So I've been reading all over the site lately... And I've decided to keep my 2.9 rather than 4.0 swap like I was planning.
My start off list to get it built up is this...
The k & n- cone or stock replacement?
Electric fan
JBA header- cali emissions legal?
I already have a magnaflow cat back single exhaust, and brand new cats.
Maybe later I'll do a true dual... If I can get away with it
Later I want to do the floating rockers, and port and polish upper and lower intake. After that, find a good set of heads.
It my list realistic? Is it in a good order? Or should I be worrying about other things first?
Ok, in order:
The K&N filters, are, in my opinion, pointless. A stock paper filter will flow all the air your engine needs, and filter better at the same time. Just replace it every 6 months or so and you'll be fine. More often in dusty conditions.
An electric fan on a nearly stock motor is pointless. Just get the new fan clutch if you need it. Also if your fan has any cracks in the plastic, get a new one.
I've always been partial to headers. However, remember that the stock exhaust manifold will always be more reliable. Headers have a tendency to either crack, or rust out after a few years. If you get the good coated ones it might be ok though. The factory didn't use them due to reliability concerns, under hood temperatures, and higher costs to manufacture.
Single exhaust is all you need on a 2.9. I wouldn't go bigger than 2 1/4" pipe though.
Full floating rockers, IMO, are pointless. The stock setup is already pretty good. If you could get roller rockers it might help a little, but still not worth the cost.
Porting and polishing the intake will help a little. What you really want to do, if you want to take the time, is port and polish the
cylinder heads. That has helped all motors since the beginning of time. The factory didn't do it because they had to balance low speed torque, fuel economy, and cost to manufacture the heads, with power. A good port cleanup will help. But don't waste your time on the factory heads.
Before you do any of that, you should be concerned with getting all the factory control systems of the motor perfect. Then make sure the engine has good oil pressure, runs quietly, etc. Basically make sure it's in good working order before you start worrying about performance.