Replacing the Exhaust on a Jeep TJ 2.5L, 4 Cylinder

Рет қаралды 9,846

Күн бұрын

Project TJ - working on my 1997 Jeep Wrangler. It's the SE version of a TJ with a 2.5L four cylinder and a standard transmission. At the time of making this video, the Jeep had ~204,000 miles on it.
Installing a new exhaust manifold made it crystal clear that the entire exhaust setup on the Jeep was trash. Out with the old, in with the new! I give an overview of installing a Walker exhaust setup to essentially bring the Jeep back to a functional stock configuration.
I was also getting a Check Engine Light after replacing the manifold due an oxygen sensor issue (code 51). I guess air was flowing out the exhaust after the manifold was fixed and the sensors didn’t like it. Replacing the exhaust also took care of the Check Engine light.
After I replaced everything and drove it for ~20 miles, I got a Check Engine Light again (code 21). It turns out that this is common after replacing O2 sensors if you USE THE WRONG ONES! Yup, at least for the early TJs (e.g. 1997), you have to use NTK/NTG brand. If you don’t, the Jeep won’t work properly. I didn’t learn this until after I installed Denso brand. Bosch brand apparently also don’t work well. Learn from my mistake - use NTK/NTG brand! It’s not worth the hassle of replacing O2 sensors again (though it's pretty easy when you are replacing sensors you just installed - they come out easily).
I hope you enjoy! Subscribe to the channel and if you’re interested, you can support me on BuyMeACoffee at www.buymeacoffee.com/edvancise
Parts (some links are Amazon Affiliate links):
• Walker Exhaust Ultra EPA 15841 Direct Fit Catalytic Converter (amzn.to/3JaFIPg)
• Walker 35336 2 1/4 Inch Heavy Duty Clamp (qty. 2) (amzn.to/3sgPPMj)
• Walker 52319 Front Exhaust Pipe (amzn.to/3e2Xzct)
• Walker 21337 Quiet-Flow Stainless Steel Muffler (amzn.to/3p8k4Dm)
• Walker 54227 Tail Pipe (amzn.to/3p4btBw)
• Walker 35337 Hardware Clamp (qty. 1) (amzn.to/3J2jNti)
• Rust-Oleum High Heat (amzn.to/3p4bvJE)
• PERFORMANCE TOOL W84008 Compact Oxygen Sensor Socket (www.rockauto.com/en/moreinfo....)
• ONLY USE NTK BRAND OXYGEN SENSORS!
o NTK 23506 Upstream Oxygen Sensor (amzn.to/3p5gUQw)
o NTK 23099 Downstream Oxygen Sensor (amzn.to/33GRJeX)
Reference video I used:
• Jeep TJ Dynomax Cat-Back and Bosal Cat Install | Wrangler Exhaust: • Jeep TJ Dynomax Cat-Ba...
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Intro (0:00)
Survey old exhaust (1:25)
Oxygen sensors (2:14)
Disconnect downpipe (3:37)
Remove downpipe and cat (5:03)
Remove tailpipe and muffler (5:49)
New parts prep (7:05)
New oxygen sensors (8:40)
Installing tailpipe (11:53)
Installing downpipe and cat (12:53)
Installing muffler and final assembly (13:21)
U-clamps (15:13)
Making some noise (16:28)
Final Thoughts (17:17)
Disclaimers:
This video is NOT sponsored by any of the brands mentioned throughout this video or video description. All thoughts mentioned are my own. Some links provided are affiliate links. They do not cost you anything, but I make a small percentage from the sale. Honesty is key on my channel, thank you for supporting me!
I am a Do It Yourself, also known as DIY, mechanic. I am NOT a professional mechanic. I do not have any formal training in the automotive field. I assume no liability for anything you choose to do to your car/vehicle or equipment before or after watching one of my videos. All DIY repairs or modifications you perform are made at your own risk. Sometimes, even if you've done everything the right way, you can destroy or damage one or more things on your car or equipment. You must understand this, but by leveraging knowledge and patience, the probability of encountering one or more problems can be reduced.
Also, if for some unfortunate reason, I do give incorrect instructions and something breaks because you followed my instructions, I will NOT reimburse or pay in any way for whatever cost that may be incurred due to following my wrong instructions.
Lastly, please don't do anything to your vehicle or equipment unless you yourself feel comfortable and confident in doing so.

Пікірлер: 34

@CarbonsDIYGarage Жыл бұрын

Check out the video description for extra info, parts, tools, torques, and any updates.

@dylweezy117 3 күн бұрын

Man, you make it look easy! Hopefully I can do the same.

