I'm not so sure that you should be "sure" that you're going to do better than 21 mpg.

This model Trooper is basically a brick on wheels....high wind-resistance....gust-sensitive....and 21mpg is -good-, if that's your average over all conditions. I doubt you'll ever do much better than that, for average-mpg.

1500-2000 sounds really high to me for a basic rebuild. I just had a 2.6L in a 91 rebuilt for about 675 bucks. New rings and bearings, and had the head hydrostatic-checked, leveled, and valves done ($125) (original problem was blown head gasket).

The cylinders and crank were still within wear-limits (210K miles), as were the pistons; so only new wear-parts were required...no machine-work. A set of pistons might've added another $100 I guess.

And I didn't do the work on this one...no time right now. That was paying my local "little shop" to do the work. Just a one-man place...but the one man has 30+ yrs of heavy-equipment overhaul experience...he's pretty sharp.

Anyway, before spending 2 grand...talk to a few more shops...see if you can find one of those "great little places".

Harmonic-balancer: as I recall, the -rear- half of the pulley assembly is steel-on-steel onto the crank; i.e. it doesn't ever move. Line up the crank and cam and cut a TDC notch on the -rear- pulley rim. That new timing-mark shouldn't ever change; even if the front half keeps slipping over the years.

Rear oil-leak: yeah, flywheel bolts...been there...got the puddle to prove it... <img src="/forums/images/graemlins/lol.gif" alt="" />

You said front-seal was leaking too....haven't seen that before on a 2.6', sorry...not a common problem on this motor, is it?


Lack of power: are you SURE you got the cam-timing right? One tooth off could cause a power-loss...and you said something about not being able to get the disty timing in...was still 7-8 degrees out?...which kinda sounds like a typical "one tooth off" error...

In any case, to put your mind at rest about power, borrow a G-meter and check your HP. If the adjusted test-result matches the factory rating for the motor, then cam-timing and all else is likely OK. Or if you're reading low, then keep troubleshooting.

Otherwise, I wouldn't mess with the 2.6 at all; other than a decent exhaust system. It sounds like you won't be happy unless it's a real neck-snapper; and a 2.6L is -never- going to feel like a Grand Cherokee, which feels twice as quick...because it's got twice the engine! <img src="/forums/images/graemlins/lol.gif" alt="" />

(5.2L, 225hp, 18mpg avg, 21 fwy).

To make the Trooper feel anything like that, you need to put a 4.3L Vortec and matching trans in it (probably the easiest 'big' motor swap, I'd think).