Renix to HO Intake, Header, and TB on 96' block with 95' head

[thousender]

Hey guys! I've recently done an engine swap from an 87 2.5l to 96 4.0l running on 88 renix FI and accessories all on my 87 4×4 SWB. The header is cracked, the TPS needs replacement, and I have a 95 head which would allow me to benefit power from the improved design and porting of the HO intake manifold and TB (to my understanding). I did a search and didn't find much info on here, but if I missed it I apologize and hopefully someone can point me in the right direction!

 

I have 4.10s from the 2.5l, so I do indeed use my higher rpm range and will benefit from more HP from the HO intake manifold and header.

 

I'm wondering if anyone has done this and what else I must change? I've read stuff about having to adapt either TPS or IAC for the TB, which is it and is there an aftermarket solution available? Does anyone know if the renix fuel rail and injectors work on the HO intake manifold as well as fuel pump, vacuum lines, sensors, throttle linkage, air box etc. In short what needs to be changed if I'm keeping the renix ecu and wiring harness. Hoping it's mostly just replacing connectors haha 😂

 

I'm starting from scratch with sourcing these parts so is it worth spending the money on aftermarket air intake or header (looking at the ATP Challenge Y-Headers 101212).

 

Thanks in advance for any advice or direction you guys can offer, have a great day!

[Eagle_SX4]

I am running Renix fuel injection on a '91 4.0 liter. I have the '98+ horseshoe intake and am running the Renix fuel rail.

 

There is a lot that needs to change to make this a seamless swap. 

 

Your TPS needs to be adapted to the throttle body. I made my own. I made something similar to what is detailed here.

 

 

You will need to add the Renix coolant temp sensor to the side of the engine block. There should be a plug that will need to be removed and the sensor will go in its place. (the location of the sensor does not change)

 

I did use the Renix fuel rail but I trimmed the center 2 feet and welded some new brackets on to all 4 legs pick up the different bolt locations. This seemed easier than making new fuel lines for the H.O. fuel rail. I also like Renix fuel rail better due to the flow through design keeping the fuel rail colder than the H.O. dead head style.

 

You will need a new power steering pump. The Renix one doesn't bolt up to the H.O. intake manifold.

 

Your exhaust will likely need to be changed. I have a H.O. exhaust manifold and down pipe. It moves the oxygen sensor to a different location and deletes the EGR. Speaking of EGR it will need to be deleted because the H.O. intake manifolds don't have a provision for it.

 

The Renix 4.0 IAC valve will bolt into the H.O. throttle body. It does function but the H.O. IAC has a slightly different pintle shape and is a plug and play swap.

 

You will need to get a new air box and intake hose. The location of the intake hose changed enough that Renix airbox doesn't work very well. The junkyard is the best place to look for these. I recommend getting a late XJ box as it is a much better design than the early boxes. You will need to add a port to it for your CCV tube that was on the Renix box. I just cut it out of the Renix box and used my soldering iron to "weld" it into the new air box lid.

 

The last thing you might need to do if you are changing to the open cooling system is relocate your thermal fan switch which is in the Renix radiator tank. I got an aftermarket one and installed it into the port on the H.O. thermostat. The existing wires will need to be extended. It is a 200 degree switch. The E-fan comes on sooner than before which I think is a good thing. This is the one I used.

https://www.pegasusautoracing.com/productdetails.asp?RecID=27900

 

[Gojira94]

Looking at your pics - it appears you've got most of what you need there. That looks like the Renix fuel rail and throttle body, both just kind of sitting there. Eagle_SX4 is spot on, you'll need to adapt the Renix TB and linkages to the HO intake and make a way to secure the fuel rail. The Renix fuel pressure regulator will have you at the right pressure. Those injectors look like 33007127, from a 91-93 HO, not the 53030778 grey tops that would have come on a 96 engine. Also looks like you already have a temp sender or fan switch in the thermostat housing, which is it?

 

EDIT - forgot to mention that you'll need a Renix distributor, the HO one won't work due to the CPS to sync sensor signal incompatibility. That begs the question of what transmission is behind this engine you've swapped as well. An AX15 will need a Renix flywheel, AW4 will need a Renix flexplate.

[75sv1]

     I don't think the '95 head is that much of an improvement over a 96+. The '96 plus will have holes for the dowel pin in the 96+ block. I'm the only one I know who has had issues with a '95 head interfering with those dowel pins. 

    You did mention that you were going to port and polish the heads. I am not sure if you plan to go with larger valves? Upgrade the camshaft? Also, a 'bored' Throttle Body does help some.