Join Date: Jun 2010
Location: Tiona, PA
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Just stick with a 4cylinder. To rebuild it, with all of the machining, and rebuild kit, and labor your going to more than a used motor will cost. A used motor should run you $600-$700.00. to Rebuild it it will cost you about $1,200 - $1,500.00.
If your bearings are just bad and the crank isn't damaged, you can get away with getting new bearings. Worst case scenario is you'de have to pull the crankshaft and get it re-ground with oversize bearings which will run you around $350.00 for re-grind/polish/bearing kit.
If your crank is OK and you just need bearings, it should cost about $100.00 for a bearing kit. For both of these situations you might as well get a new Oil pan gasket.
All of these prices are not including labor also..
To swap the 4cylinder to a 6 cylinder you will need a V6 motor first of all, which they run $800-$1000.00 for it. You will need a V6 transmission which will be $500-$600.00, you will need an ECU, Complete wiring harness (Computers, under-dash harness, motor harness), Motor Mounts, Hydraulic Fans, Axles, (might as well swap the Spindle assemblies out too and get V6 rotors, calipers, etc..) The I4 > V6 is possible, but very expensive.
I would honestly try to see if you can just swap the bearings out first... should be 2-3 HR labor + $100-$125.00 in parts. If you need machining it will be a bit more labor because the transmission will need to be removed.
hope that helps