Removing a 1993 4.0L Jeep XJ engine

Fresh to the shop, we welcome this 1993 Jeep Cherokee with a 4.0L I6. It's a bit bigger than our previous project and it brings some more modern features that we're not used to seeing in the Redline garage. I'm looking at you, electric fuel injection. But, Davin won't let that stop him from unraveling this puzzle as he sets out removing this engine from its home. It should be straight forward right...
Thanks to our sponsor RockAuto.com. RockAuto.com is an auto parts retailer founded in 1999 by automotive engineers with two goals: Liberate information hidden behind the auto parts store counter (by listing all available parts, not just what one store stocks or one counter-person knows), and make auto parts affordable so vehicles of all ages can be kept reliable and fun to drive. Visit www.rockauto.c... to order auto parts online 24 hours a day, 7 days a week, and have them conveniently delivered to your door. Need help finding parts or placing an order? Visit our Help pages for further assistance!
Subscribe to our KZbin channel for new videos every day! bit.ly/HagertyY...
Visit our website for daily automotive news, cars stories, reviews, and opinion: www.hagerty.co...
Stay up to date by signing up for our email newsletters here: www.hagerty.co...
Follow us on social media:
Facebook | / hagerty
Instagram | / hagerty
Twitter | / hagerty
If you love cars, you belong with us. Hagerty Drivers Club is the world’s largest community for automotive enthusiasts. Members enjoy valuable automotive discounts, exclusive events and experiences, roadside service created specifically for collector vehicles, and a subscription to the bimonthly Hagerty Drivers Club magazine. Join Hagerty Drivers Club here: www.hagerty.co...
Like what you see? Watch our other series including:
Redline Rebuilds | Time-lapse engine rebuilds from start to finish bit.ly/RedlineR...
Barn Find Hunter | Tom Cotter searches the country for abandoned cars bit.ly/BarnFInd...
Jason Cammisa on the Icons | The definitive car review
bit.ly/JasonCa...
Revelations | Untold Stories About Automotive Legends with Jason Cammisa
bit.ly/JasonCa...
Contact us:
Suggest and feedback - [e-mail]
Press inquiries - [e-mail]
Partnership requests - [e-mail]

[@finalmage6]

Inline sixes are just amazing engines. Glad to see one on the channel!

[@ekscalybur]

The only thing better than an inline 6 is two of them sharing a crankshaft.

[@marcryvon]

Gas guzzlers but were tough cars. I had a base 1988 (?) Comanche Chief pick up 5 speed. A pure work horse. And FAST. Very fast ! Had it for clearing a wooded lot and build our cottage up north. A female friend bought a similar Cherokee after driving the truck. She had it for 16 years ! Gas and oil changes. That's it ! Jeeps were Jeeps at the time.

[@negativeindustrial]

I’m used to my 1JZ-GTE. These two inline sixes couldn’t possibly be any different yet they probably make about the same power. Pretty interesting for me.

[@brarautorepairs]

Camera man standing on the hot nut😂

[@brarautorepairs]

It has a rated 190 HP from a 4.0l displacement engine. A 4 cylinder now outputs more power than torque than this engine. Only thing that this engine is good for is the scrap pile

[@1917Enfield]

The XJ 4.0 is phenomenal engine. It has it's own name for the noise it makes, "Jeep clatter", leaks oil, and they have a tendency to crack or warp the head. And I promise that exhaust manifold is cracked. I drove my 2001 XJ until it had 311K. Didn't burn any oil. Still had plenty of get up and go. This is gonna be a great build!

[@1917Enfield]

@@Future-Preps35 Never said the head on my 2001 Cherokee cracked. 2001 was the last year the XJ was made, so its head was one of the later heads. I said they had a tendency to crack or warp the head. Referring to the 90s XJs like the one in the video. My son had a 95 that was a former Conservation Police XJ that had the HO engine. First the head warped and two years after we had it shaved, it cracked.

[@davidhansen9665]

@@1917Enfield and throw pistons threw the engine at about 240,000 miles

[@MattulaTaylor]

Great work, no foul language, straight talk! THANKS !! Keep em coming!

