2000 Jeep TJ 318 5.2 Magnum Swap Build

Its alive! Tested it with a verified non-skim ecu from a buddies Jeep and it fired up and ran great! Such a good feeling knowing that I did the wiring correctly, etc. Now for all the other items: radiator/cooling system, driveshafts, and exhaust and it will be driving on the road! Also have to do something with my shifter but I have a pretty good idea of what I'm going to do, based on what I saw another member on here do in his build thread. Stay tuned!
 
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Its starting to look like a Jeep again, installed the radiator, ZJ clutch fan, and 4.0 fan shroud, which all worked out perfectly.
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Well, everything is installed. I tried to go for a "factory" looking install, and I feel like I accomplished that. The only things holding me back from driving it are modifying the shifter, and a driveshaft. My Tom Woods rear driveshaft should be here tonight, so I will install it after work today.
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I also found a almost new Bestop factory replacement top locally, with ALL hardware (door surrounds, everything) for $300 so I picked it up and put it on. I went with black, because I think it looks better personally. Even with the tan interior. All 3 of my TJ's had tan interior with a black top and always looked good. I also ordered a front driveshaft from Oliver's Driveline and Gear, and the Novak transfer case shift linkage. More updates to come.
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Jamison C said:
Curious what brand of radiator and hoses you used? Asking for a friend 😉
Click to expand...
Youre in luck for this, since there is no info ANYWHERE on the internet for the lower hose combination when using the OEM Mopar radiator. The lower hose combination is:
Dayco 81251 - https://www.amazon.com/gp/product/B000C0TEAA/?tag=wranglerorg-20
and
Gates 25477 - https://www.amazon.com/gp/product/B000C2Y6GA/?tag=wranglerorg-20
The combination of those 2 hoses (using a 1.5" to 1.5" adapter to connect them together) fit perfectly to the 1 3/4" opening on the water pump, and the 1 1/2" opening on the radiator.
The upper hose used is:
Dayco C71659 (Got from Autozone for $11)
Many people go with ebay aluminum radiators, and I thought about it as well. I just trust the OEM radiator more, since many of the even higher end brand aluminum ones have been known to leak. Hope this helps someone in the future!
 
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Whitetrash said:
Youre in luck for this, since there is no info ANYWHERE on the internet for the lower hose combination when using the OEM Mopar radiator. The lower hose combination is:
Dayco 81251 - https://www.amazon.com/gp/product/B000C0TEAA/?tag=wranglerorg-20
and
Gates 25477 - https://www.amazon.com/gp/product/B000C2Y6GA/?tag=wranglerorg-20
The combination of those 2 hoses (using a 1.5" to 1.5" adapter to connect them together) fit perfectly to the 1 3/4" opening on the water pump, and the 1 1/2" opening on the radiator.
The upper hose used is:
Dayco C71659 (Got from Autozone for $11)
Many people go with ebay aluminum radiators, and I thought about it as well. I just trust the OEM radiator more, since many of the even higher end brand aluminum ones have been known to leak. Hope this helps someone in the future!
Click to expand...
You used the Wrangler Radiator or the ZJ radiator?
 
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Whitetrash said:
Youre in luck for this, since there is no info ANYWHERE on the internet for the lower hose combination when using the OEM Mopar radiator. The lower hose combination is:
Dayco 81251 - https://www.amazon.com/gp/product/B000C0TEAA/?tag=wranglerorg-20
and
Gates 25477 - https://www.amazon.com/gp/product/B000C2Y6GA/?tag=wranglerorg-20
The combination of those 2 hoses (using a 1.5" to 1.5" adapter to connect them together) fit perfectly to the 1 3/4" opening on the water pump, and the 1 1/2" opening on the radiator.
The upper hose used is:
Dayco C71659 (Got from Autozone for $11)
Many people go with ebay aluminum radiators, and I thought about it as well. I just trust the OEM radiator more, since many of the even higher end brand aluminum ones have been known to leak. Hope this helps someone in the future!
Click to expand...
I’ve read the forums too as I almost did this swap myself, lots of folks swear the 4.0 Mopar radiator isn’t enough to cool a V8, though I’ve never seen the data to back that up.

However, I have read several accounts where people have a run it successfully with a V8. Considering how hot the 4.0 runs, and what our jeeps are designed for (low speed crawling etc.) it makes sense that the factory radiator is more than capable of cooling a small V8.

