L and 4L60E Automatic Overdrive Transmission Swap. I found a buyer for the engine and trans, he came over on 2/21/04 to help me pull it.
Follow along on the journey....(Click on Images to Enlarge)
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The "Stock" YJ Wrangler
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After the 4" Lift and the 32" BFG Mud Terrains were installed
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Shots of the original 4.2L 6 Cylinder Engine
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Shots of the Jeep
with the engine/transmission removed. The front clip was removed to
make the job of removal/installation much easier.
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The donor of this
engine was a 1996 Chevy S10 Blazer. Its a 4.3L Vortec V-6.
4L60E Overdrive Automatic Transmission and an NP231C Transfer
Case.
The Engine came with all of its wiring harness, relays and Computer. If you
contemplate this swap, be sure to get all of the accessories, wiring, computer
and anything else you can possibly think you will need.
DO NOT PIECE MEAL AN ENGINE SWAP!
3/23/04
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These are a couple of shots with the motor mounts clamped to the frame. The transfer case is oriented where the original one was. It just didn't look right (far too much clearance between the engine and firewall) so......
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This looks much better. I pushed the drivetrain back another 3-4" This will make it easy to service anything in the back of the engine. Since I am using the stock 231C Blazer transfer case, I ordered a SYE kit from JB Technologies. It will shorten up the stock output shaft almost 9". With the SYE kit, I estimate the rear driveshaft to be almost 3" longer than the original stock driveshaft.
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Left and middle shot
of the passenger side motor mount from Advance Adapters. Right picture is the
modified skid plate to accomodate the T10 Blazer rear
mount. This was a piece of heavy walled 2" square tubing cut to be
1-1/2" tall, then mig welded to the skid plate
and the opening cut for access to the bolts.
3/28/04
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Integrating the GM Vortec Harness with the Jeep Harness is not an easy
undertaking....that is unless you have a good friend
who specializes in vehicle electrical/electronics/computer systems! AND has the
diagnostic tools. Bill VanOrden (aka: Beevo) is seen here having far too much fun cutting out the
original Jeep MCU (Micro Computer Unit) and its harness. The MCU is located
behind the glove compartment. Since we had the entire S10 Blazer 4x4 Harness,
we'll use the mating connector married to the Jeep Harness. (Shown in the far
right photo)
3/29/04
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Today I decided to
get the fuel pump/sender assembly put together. Essentially, the lower half is
out of GM TPI vehicle. It includes the reservoir and the fuel pump. The
reservoir is there to keep the pump with fuel incase of a hard turn or incline
with low fuel in the tank. I had to marry this assembly to the original Jeep
plate and the original sending unit. I used the GM electrical connector to
connect it to the Jeep. Fuel pump the the
computer and the sender to the Jeep's harness. Note that on the
far right picture, that I had to file the tank opening
slightly. Not enough to cause a problem. There is still plenty of seal for the
tank.
4/3/04
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Today, I installed
the 231C HD Super Short HD Slip Yoke Eliminator Kit from JB Conversions.
Instructions are great, (and on line) Price was $340. John is great to work
with. Great customer service.
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Beevo
is at it again. After the SYE kit was installed, the engine was put back in the
engine bay. Disection of the Vortec's
harness was next on the list. Armed with OOODLES of schematics, Beevo digs in. Useless? wires were cut out, keepers were tagged. We had the ENTIRE
wiring harness from the S10 4x4. This sure seems to be helping, we will graft
the connectors to the Jeep Harness as necessary...or should I say Beevo will graft the connectors. :-)
Not for the faint of heart guys...some serious electrical work here. We also
found that the 96 used a fuel tank pressure sensor,
the VCM also wants to see a signal from the fuel level sending unit. Can you
say 2 fuel level senders? I knew you could!
4/10/2004
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More work on the
harness, bringing the VORTEC Engine harness and Jeep harness together has
begun. Beevo seen on the left doing some crimping. Next picture shows
all the tagged wires, soldering and heat shrink tubing put on the splices.
The far right shows Beevo's Scan Tool. Yup, Beevo, breathed life into the VCM (Vehicle Control Module).
No "magic smoke" was released in the process. Next goal is to get the
wiring harness far enough along to do a test fire of the engine.
4/26/2004
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Project update. The driveshafts are being fabricated for the Jeep. The original S10 Blazer front driveshaft is being lengthened while the rear driveshaft is being made up completely new with front CV joint. After the driveshafts are installed, the Jeep goes for an exhaust system. Otherwise minor things have been done, a "T" installed to run both Jeep and GM oil pressure sending units. Jeep water temperature sending unit has been installed and a trip to the wrecking yard yielded a transmission shifter cable, throttle cable and some electrical bits and pieces. |
5/4/04
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No pics, but Jeep returned today
from Muffler Shop. Autoplex Autoservice
in Driveshafts were made by Arizona Drivelines I took the Jeep down there and Oscar measured it up. I'll try and take pictures when they are installed. Update: there was a hiccup. The front driveshaft came back too short. Some what understandable as the front S10 Driveshaft has an odd sort of CV joint. Its back at AZ Driveline. They are correcting it. Will post the outcome soon. |
5/15/04
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Lots of "nickel and dime" things going on, fuel
tank is in, fuel injector hoses connected with special fuel injector hose
clamps. A couple of broken exhaust manifold bolts were removed (typical of
these engines, rear two on the driver's side).
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5/29/04
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Transfer case shifer installed. Had to modify the mount. None of the tabs would line up as the 231C and 231J had different bolt circles on the transmission adapter.