[@justinshultz120]

Yes! Stoked for this one. Rebuilt the engine in my '91 XJ

[@seahorse5677]

FINALLY! Davin gets one of these in the shop. I'm not sure if there has ever been a better production vehicle than the 87'-01' Jeep Cherokee

[@joshuagibson2520]

Yah, till you have to replace the 45 degree remote oil filter. Jaaaaysus. That's not a fun one.

[@betinjuarez3391]

@@joshuagibson2520 haha ehat are you talikng about its the fkn easy bro

[@PlumbMaster]

90s Toyota land cruiser inline 6 but not by much

[@seahorse5677]

@@PlumbMaster The Jeep engine is obviously much better. Good luck with those closed knuckle front Toyota axles, what a disaster. The Jeep's Np231 transfer case is unbeatable. Both the Land Cruiser and the Jeeps share the same auto transmission so that's a wash. You could argue that the Toyota has a better rear axle due to the slightly larger ring gear, but that's about it. 87'-06' Jeeps are really hard to beat. They are also much easier to work on/service and they have much more aftermarket support.

[@PlumbMaster]

I personally own a xj lol and love it. And far cheaper than the cruisers. I just love my buddies 97 cruiser with factory front and rear diff lock

[@Veldkamp88]

I'm going to love this video. I have a 99 Grand Cherokee with the iconic 4.0. Looking forward to learning and doing some homework. My baby has over 272k miles.

[@snoopy5736]

Dammm, i want it mann

[@Veldkamp88]

@@snoopy5736 just had the 4wd rebuilt

[@snoopy5736]

@@Veldkamp88 sounds like your keeping it forever

[@Veldkamp88]

@@snoopy5736 It refuses to die. I don't need a new car.

[@snoopy5736]

@@Veldkamp88 Right, i know what you mean. I'm the same way with my 04 passat v6 4motion. I'd rather not have a $700 car payment

[@mzungusi]

I love this car! I had one for 5 years in East Africa and it was a total star. It took that old Jeep to some hair raising places. I'd love to find another one ( 2 door! ) and rebuild it. So this is just hitting me just right this morning. Thanks!

[@tedschaefer9237]

It's nice to see somebody working without rubber gloves like we did. We used gasoline first, then GOJO Hand Cleaner, then lava Soap. When weekends came and it was date night we'd add a fourth step of using white wall cleaner and a white wall brass wire brush to get the grease out of the cracks in our hands and under the fingernails.

[@moparedtn]

The famous 4.0L Jeep - last in the long line of incredible AMC/Jeep inline 6's. Absolutely bulletproof engine if given any maintenance at all. Will last 300k before a rebuild if you're good to it easily. Now, is it all-world powerful? No, but that wasn't the intent. An entire automaker based their whole existence on one iteration of this engine or the next over the decades and whatever size, whatever application - the thing just worked. The single dumbest thing Jeep could have done in their current series of vehicles was to eliminate their indominable inline 6 in favor of the "corporate V6" - which, of course, they did. Nothing wrong with the "Pentastar V6" - but it ain't a Jeep engine. Now, I understand there's been lots of requests for Davin to do up one of these, no doubt - question is, does *he* like the project himself? I'm betting this will be a "soldier on, Davin" sort of deal; I don't see the twinkle in his eye over this one, honestly - but that's ok, it's still Redline and it's still Davin, so all is good.

[@timearll266]

I worked on those when they were current and I always thought they were one of the better engines of that era.

[@elijahheadrick1389]

Great to see my exact model being worked on on Hagerty! Ive got a 1994 two door, 5spd, Flame Red XJ just like that one!

[@Mr.XJ.96]

Wanna sell it? Im lookin for a 2dr 4.0 with a Ax-15.

[@joeturbo7406]

Love the XJ platform. Looking forward to more videos!!! My 2001 has 252k miles and still running strong (albeit with its share of oil leaks too).

[@Mr.XJ.96]

I just finished my 96 XJ Project. All I drive own and fix are Cherokee XJs. It is Much Much easier removing the header panel and rad support and Rad. It only takes a few extra minutes makes alot more room and the job easier. I also pull the motor trans transfer case all as one unit. With the whole front of the jeep opened up makes it easier and quicker. I install the motor trans amd transfer case as one unit as well. Sometimes I do Remove the Transfer case to make it alittle lighter to move around by myself. If I've got a helper it gets removed and installed all as one unit. After you tale the transfer case off put the cross member back on without the trans mount to rest the transmission on. It doesn't take but 5 to 10 minutes to take the header off then rad support and rad. Once you install a 4.0 that way you'll never go back. After you get the header off it makes it easier to get the trans cooler lines fan shroud fan and the accessories off. Taking the few extra minutes to remove the header saves time in the long run.

