A XJ named Guinea One - Kubota kit develpoment

SPMachining

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Long time reader here first time really posting here.

Last weekend I picked up A 1992 Jeep Cherokee XJ that I will be using to develop a complete Swap kit for a 1984 - 2001.

Guinea One is an 4.0 / automatic 4 door 4wd - so once complete, the kit should work for any JK drivetrain combo that came with the 4.0 under the hood
Plan is to have a complete bolt in kit now welding required


This kit will consist of everything needing to bolt in a Kubota 03 series in place of a 4.0 inline 6 Jeep in a XJ Cherokee
Motor mounts
Oil pan
Accessory mounts
Throttle assembly
Transmission Adapter
any bracketry needed for cam sensor / crank sensor to make sure the swap uses stock gauges and transmission controller (97 and older)

Here it is
Found it local, has 210k miles and a blown head gasket along with other issues. Knowing its current condition I made the choice to drive it home, test my luck. Drove very nice, brakes worked good, no wierd noise and 75 mph on the freeway. Made it about 15 miles and wound up on the side of the freeway.

From the local Craigslist AD
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From The side of Highway 680
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Sorry for image size

This will document all development, fab work, install tuning and driving. This will be a long thread, and slow going at first.

Ken Stauffer
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homelessduck

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Definitely a cool idea. I will be waiting for the kit for sure. ;Sweet
 

SPMachining

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I have not forgotten about you!!

Project update:
When I take on a project like this I like having everything planned out as best I can.
I have spent probably 10 hours with a tape measure climbing around Guinea One taking lots of measurements.
Making sure things will fit. I am sure you all do this too. Also in the last 3 weeks I have taken on a Customers vehicle.
So this build thread will not be for just one 1992 Cherokee XJ but TWO 1992 XJs.

I Went and picked up this Cherokee for my customer last weekend, and I am Jelous!!
1992 Cherokee Laredo - Everything works. Interior is nearly perfect, body is straight .4 inch lift. To top it off, a 5 speed!

Building both at the same time. Hoping to have back to back comparisions on both vehicle. AUTO vs. Manual

The auto comes with 3.55 gears and the manula with 3.07

The manual I have been driving for a couple days now and gearing is perfect 1900 RPM @ 70 MPH

The auto will see slightly higher freeway RPMs @ 70 MPH but I very rarely drive 70 locally. My normal commute is 26 miles on a 2 lane road thru the hills.
Generally running about 55.

I have set a time frame of being finished by mid April for both vehicles.


So onto fun stuff. Items have started being purchased
31x12x3 intercooler and plumbing
Turbo k03-017 / rebuild kit and downpipe flange and gaskets
v2403T exhaust manifold and gaskets
glow shift gauges
new motor mounts
pillar Gauge pod
NPR alternators
Motors are being picked up later next week if I can swing the drive
Manual is getting a v2203 DI with 2 hours, yes 2 hours
Auto is getting a v2203 DI with approx 2k hours

There are alot of parts I will be manufacturing.
tranmission adapters
exhaust manifold flip kit
radiator spacer kit
motor mounts
throttle assembly
oil pans
Accesorie pulleys
accesorie brackets

I will also be adding alot of videos to my youtube channel of the build.
going to try to record as much as possible.

Thanks
Ken
 
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lotzagoodstuff

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Pretty cool swap, lots of the older XJs out there. Nothing wrong with the inline six, but defintely a neat idea to stuff a Kubota 4 cylinder in one.

Keep us posted, sounds like you've got a couple of good test mules :thumbsup:
 

compressionignitionrules

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any internal improvements planned for the turbo charging mod to the little kubota ****** engine? how many hp do you figure on when finished?

definitely liek the 5spd manual idea better with that engine.

watching your new thread while I stuff my MB diesel in.
 

SPMachining

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Other then a governor spring for higher rpm and changing the timing these motors do very well turbocharged. The motors are holding 30 psi without any failures to speak of really,other then operator error.

Only a few have been on a dyno but then ones that have, have seen 95hp/290tq at the wheels below 2300. So I should have about 50 more ft lbs of torque at about 500 rpm earlier.

I am hoping to find a local dyno shop and try to take both XJs there when complete.

Ken




any internal improvements planned for the turbo charging mod to the little kubota ****** engine? how many hp do you figure on when finished?

definitely liek the 5spd manual idea better with that engine.

watching your new thread while I stuff my MB diesel in.
 

SPMachining

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Turbo along with gaskets and rebuild kit arrived yesterday
K03-017 from an Audi A6

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So did the alternator. Off an isuzu npr. Has built in vacuum pump

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The 1992 xj 4x4 manual. This is the customers vehicle.
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Looks like i have got my gauge pillar pod and another box today but havent opened them yet.

More to come.

Ken
 

The Warden

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Looks awesome!! ;Sweet

I have to ask, though...looks like you're in the metropolitan Bay Area. IIRC the Cherokee was never available with a factory diesel in the U.S., so how are you going to handle titling/smog issues?

Looking forward to seeing this happen ;Sweet
 

SPMachining

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I have "heard" that with the right paperwork you can walk into dmv and ask them to verify it is a diesel without going to the ref. Now this will only work for 97 and older. I am going to try this but my vehicles are regestered in a non smog county anyways. The 92 4x4 is heading to chicago illinois where there is no emissions testing

I have alot of updates just need time to sit down a do the update for you all.
 

SPMachining

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2014 v2203 with 2 hours on the clock for the manual trans!!

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Turbo adapter v2403t manifold to Audi A6 k03-017 turbo
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Once I finish the manifold flip kit this will be the approximate location of the turbo. Nicely tucked under the mastercylinder.

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Thanks
Ken
 

SPMachining

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Ordered up a harmonic balancer for a 1gr-fe. 4.0l toyota v6. Fits the kubota crank shaft 31.01mm. I will use this to base my pulley setup off of.

Will also make a alternator pulley that measures 2.45 od to have 95% charging amperage at 1900 (90 amp) and at idle 850 rpm should yield 75 amps.

Need to go out and measure the stock kubota crankshaft pulley and waterpump pulley to find the ratio and then design a new waterpump pulley.

The PS and AC will be underdriven by about 15%.not seeing this as a problem though. I think everything should work well.

Ken
 

lotzagoodstuff

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Looks and sounds like a well laid out plan. I'm anxious to see a finished test mule, keep us updated ;Sweet
 

compressionignitionrules

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2014 v2203 with 2 hours on the clock for the manual trans!!

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WOW 2hrs! I could sell that engine to the Carrier dealer for 3 or 4000.
how did you snag that? rolled over ****** trailer? nice score.:cheers:

what are you building for an oil pan? you won't need the 12 litre capacity .

nice low hours , all the bolts come out by hand.
 

SPMachining

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To remove the crankshaft pulley you need a very deep 46mm socket. Well i dont have one. So i made one..

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Counterbored so the splined section will help keep the socket straight whenbyou apply the 120 ft lbs to remove

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That was a yesterday project.
I am pretty happy with the motor. And yes bolts loosened nicely. Going to try to get the motors on a stand this weekend.

Last time it will see a gas pump. Starting to pull it apart this weekend

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Ken
 
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