'85 CJ7 5.3/4l60 build up

[boz42]

I made two new brake lines to run from the booster to the proportioning valve & I built a linkage to connect the column shifter to the trans. There was no way to make a straight shot to the trans so I built a tower off the frame with a lever & ran rods from the column to it & them from the frame mounted lever to the trans.

Also got the frame, booster & headers painted & pressure washed the engine:

 

[boz42]

The water pump had two nipples pressed into it for the heater hoses. It was too tight against the inner fender to clear without running preformed heater hoses. I didn't want to source some that would work, so I pulled the nipples out of the water pump & tapped the holes for pipe thread. They were already the right size to tap so it was easy. Also mounted an overflow talk for the radiator.

 

[max 02]

Very cool and nice work!

I like it alot!

 

[boz42]

Thanks Max02

The driveshaft to trans pan clearance didn't work, even with the engine & trans shifted over 1.5" I cut the side out of the pan and welded a panel back into it. I was running out of time for this project so the decision was made to order a stand alone harness. I intended on modding the Tahoe harness, but time will not permit. Also a partner of mine just got EFI Live & a wideband O2 moniter set-up so I will be doing the PCM flashing.

 

[boz42]

Got the transfer case painted & Pulled the oil pan & rear cover off the engine to re-seal. they were both weeping oil. I also had the intake off pulling & installing the engine so I went ahead & put new knock sensors, new knock sensor pigtails & new updated intake gaskets. I did away with the A/c compressor, cause the jeep has no air, & I plugged the EGR & Canister purge with freeze plugs. When we reflash the PCM I will delete the rear O2's, & EGR from there. I also plan to turn off the abuse mode, & torque management. For power steering lines I threaded the old pressure side fitting from the original saginaw pump from the Jeep into the 5.3 steering pump. That way I could use the original jeep power steering pressure hose.

 

[boz42]

While the engine was out I welded up some holes in the firewall & painted it.

Everything going back together!

 

[Deuling]

You fab some sweet stuff

Great job, you do nice work

 

[y5mgisi]

Awesome work!

 

[82355]

You replaced a manual with an automatic, and I still like this build, that is impressive.

Martin

 

[magik235]

Nice build.

 

[K85 Octane]

how the hell did I miss this build? It went quick though, yes.


sexy with all the aluminum

 

[boz42]

Thanks guys.

So I got going on the wiring. I wanted it to appear somewhat stock & there was really no room under the hood for the PCM. Under the dash was tight too. I finally mounted the PCM under the dash just to the right of the steering column. I also mounted the Fuse block & relays to the right of the steering column. The original engine was an PCM controlled Carb so there was a lot of wires to gut from the factory harness. This aftermarket harness was set up to run the MAF mounted to the throttle body. I didn't want it that way so I un-loomed the new engine harness & moved the MAF wires over to the passenger fender well. I also mocked up the intake tube so I would know about where I was running those wires to.

 

[boz42]

Here is a picture of the sheet metal mount I made to hold the aftermarket fuse & realy center, & a pic of the mounted PCM. The radio to the right was already mounted under the dash cause the owner didn't want to cut the dash to get the CD player in. It's a rats nest of wire in that pic. I did go back & straighten it up.

 

[boz42]

So with all the wiring buttoned up I hooked up to EFI Live to flash the PCM. I downloaded the calibration from the PCM & edited a few things. I had to set up the Fan control, turned off the Abuse mode, torque management, traction control, rear HO2's, Cat converter protection, Canister purge, EGR, & VATS. Now I believe you all know this but I am gonna mention it anyways. This Jeep is intended to be offroad only, that is the only reason I disabled all of these emission controls. If you have a street driven vehicle it is illegal to disable any emissions equipment. Then reflashed the PCM with the new calibration. It cranked the first try. After letting it run through a run cycle & topping off the coolant & trans fluid I was ready for a test ride.

First impressions were good. It was very peppy. Temperature stayed in within range, & everything seemed as it should. I ran around the block, about 5 miles & came home to check for leaks. After letting her cool completely off I made another longer run. On this outing the check engine light came on. I had wired the check engine light into the Jeep's original idiot up shift light. I came home & plugged the Tech II to the Jeep & had a Right front HO2 circuit code. I slid under the jeep to check the plug & noticed the Ho2 wires were melted. I thought oh ****! I pulled the HO2 & unloomed the wiring harness before the plug. The wiring harness was fine so I loomed it back up. I ran to Napa & picked up another HO2. When I got back I decided I would check the pinout on the HO2 connector. There was no power in it. I checked the fuses & the HO2 fuse was blown. I replaced it & checked the pinout again. The power wire in the plug was in the wrong location. The harness was supplied to me in that condition. I un-pinned the connector & placed the wires in there correct location, & put it all back together. This fixed my HO2 problem.

 

[Pizza_Man]

Very nice build! I'd kill to even put a vortec 4.3 in my dads CJ-7. That 5.3 is gonna make that thing fly!

 

[boz42]

This project went fast. I really needed it to, so my shop wasn't tied up. Now maybe I can find some time to get back to my K5. Father-in-law is really happy with it & after several tanks of fuel it is reliably getting 17 miles to the gallon. I think there could be some more MPG's there cause after data logging the widebands it is a little on the rich side. I haven't had time to edit another tune for him to see if we can improve it. He really isn't that worried about it anyhow.

Here are a few of the finished pics:

 

[boz42]

 

[boz42]

 

[boz42]

 

[Chevy305]

Cool build! Makes me want to do one myself.