@CarbonsDIYGarage 3 күн бұрын

@@dylweezy117 You got this! Thanks for watching. If it earned it, please consider giving the video a 👍🏻 and/or sub to the channel.

@ForceBuilt 3 жыл бұрын

Nice job as always Ed! I don't have a Catalytic converter on mine. Cats are very pricey. I had heard of the O2 sensor problems before. Didn't know if it was actually a thing or not. Now I know it is. Glad to see you get it done right! Sounds great!

@CarbonsDIYGarage 3 жыл бұрын

The cat from Wagner wasn't too horrible but it did cost about as much as the rest of the exhaust combined. Fixing the exhaust led to all sorts of new "awareness" from TDSR. Not only did it have to start using O2 sensors again, but it ended up having to relearn how to idle. I've had to replace the MAP sensor and Idle Air Controller but I think she actually sounds close to what she's supposed to now. Thanks, Previous Owner... I don't know if I'm doing it right, but hopefully getting it close. Thanks for the kind words and thanks for watching!

@jaimemorenonevarez8862 6 ай бұрын

perfect video !

@CarbonsDIYGarage 6 ай бұрын

Thanks for watching!

@jarhead6153 3 жыл бұрын

Around 15 yrs or so ago, there was a catalytic converter “silent” recall. If it sounded like a bunch of broken glass inside, it is bad. Just an FYI. Mine was replaced by Jeep for free. They were even reimbursing folks who paid to have it replaced.

@CarbonsDIYGarage 3 жыл бұрын

Oh wow, that’s good to know! Given the state of my Jeep I think they’d just laugh at me but good tip for others. Thanks for watching and subscribing.

@BerniesBastelBude 2 жыл бұрын

finding the NTK sensors in Germany is almost impossible - for the 23506 I had to ask a friend to bring it from her USA vacation and even that was difficult ($74 btw)...

@ryanbird5142 Жыл бұрын

Hey man you've literally saved me a few thousand bucks over the past few weeks, much obliged! Did you notice a smell similar to electrical burning after install, i know some odor is normal but mine was pretty damn pungent going down the road today. Ill check the sensor wires but i was pretty careful securing them.

@CarbonsDIYGarage Жыл бұрын

So glad to hear that this video helped you out, Ryan! I don't recall an electrical/ozone type smell but I do remember that there were smells. Since I painted everything, I think it was the paint baking off, plus maybe some PB Blaster type of stuff burning off. You might check your O2 sensor wires, especially the upstream sensor because that wire can easily go up against the exhaust manifold or down pipe. I zip tied my upstream sensor's wire out of the way. If any sensor wire actually burns through, I'd think you'd get a check engine light. If the smells don't go away after a couple of days, probably something to look into more. Sorry I don't have a definitive answer.

@ryanbird5142 Жыл бұрын

No problem at all! I confirmed sensor wores are in tact, i think it may have been chemical residue from the factory. It still smells, but not nearly as bad, and it's running the best it's ever run. I can actually hit 60 in 4th again lol

@CarbonsDIYGarage Жыл бұрын

@@ryanbird5142 That’s awesome! Congrats!

@soundman38372 Жыл бұрын

What do you think about running straight pipes past the catty into duel exhaust

@CarbonsDIYGarage Жыл бұрын

Being honest with you? My thought was that since it was/is a 2.5L, 25 year old, 210,000+ mile Jeep, I would just put it back to a stock configuration because it would be the least expensive, least likely to cause unforeseen problems, and there's not much I can do to make the thing look prettier or run faster. :)

@charltonrich 3 жыл бұрын

Your video was very helpful! I have a 1998 tj with the 2.5 liter and just replaced the entire exhaust system. Did you have to get extended exhaust flange bolts? If so, what did you buy? I had to replace mine because the stock ones were to short. I have a temporary fix in place now.

@CarbonsDIYGarage 3 жыл бұрын

Thanks for watching, Charlton and I’m glad it was helpful. By flange bolts, I assume you mean the bolts from the exhaust manifold to the downpipe. No, I used the bolts that came as a part of the manifold (see separate videos on replacing the manifold). I had to line the downpipe up, tilting it “just right,” to get the bolts to extend far enough through the flange on the pipe to get the nuts started. Definitely a pain in the @ss. I know that probably doesn’t help you though. The TJ parts list says the stock studs are .375-16x1.69 (3/8-16 x 1-11/16), part number J4007109

@andrewgabrielse9073 2 жыл бұрын

In the process of replacing the entire exhaust on my 00’ TJ with the 2.5. I bought a Crown Automotive kit. I discovered however that the bracket on the down pipe doesn’t fit with the stock bolts from the exhaust manifold… I can’t return the kit because I am past the 90 day limit. Any advise on either adapting it or making it work some other way? Thanks for the help!