[@mistakitty]

"it's clacky and it's clunky" Sounds like a Jeep in working order 🙄. Gonna follow this one for sure, currently in the process of a cooling system rebuild and replacing the good ole cracked headers on my 4.0

[@JeffDeWitt]

Been there, done that. Mine has 600 k on it and I'll be driving it tomorrow.

[@mdendot]

my dream car on my favorite car youtube channel!

[@colin5064]

WoW having a shop with all the lifts and space to work in is such a big bonus. Not to mention a clean flat floor and good lighting of the work area. One day maybe for me !!!

[@briantheoldjeepguy6793]

Gotta love a iron block straight six. I've got a '97 XJ Country w/ 296K, engine & trans have never been apart. It's my winter beater that refuses to die.

[@PrairieDad]

My first car was a 1990 Cherokee Laredo. Almost the same red as your Sport. I will be watching these videos with glee.

[@brandonmulford5524]

Ahhh the ole classic 2 or 4, 40 AC joke. A classic of 80s dad's everywhere!

[@gapratt4955]

I was always a fan of 2/60 AC myself. 2 door late 70's Corolla with the "Pop out" back windows. With door glass rolled down worked the treat, even high summer AZ!

[@Mister006]

This is going to be a fantastic project and will SKYROCKET in value... the 2-door is the one to get! AMAZING vehicle, and loads of possibilities! That 4.0L engine, is unstoppable! With the Manual transmission too!!!! OMG EPIC WIN!!!

[@tadassmulkys570]

Old but gold. Love these videos

[@MoparMattt]

This is like holy grail of cherokees in my opinion 4.0 2door 5 speed and 4wd my goodness what a unit!

[@timwing4379]

Bro, I know the classic Mini is small (actually owned one back in the early 2000's), but damn! The VW Beetle looks HUGE next to it!

[@xj_overlander]

I’m really excited to see this happen. I love my XJ and love seeing other’s work on theirs. Recommendation for when installing the power train again: look into the Azzy’s linkage for the transfer case. The factory linkage is a garbage setup and can be picky to deal with. The azzys one is a far easier install and works much better in my experience. Also look at replacing that crappy upper bell housing bolt that’s an E12 socket with a hex equivalent. Letting the transfer case droop a little bit makes install and removal much easier. I found installing the transmission separate from the transfer case was a lot easier too. Far easier to get those bell housing bolts in

[@IGrocker]

I have that on my wife’s ‘98 XJ. Works slick!

[@RA-gj8ud]

Джипп Гранд Чероки, очень простой и выносливый авто!!! У нас они в большой цене! =) i lake you video. That's for work. (from Belarus) =)

[@Paulster2]

My son had this same Jeep. Red. 2dr. Sport. 4.0L. 5 speed. I mean ... just like this, lol. I replaced the head on his 4.0L. Thing ran really well after that :o)

[@rogersmith8096]

There is a 3rd prop rod hole in the hood which raises the hood verticle. Also you do have to remove the little wire clips from the injectors - but they don't ever unplug themselves!!!

[@peaceabsolute3103]

I can't believe it! Finally. I've always loved that Engine

[@meadows408]

I've owned 4 and owe my life to number 3, it crumpled like it was designed and I walked away. Number 2 was a 92, two wheel drive and 5 speed, I could give kids fits in their little beemers stop light to stop light. Great vehicles, I wish I still had one.

[@s38b36]

I’ve owned many XJs. Glad to see one on the channel

[@elij.s.7580]

wow i'm glad to see the 4.0 isn't quite as tall as i expected. i was convinced I'd have to remove the entire core support to have enough clearance. mine currently has 342,000 miles on the original motor, burns zero oil and pulls HARD even in 3rd and 4th. whenever I do pull it I'm going to bore it out .040 over and get rid of the AW4. I really want to get an AX15, but a tremec would be badass. No luck on clutch pedal assemblies, may have to go with a Wilwood pedal box.

[@sporty196071]

The jeeps are beasts with the stick shift!!

