toyworx said:
beaker
Only problem with the 5.0 is all the other $$ to make it work. For someone who has a 4.0 that is in need of a basic rebuild, the stroker option is not that much more $$ and all of the other items can be retained like the radiator, accessories and such. Making a 5.0 work in a new TJ is $$$ as you need to change a ton of other parts to get everything to work.
I've only rebuilt one engine but from that engine, I'd think $2000 would be a reasonable budget for rebuilding the engine. I spent more but to get a good fully rebuilt engine (your pulling it apart, do the whole job, not half of it). Between the parts and machining, boring, valve job, custom pistons, new bearings, new cam etc. It's not a $500 dollar job.
You can do one much cheaper, but it's not going to be as reliable, smoke free, smooth running nor as powerful.
To do either job will be a lot of money and time. Now emissions is another story, TJ's are OBD2 and thus any engine you put in needs OBD2 elecronics otherwise the emissions people will be all over you when they plug into the connector and find it not working (in CT, don't know other states). Pre OBD2 YJ would be a better choice for a motor swap.
In my research, a supercharger from a buick park ave would probably be the best bet (eaton mp90). A rising rate fuel pressure regulator should cover most EFI tweaking, some custom mounting brackets and tubing should work. TJ might work, cherokee doesn't have enough room for the belt in front (atleast not without moving the cooling fans). The superchargers have a self contained oil system, multiple mounting angles, sized for nearly the same size engine and are cheap on EBAY. Though that opens a can of tuning worms. Quirky engines don't work well on trails from what I've seen.