@redgeciccone8218 3 жыл бұрын

Nice video, There's a way to remove and repair the exhaust without removing the skidplate ?

@CarbonsDIYGarage 3 жыл бұрын

Thanks for watching, Redge! If you're doing cat back, leaving the catalytic converter in place, you can certainly do it without removing the skidplate as long as the connection between converter and muffler isn't welded. If you're Jeep's lifted so you have more room to work/see under the Jeep, you can probably do the whole thing without removing the skidplate, though sliding the catalytic converter off its mount on the transmission might be tricky. Frustration may drive you to dropping the skidplate. If you end up having to cut the connection between converter and muffler, you'll probably have to drop the skidplate too. And the O2 sensor will be a bit more challenging to remove with the skidplate installed, unless you just disconnect the sensor harness and take the sensor out with the converter. I hope that helps (and makes sense).

@jwestrik9308 Жыл бұрын

Hi thanks for showing this. I have to replace the muffler and tailpipe and ordered the ones that were supposed to be for the YJ 4.0 1994. But the tailpipe (and probably the cat) do not slide into the muffler. Looks like the muffler inner diameter is about 0.2 mm too small. What do you think is the best option? cutting the pipe and mufler short and use a adapter connector, or try sanding/grinding the outsides of the tail pipe and cat back and perhaps a bit of the inside of the muffler pipes?

@CarbonsDIYGarage Жыл бұрын

I would say it depends on how good you are at that kind of fabrication. I know I’m not good at it so I’d go with an adapter because I can slip it together and clamp it with u-bolts. I think as long as you get the pipes all connected somehow and have them hanging off the ground and not hitting other vehicle parts, you’re good. Sanding/grinding, adapters, straight up welding, etc. Good luck and thanks for watching!

@jwestrik9308 Жыл бұрын

@@CarbonsDIYGarage Thanks a lot for the reply. I will ponder...

@jwestrik9308 Жыл бұрын

@@CarbonsDIYGarage Actually, just saw a reference to a tool called Exhaust pipe expander, basically something that goes into the pipe and you expand it by turning a wrench or heavy impact: Found some on Amazon in the uk "Exhaust Pipe Expander Tailpipe Expander Tool Set 1-5/8 Inch to 4-1/4". I will let you know if that worked...

@CarbonsDIYGarage Жыл бұрын

@@jwestrik9308 Cool! Yeah, let us know how it goes.

@zerosk8er263 Жыл бұрын

I have a 2001 tj 2.5 , trying to find the entire kit and am having no luck. Im wondering if the 97-00 kit will fit. Also cant find the down pipe that connects to the manifold. Its driving me insane haha, Any ideas? Thanks

@CarbonsDIYGarage Жыл бұрын

Walker exhaust has a catalog that shows you all the parts, starting with the catalytic converter, and you can order them from Walker, Amazon, RockAuto, etc. www.walkerexhaust.com/find-my-part.html But I also couldn’t find anything about the down pipe, which is crazy. Even the Jeep parts catalog doesn’t have info. Just shows the pipe connected to the cat. (Figure 011-110, page 162) You might consider calling Walker or maybe Summit Racing to see if their customer service folks could help. Sorry! Good luck…

@zerosk8er263 Жыл бұрын

@@CarbonsDIYGarage Yeah I will call them. Thanks so much for going out of your way! It is crazy lol

@SeriouslyAwesome Жыл бұрын

TJ's are notorious for only taking cheap NTK stuff. Not all sensors, but when they do it's usually best just to use them

@CarbonsDIYGarage Жыл бұрын

It's too bad that it's becoming harder to find some of these NTK/NGK sensors.

@SeriouslyAwesome Жыл бұрын

@@CarbonsDIYGarage I haven't replaced any sensors in a good while. Good to know. Might buy a CPS b/c I don't recall replacing that one yet

@isaacjones6172 3 жыл бұрын

How much did all this cost you? Thanks

@CarbonsDIYGarage 3 жыл бұрын

Thanks for watching, Isaac. All totaled it cost me around $525. Half that was the catalytic converter. The rest of the exhaust parts are pretty cheap (you can certainly pay more for a specific look or sound). Definitely shop around. Amazon may not always be cheapest, especially for things like paint , oxygen sensors, clamps, etc.