[@pb3033]

👍 Nice candidate for a dry ice clean also...

[@scotte2815]

inline sixes are my fav engines. The Ford 300 is at the top the Older AMC 232/258 and its descendants are also GREAT. silky smooth torque monsters all

[@christolbert4628]

That is a great engine. Carried over from the Rambler.

[@barrishautomotive]

Love the XJ. I've had 19 of them over the last 20 years. It's crazy to me what's happened to prices in the last 5 or so years. 15 years ago I was picking up clean XJs with a bad motor for $200. I don't even know how many 4.0 liter Jeeps I've given a dingleball rebuild and put back on the road. That 4 liter is awesome, but they love to leak. If people would just keep oil and coolant in them they'll run forever.

[@mattgilbert4690]

That’s where I’m at now I think my a piston skirt went on this xj I just got but I’m debating doing one piston or just getting a junk yard motor and rebuilding the one that came in it

[@barrishautomotive]

@@mattgilbert4690 drop the oil pan and have a look.

[@GrundlThief]

YES! A Jeep 4.0 build! I've been waiting for this, and the fact it's coming from an XJ is just icing on the cake!

[@matthewbardeen4821]

You've got my Jeep! I've got a '95 4l 2dr Sport as well, rust free. Rare cars!

[@JeffDeWitt]

I've got a red, 96 2 door Cherokee that I've had since 97. It had 20k on it when I got it and has something like 600k on it now (second engine). Best car I've ever had and after a quarter century and all those miles I still love driving the thing.

[@Lagrange1186]

Just bought an XJ… pretty glad you guys are doing this project right now! Can’t wait to see how it ends.

[@murraymitchell22]

I merged a 1996 Jeep XJ with a 1990 XJ. Its one the road as as cool as.... Rust free Texas 1990 Jeep Cherokee with some bits from a 1996 Connecticut XJ.

[@Taverius]

Is there anything more relaxing than watching someone else working hard and struggling a bit? 😊

[@saxdogg69]

I admit I wasn't a big fan of the mini, but I'm excited to see this series! 👍👍👍

[@nathangreer8219]

Matt's Banana nearly done.... the "Rudycon" nearly done.... and now Hagerty also rolls out an XJ... is the universe trying to tell us something?

[@matts.8342]

I have a 2000 XJ sitting in the drive waiting for the bathroom remodel to be done. The wife says I have to finish that before I can rip apart the Heep.

[@scottimusgarrett15]

I really appreciate the way that you just dive into a job and get it done. Looking forward to this series! ✌❤🙂🇨🇦

[@MarkMeadows90]

I love those 90s Jeep Cherokees. Tough machines they are.

[@dillionrainwater6910]

I love the old classic cars you do. But I’m a jeep fan who drives a 2000 TJ with a 4.0 so I’m stoked to see you start this project. Hopefully you put a small lift on this with some other aftermarket stuff. Small lift with bumpers, a winch, maybe a roof rack and some other goodie’s would be cool

[@sparkplug0000]

Correct me if I’m mistaken but that 4.0 engine is a descendant of the old Jeep 258, which was originally a Rambler motor. I had the 258 in a 1981 CJ-7 that took me over 200k trouble free miles of going places I had no business going. Loved that engine, so much easier to work on than the V8 and didn’t twist the Jeep frame like the 8. I like inline 6’s so much better than a V6, and the torque was perfect for an off road vehicle. Kinda sad to see it burdened down with all the hoses and paraphernalia of emissions compliance. At least in 1993 you could still SEE the engine.

[@mikestewart7338]

This is going to b so much fun! Just keep the lights on.

[@adubbelde1]

When disassembling my37 PU I found that a combination of heat with my propane torch followed by quenching with cold water shocked the bolts and made them much easier to remove.

[@scottdoubleyou563]

Pro Tip- Don't put the stock injectors back in. Get 6 injectors from a Dodge Neon. They are direct fit, the plugs on the harness will be direct fit as well. The advantage id 4 holes in the nozzle as opposed to the single hole in the Jeep injectors. Better spray pattern, better fuel atomization. No need to adjust the ECU.

[@revolutionday1]

I'm currently running 4-hole injectors from a Cadillac Northstar V8 in my 4.0L engine.

[@skylinefever]

I have heard Crown Vic injectors also work.