Beevo also cleaned up the wiring harness. We also fired it up for the first time. Ran terrible. Beevo warned me, these TPI engines have terrible injectors as they stick shut after sitting for too long. Need to cough up another $300 for 6 new fuel injectors. Getting close. Last major hurdles are shift linkage, injectors, front clip and fitting the Charcoal cannister and a few other nickle and dime things.
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6/12/04
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Work has been
progressing. This weekend I replaced all the injectors in the engine, I did
nearly all the tear down/reassembly. Beevo, installed the injectors themselves and dropped the
intake back on the engine. Started it up again, running much better. I worked
on the shift linkage. The original 3 speed automatic colum
is being retained. I could have opted for a B&M Floor mounted cable
shifter but then it wouldn't look factory original. So, spent at least a good
day and a half tinkering with shift linkage/geometry. I think I have it down
now. I need to lengthen the transfercase linkage as
its about 3 inches too short. I will snap pics tomorrow. |
6/26/04
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Front clip was reinstalled. Wired up, radiator was cleaned
and modified by DANA Radiator in |
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6/28/04
A bit behind, these are pictures of the Abbott Cable-X Speedometer
cable. Essentally, the Cable-X is a controller and
motor that drives a speedometer cable connected to the original Jeep Mechanical
Speedometer. Cable-X has dipswitches that are set, taking into account tire
diameter and Speed Sensor input. Currently I have an e-mail into Abbot to clarify
whether or not I use the electronic Speedometer 4000 pulse output from the VCM
or get the signal directly off the speed sensor. Things have gone so well, that
I don't want to get impatient and toast the VCM.
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Here is a shot of the unit. When I hook it up and calibrate it, I'll post a picture of the inside showing the dipswitches. |
July 3
No pics today, but Beevo
and I spent the day tidying up the wiring harness, hooking up the cruise
control and giving the Jeep a good test drive while Beevo
had a Master Tech Automotive Engine Analyzer and his Master Tech Multi-Function
Tester on it. He discovered a weak/bad O2 sensor. I replaced it this afternoon.
Tomorrow we give it another good test drive. I also pulled the A/C hoses off
the Jeep so I can have some new ones made to fit the Vortec's
compressor.
July 5, 2004
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Tomorrow, I hope to have the A/C hoses made up for the Jeep, I also found a Posi-Lok for the front differential to replace the poor design vacuum motor axle engagement. |
July 10, 2004
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I almost forgot to mention that the
Jeep was due for emissions test. I took it in on Tuesday 7/6/04. Played
stupid :-) They checked it over, ran it on the emissions dyno,
checked the emissions evaporation system and it
PASSED! When I looked at the results sheet, it was listed as a 4 cylinder! Left to do, test and check cruise control and install the front differential Posi-Lok. Then I think its done mechanically. Come fall, I will be stripping the paint off the truck and repainting it. My wife will be redoing the seats. I will be posting a cost tally sheet showing the expenses. Remember, none of this includes my or Beevo's labor. I will also report back after a tankful of gas the mileage, which was part of the reason for the conversion in the first place, along with driveability of a fuel injected engine. I think what made this project so successful so far was patience, a good knowledgeable friend that I tried not to impose too much on, and the funding to see the project through. You must think really hard before committing to do a swap like this. |
July 26, 2004
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Ok, project status
update. Posi-Lok for the front differential has
been installed. Had to replace the high pressure hose on the air conditioner
and recharge. That's all done. Currently awaiting a fan shroud extension, though
the Jeep does not over heat, the airconditioner can
use all the help it can get. My wife is extatic to
be driving her Jeep again. I'm quite please as is Beevo,
to the way it all turned out. I have left, to install fan shroud extension
and track down an annoying vibration at idle. I suspect is the Adavance Adapters motor mounts. The vibration goes
completely away when I bring the RPM up just a tad. Not sure what is causing
it. I have also been driving the Jeep, it is fun to drive. Much, credit goes
to Bill VanOrden (Beevo)
for all the help and perseverance on the project. Without his help, I'm sure
I'd still be muddling through the electrical.
What did I learn? I learned that
putting in a Vortec Engine in ANYTHING is an
intense project. Could I do it by myself? Maybe with a Painless wiring kit or
if Beevo would put up with me again. :-) Here is a break down of my expenses, remember, we did nearly all the work ourselves. You BEST be committed both in time and financially to such a project!
Sold Old Engine Trans/Transfer/Case
-$700.00 GRAND TOTAL $3,001.78 |
UPDATE 12/17/2006
Big changes
happened in my life since the conversion. I finished a second conversion for my
father in law with the 4.3 TBI engine. Folks I recommend this swap over the Vortec swap with the inexpensive and easy to install
PAINLESS WIRING KIT. Far less trouble and less
sensors!
We promptly
sold this Jeep and my father-in-law bought my wife’s Jeep. We sold our
home and shop, built a home and sold it up North, and bought a new home. We
both got newer vehicles. My father-in-law drives the Jeep daily. I am VERY
proud to say, its been DAMN reliable. Not ONE problem
has crept up since the conversion. Again, my recommendations,
have plenty of money, time and the drive to finish the project. Buy a complete
engine, transmission WITH its wiring harness and computer! Solder and heat
shrink every wiring connection. I hope this page has served to inspire others
and make the decision to convert your Jeep easier. I could have not done it
without the help of my very knowledgeable friend Beevo.
Marty