4.0 motor swap, need advice......

Here's the skinny..............................
What it's going in........
'74 Jeep CJ5 all orginal drive line, I.L. 232 6 banger..............
The motor that's going in is a H.O. 4.0 comin' out of a '96 jeep Cherokee or something like that???
The history..............
My son is going to Johnson College for Auto Mechanics.
He did a motor check over on this 4.0 that came in to the class.
Flat cylinder in #5, HE thinks valve, the motor has a million miles, oil leaks.
The kid that own the wreck is in the class and is gonna drop a different motor in there, so I can have the old one, (well for $75).
My son is gonna do the motor over, (he has to do one for a grade).
His teacher is a REAL sharp cookie, so I'm sorta kinda comfortable with the school and my son doing it, (my boys isn't too bad either, but a rookie on mulit cylinder motor rebuilds, but good on motorcycles engines).
I won't see too much of this swap other than to look at the engine in pieces, (maybe), and pick up the parts.
So here's where I'm at.................
What WILL or WON"T fit from my 232 onto this 4.0????
It was bolted up to a standard trans, so the pilot bearing is there. Is the imput bushing hole the same size?
Will my manifoilds bolt up, ( was thinkin' a header, but......)
Fly wheel?
Bell housing???
This motor is fuel injected, is there a hole for a mechanical fuel pump?
I want to make this as painless as possible swap, get as much of the "prework done as possible BEFORE it goes into the "Expensive Care ward" (for my sake as well as my sons).
The last thing I need (and my boy) is for HIM to have to start making things fit or finding parts while it's in the shop.
I have until next Sept to find any parts (if needed), so I have plenty of time to show him a motor repair, (I have a ticky lifter in my 232 I'll address and some seal seeping, and I want to replace the clutch, so I'll give him a quick look at a motor J.O.B. this summer).
Thanks for the help!
Joe
I swore I wasn't gonna do sheet to this jeep when I dropped the fibergalss body on it.
"This is DONE! I don't have to do squat to it"
Well, that was a LOT of $$ and parts ago!!!!bunny with a pancake

 

I would keep the fuel injection. On a '96, it's the excellent Mopar multiport injection (MPI). Have your son and teacher yank all the EFI stuff and run it on their test bench with the computer etc (assuming it's coming out with the old engine). It'll be just like running it with a carb, but with more wires.

If you must have a carburetor, you'll need to use the 4.0 exhaust manifold. I think the 1V manifold from the 232 will bolt up if you do some grinding on the alignment pins. The heat riser flange is probably in the way, so you'd have to cut that off (4-bolt flange between the intake and exhaust). Most people would get an aluminum 2V intake manifold from a '81 or later 258 and use that. I'm sure that will bolt up with a little diddling with the alignment pin locations.

Flywheel and bellhousing will work. There is no hole for a mechanical fuel pump on a 242/4.0L.

Don't know about the pilot bearing. I suspect the pocket in the crank is the same, but you'll need the part for the 232.

There's a "swapology" forum on www.jeepstrokers.com that might be just the ticket for this job. They also have some useful FAQs there about blocks and such.

 

I WAS hoping the kid was gonna junk the donor jeep and I'd put the fuel injection in mine.
I thought Gary would learn TONS swapping the injection out, (the hows and whys of injection. I always learned tons "creating" like that), but alas the kids wants all that for his swap.
I have to look @ the yards as soon as the snow melts for a hard top to cut to a 1/2 top, so maybe if I see a jeep with the injection system intact, I may yank it out.
I will look @ for an intake, (I'd like to keep the 232 complete incase this jeep ever goes down the road).
When I yank the 232 out to reseal it and clutch I'll mic the imput shaft and then I can always MAKE a bushing. The motor will be at school, so I can mic the dia. of the hole, (won't be the first time I've made parts for jeep swaps).
Got to thinking...... electric fans, higher amp alt, gear drive timing, "bumper cam .......
Joe
See! This is how it starts, then it sprials out of control