Thanks for the info! I plan to do a Hemi in my next jeep and I hate the look of the aluminum radiators. Yours does indeed look factory. Maybe get us another video of it running 😉
 
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Well, here's a pretty big update. Friday, instead of going "Black Friday" shopping like I usually would for crap I don't need, I decided to bleed the cooling system and take it for its first drive. I pulled it slightly out of the garage for this, because with the open headers, it was NASCAR loud (if you've ever been to a race).
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Cooling system was bled properly, and fairly quickly. Took it to a local exhaust shop to have a custom Y-pipe made. I had already bought a MBRP "cat back" exhaust and a high flow cat (cant stand no cat "lawnmower smell"). They made the Y-pipe for $175! Also, threw the exhaust on for free. May not look the prettiest, but the guy was also a fellow Jeeper, so he knew how the clearances needed to be up front for the driveshaft, etc.
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Now that it wasn't deafening loud, I took it to a local Arby's and got some food.
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A few small issues to address, when I cut and modified the shifter, I didn't bend it back enough, so the shifter comes in contact with the console. Not a huge issue with just letting the console sit there with no bolts holding it down, but it looks like crap.
S1.jpg


Other issues - the alignment is WAY off, and the tires are beyond needing replacing. I knew this going in, I just wanted something to roll on. I ordered a set of Falken Wildpeak AT3's over the weekend so when they get here, Ill have them thrown on and have it aligned. Then it should ride MUCH better. I did drive it to work thismorning, here it is sitting in the parking garage where I work.
W1.jpg

In the last picture, you cant tell that yesterday I hit the entire thing with a claybar, followed by Meguiar's Ultimate Compound, then a nice paste wax. Actually brought the paint out quite a bit, and gave it some protection from the shitty (yet fun) winter weather we have here in Ohio. Stay tuned, a lot more updates to come for this thing!! Still need to paint and install the rear bumper (LOL) and paint the skid plate. Front driveshaft arrived on Saturday, just waiting for the Novak T-Case shift linkage to get here on Tuesday to install them together, etc.
 
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Jamison C said:
I’ve read the forums too as I almost did this swap myself, lots of folks swear the 4.0 Mopar radiator isn’t enough to cool a V8, though I’ve never seen the data to back that up.

However, I have read several accounts where people have a run it successfully with a V8. Considering how hot the 4.0 runs, and what our jeeps are designed for (low speed crawling etc.) it makes sense that the factory radiator is more than capable of cooling a small V8.

Thanks for the info! I plan to do a Hemi in my next jeep and I hate the look of the aluminum radiators. Yours does indeed look factory. Maybe get us another video of it running 😉
Click to expand...
What most who have done the V8 conversion will agree on is that running the stock 4.0L radiator "will" cool the 5.2L engine but using it on the 5.9L is the issue. The 5.9L definitely produces more heat than the 5.2L engine. Even the 2.5L radiator will cool the 5.2L adequately, it's really the same radiator I have compared the two side-by-side and it is the same core. I ran an aluminum aftermarket radiator to get the outlets on the correct side partly but the real reason was my 2.5L original radiator made in January of 1996 was in bad shape with lots of fin damage in the core. That was the ONLY reason I chose to go with an aftermarket otherwise I would have run the OEM radiator and saved some cabbage.

RR
 
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RangerRick said:
What most who have done the V8 conversion will agree on is that running the stock 4.0L radiator "will" cool the 5.2L engine but using it on the 5.9L is the issue. The 5.9L definitely produces more heat than the 5.2L engine. Even the 2.5L radiator will cool the 5.2L adequately, it's really the same radiator I have compared the two side-by-side and it is the same core. I ran an aluminum aftermarket radiator to get the outlets on the correct side partly but the real reason was my 2.5L original radiator made in January of 1996 was in bad shape with lots of fin damage in the core. That was the ONLY reason I chose to go with an aftermarket otherwise I would have run the OEM radiator and saved some cabbage.

RR
Click to expand...
Yeah the 2.5 and 4.0 rads are the exact same from what I have seen. Same part numbers and everything. Cools my 5.2 extremely well, no idea how it would do behind a 5.9. To anyone looking to do the swap, the radiator hoses are easy to fab up if you use the stock radiator.
 
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Just a random update. Over the weekend, I got a new set of tires installed. (Just about the only thing I pay a shop to do, because I don't own a tire machine). I purchased a set of Falken Wildpeak AT3W's. They ride SOOO much better than the old, dry rotted M/T tires that were on there. Matter of fact, when the tire tech was dismounting the tires, the old tires were literally just coming apart. One had a date code of 2004! Yikes!
All is good though, riding nice and smooth now. I did have a crankshaft position sensor go bad on me, and after some help from a few members troubleshooting, replaced it and all is well. Also installed the Novak transfer case shift linkage and Oliver's Driveline and Gear front driveshaft. Once Christmas is over, I'll start on some new modifications. As of now, I am going to enjoy all my hard work and just drive it! :)

A picture of the new tires, in my parking spot at work. Cant wait to hit some trails when I get some free time!

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In the process of doing an identical swap (5.9 instead of the 5.2) and from what I had read, it was easier to use the 5.9 harness and roll with that. What made you choose to keep the TJ harness besides just having it run along the firewall better? Don't know about you, but just about every sensor plug is different on the 5.9 vs my 2.5. So all that splicing and such would have been a lot more for me to tackle. I'm not too far into the wiring stuff to reverse and go the route you described if you can talk me into it. Also, what did you do for the dust shield on the transmission? I'm struggling to find the right part.
 
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