[@emanuelvega56]

Really cant wait to see whats coming up with new project 👌👌

[@nolangoldberg3845]

I enjoy your videos and learn a lot. I would appreciate you wearing safety glasses for your protection and to encourage others, especially younger impressionable viewers, to do the same.

[@zambonidriver42]

I had a ‘94 XJ, identical to that. I wish I’d never sold it, but I love SWB Jeeps even more than the XJ.

[@jamesdiehl8690]

At least this one isn't so old that you have to look for manuals and specs at the Smithsonian!

[@keithmyers6121]

Have an 01 CHEROKEE with an line 6. Great engine!

[@CanadaBud23]

Ohh yeah! You got a mint cherry 2 door. ❤️❤️❤️❤️

[@alannewhall2323]

Love those in-line 6’s. Maybe a horse power upgrade? A turbo or supercharger and better breathing apparatus. Anyway I’ll like whatever you do. Looking forward to watching this series.

[@903strikerunit]

hagerty is a *restoration* channel not a performance one... sorry sir

[@robertlambert5299]

Davin and crew another good start. Looking forward to the completion.

[@robertshepherd995]

When working on a vehicle like this, if you’re having trouble reaching the rear of the engine bay or are height restricted like me, deflate the front tyres about 3/4. It lowers the front of the vehicle and gives a better angle to pull the engine out.

[@greasemonkeychris4128]

Even better, rip the wheels off and lower that hoist until just before the brakes touch the floor

[@skylinefever]

This is one of the best inline sixes ever built.

[@Raptorbomb]

I miss my 93 xj, Otsego county help take it off the road in 2010(rust of course), 355k on the odometer, lost compression in rear two cylinders. Only jeep to come with an 8 panel grill as well, instead of the typical 7 panel.

[@thomasfletcher4765]

Interesting , my brother owned a cherokee , same color in fact , with the 4.0 six and manual transmission ( but rear wheel drive ) . He enjoyed driving that rig but sold it ( ran good , don't remember the miles on it ) . Have fun with that rebuild

[@squelchtone]

Can't wait to see the rebuild process! Love my 2001 XJ, will look forward to the next video.

[@gapratt4955]

Having grown up in the deserts of the southwest I had no appreciation of what was meant by "Rust free car". That was until I lived in New England, where as like MI there is 4 months or more of the year that the roads try to dissolve your car.

[@slade9372]

Very excited for this project! I enjoyed the previous restorations but am more interested in 80s-90s cars.

[@ol_smokey9370]

Two door and a 5 speed, I love it! It's gonna be like the Mustang I'm resurrecting, I've gotten 20 or so Rock Auto magnets since I started on it 6 months ago lol

[@DanielJopQ]

I have a 2 door 99, love it and will keep loving it till I die.

[@thirdvisiongarage9148]

I had a two door that looked exactly like that down to the wheels. Got my 88 and 90 XJs currently and I’m really looking forward to this one!

[@Mr.XJ.96]

The XJ is the Best J Wranglers are For Cheerleaders and Yuppies.....The BEST years to have are 92-96. Hello from Butler County Pennsylvania the Birth Place of the Jeep and Home of the Heritage Jeep Fest Every Year in June.

[@stevekatherinewilliamson8753]

Had a 96 XJ with the same 4 litre motor. Loved that car, and I wish I still had it.

[@shawnmrfixitlee6478]

I have a 96 V8 Grand cherokee & 90 Cherokee inline 6 . Love the good ole jeeps !

[@danielkeel9265]

As the owner of a '94 4.0 (Australian) ford inline sohc six this is gonna be interesting! Obviously different engine but many shared principles. Interested to spot the differences as much as anything! Plus, I liked those Jeeps!

[@gregoryhayes1272]

So happy to see this.

[@ThePatriot87]

I get all excited when I see these old jeeps. Shame you took it from Colorado they are getting hard to find here.

[@noberet]

For my 1996 XJ 242 I6, Rock Auto and everybody else only has 3 of the 4 refrigerant lines for the A/C. Hope you have better luck. I'm probably going with a custom one, or maybe both of the lines that go to the evaporator.

[@803mastiff9]

Davin “You’re doing it right!”

[@ColinsMarine]

Davin, wake that thing up a little. Put a 4.2 crankshaft and a new cam in it. Also so bigger fuel injectors. Not a lot of money but it makes a HUGE difference to that engine. Please please please

[@jeffplant3]

Great project! A classic!

[@hyattbusbey3563]

Mine's a 96 2Door with 318k. Love it so!

[@thezfunk]

On my 4.0L I put some dodge Neon injectors in which had 4 holes instead of 2. Got me a bit more responsiveness and 1-2 MPG. They dropped right in.

[@skylinefever]

I have heard of guys using Crown Vic injectors.

[@harikrishna_ampady]

That VW bug looks huge with the Mini aside 😮

[@pappawmiked2162]

The starter bolts can be the biggest problems on the 4.0 engine. Replaced many starter bolts and use a little antisieze for the next mechanic. Exhaust manifolds not cracked definitely need tried up to ensure a proper fit. Antisieze is a definite needed compound!

[@adubbelde1]

last week I struggled with separating the 6L80 trans from the 5.3 LT1. I was sure I had all the bolts out. I consulted a transmission guy and he told me it's the Dowel pins and aluminum corroded to them. So some PB Blaster and wiggling and patience and finally got it.

[@tcperkins21]

Davin the #1 rule for working on cars and jeeps is always disconnect the battery that should be the first step you do on video.

[@blekenbleu]

Amazed that the engine came out without dinging the radiator. Without getting a clear view, those injector connectors looked similar to Bosch of that vintage, in which case pressing the spring retention wire on the broader side causes wires to retract on the two narrower sides.

[@benzoed]

When I saw you remove the upper radiator hose.... Yep we've all been there that looks like at least a 2 flush I dare you to find an older cherokee owner who hasn't flushed their heater core! but honestly that is one thing these cherokees are know for, getting hot, or clogging up the heater core. The engine bay was designed for the 2.7 4 pot not the inline 6 so the factory radiator is kinda small, seeing as most of these are now neglected trail rigs "water is fine" is to often the unfortunate answer. but as long as the coolant is clean and fresh, and both fans are working it usually cools just fine. I'm very interested to see the impeller on the water pump when that 4.0 comes apart.

[@peterbiltpusher]

I’m pretty excited! I’ve been hoping you folks would do a Jeep!

[@Friedbrain11]

Hot rod the engine a little :) There is so much these engines can put out and the factory held it back.

[@concealedfox708]

i used snap ring pliers to remove the plugs you couldnt figure out, had to pull the clip apart to release it. i also used it to pull the injectors out after removing the clips

[@ronlynch7744]

That’s a major undertaking, excellent stuff. 😎👍🇨🇦

[@JayGuitars1]

Love my xj’s! Really looking forward to seeing this project, g’day from Australia!🇦🇺

[@irritablearchitect]

Wait...3 DECADES?!? That 4.0l has its roots solidly in the 1950's!😀 Seriously, this will be another cool build.

[@JeffDeWitt]

Actually I think it's direct ancestor was the all new 232 introduced in 1964. The 196 was an earlier design. So the 4.0 is a child of the 60's.

[@JustJeep_It]

Thanks for doing a Jeep 4.0!!!!

[@wassman27]

What are the odds. I just picked up a rusty 93 5sp 4x4 XJ to convert my rust free 96 5sp to 4x4 last weekend. But didn't have the time to pull the parts. Looking forward to the rebuild.

[@WestBerlinCustoms]

If you have seen a couple episodes with Davin, you can tell : This was not an easy / short run. I kown how this "end of a day" felt. 💪🏁 But - it's really cool to see a later car / engine rebuild.

[@normansanchez8730]

I just finished pulling motor and transmission out of a 2000 jeep Grand Cherokee 4.0 4x4..it was the most difficult engine I've ever pulled... He was definitely over it 😂😂

[@kyleforeman4543]

Aww the straight inline 6cyc,, oldie but a allmost bullet proof..should be another interesting build gonna add it in the line up..lol

[@PMD_Bill]

Looking forward to this series!

[@DustinSeiger]

My dad had that exact Jeep model and color when I was growing up.

[@timothydeyoung5653]

i like all your videos, i wish you could show all the improvs you do on a wide range of older vehicles. you could also do a video on some of your add lib. tips that you give!

[@sidneysanders5726]

I've worked on many of these!!!!!!!!!!!!!! You can take the grill and radiator off and its easier