Replacing the Jeep Wrangler 4 cylinder TJ Exhaust Manifold

Replacing the Jeep Wrangler 4 cylinder TJ Exhaust Manifold - Part 1

Рет қаралды 9,854

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.
One of TDSR’s noise sources is the leaking exhaust manifold. In this two-part video series, I’ve tried to create a step-by-step on replacing the manifold. This video is Part 1, which focuses on removing the manifold. I’ve marked the various steps as chapters in the video if you want to skip around. Video Part 2 goes over cleaning the engine, test fitting the replacement manifold, and getting everything installed.
NOTE: I go through steps 1 & 2 to remove the power steering pump only to have to put it back on. Be sure to watch through the first ~10 minutes before starting this project.
There are some interesting discoveries, both good and bad, in this project so be sure to check out both Part 1 and Part 2!
Link to Part 2: • Replacing the Jeep Wra...
If I’ve earned it, please subscribe to the channel and if you’re interested, you can support me on BuyMeACoffee at www.buymeacoffee.com/edvancise
Tools (some links are Amazon Affiliate links):
• Fuel line removal tool: amzn.to/3J2dupw
• Sockets (10mm, 15mm, 1/2", 9/16”, 5/16”)
• Ratchets and Extensions
• 9/16” wrench
Parts needed for installation (some links are Amazon Affiliate links):
• Manifold Gasket: amzn.to/3IWefk6
• Exhaust Manifold: amzn.to/3mdbC3u
• Beveled washers (4): amzn.to/3mbXyYk
• Bolt Kit: amzn.to/3q9xBto
• Nuts for exhaust pipe (2) (optional): (varies based on the manifold you buy)
Links & Resources
• 1997 Jeep TJ Service Manual: jeep-manual.ru/files/TJ1997/1...
• Jeep Solid’s “Cleaning A Gasket Surface: Tips and Tricks” video: • Cleaning A Gasket Surf...
• Force Built’s “97 Jeep TJ Exhaust Manifold Gasket Replacement” video: • 97 Jeep TJ Exhaust Man...
• Trick I used to find my exhaust leak: • Finding the Exhaust Le...
• Ghostlyrich’s “HOW TO EASILY CHANGE SERPENTINE BELT JEEP TJ” video: • HOW TO EASILY CHANGE S...
• Parts lists and service manuals for multiple Jeep TJ years: wranglertjforum.com/threads/j...
~~~~~~~~~~~~~
Intro (0:00)
Getting Started (4:05)
Steps 1 & 2 (6:10)
Relieving Fuel Pressure (8:41)
Getting Started the Right Way (10:21)
Disconnect Fuel Line (10:59)
Release Throttle Cable (12:30)
Disconnect Electrical Connections (13:45)
Disconnect Vacuum Lines (17:10)
Remove Intake Manifold (18:10)
Release Exhaust Pipe (21:33)
Remove Exhaust Manifold (23:03)
Final Observations (25:05)
Part 1 Wrap Up and Part 2 Intro (27:39)
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: 48

@CarbonsDIYGarage Жыл бұрын

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

@ryanbird5142 Жыл бұрын

Your jeep is like a mirror image of mine man, your series helped me figure out where my exhaust leak was, how to get the exhaust manifold off, and i figured im pretty sure i have a valve cover leak - you have a damn well put together video for each that gives me confidence i can do the work. I appreciate the hell out of it sir, thanks for taking the time to film and document these!

@CarbonsDIYGarage Жыл бұрын

Thanks so much for the kind words! I’m glad the videos were helpful. This is exactly why I made them - hoping to help someone else in the same spot. Best of luck with your TJ!

@ryanbird5142 Жыл бұрын

I got everything back together this morning, the injectors on the fore end of the jeep didnt want to go back in, so i figure im gonna need new ones. Also, my first run through i improperly seated the intake manifold which resulted in an insanely high idle. Aside from my own user errors everything went pretty damn smooth, saved me about 800 bucks in auto shop expenses, much appreciated sir, just wanted you to know the video had effect on target!

@ryanbird5142 Жыл бұрын

Oh, and the loud hissing sound coming from the exhaust manifold is gone now 😁

@CarbonsDIYGarage Жыл бұрын

@@ryanbird5142 That's great to hear - glad the video helped and I appreciate the feedback. I feel your pain on getting the intake manifold seated. The number of times I had to take that thing off and on to get it every thing aligned... Definitely a fickle part of the process. Glad you got it, though!

@JoshWellborn Жыл бұрын

This is my first time watching one of your videos. I’m getting ready to take on this project on a 99 TJ 2.5. I like how you just brush over your “day job” at NASA! 😂😂😂 #champion

@CarbonsDIYGarage Жыл бұрын

Good luck with your your TJ and thanks for watching! and everyone needs a hobby when they’re not wrenching, right? 😄

@TaysomHugh Жыл бұрын

One of the best videos for this fix. Thank you for taking the time to make and share. And thanks for the good vibe music! Shout out from Livingston TX!

@CarbonsDIYGarage Жыл бұрын

Thanks, Joshua, and thanks for watching!

@charlyvss5440 2 жыл бұрын

Man this video is a gift to someone like me. Thanks a ton

@CarbonsDIYGarage 2 жыл бұрын

Thanks for watching, Charly. I’m glad it was helpful.

@dombomb8679 3 жыл бұрын

very very well put together video and instructions. this is exactly the video i needed, keep up the good work man

@CarbonsDIYGarage 3 жыл бұрын

Thanks for watching, Dombomb, and I appreciate the feedback! Good luck with your own, and be sure to check out Part 2 - how I put it all back together.

@dollfazar 11 ай бұрын

Thanks, man. Super helpful for me.

@CarbonsDIYGarage 11 ай бұрын

Glad it helped. Thanks for watching!

@ForceBuilt 3 жыл бұрын

Good thorough video. Great job. I have to rebuild JJ. Developed a bad rod knock! He just keeps on giving lol. At this point he will be almost new. Full engine rebuild coming soon!

@CarbonsDIYGarage 3 жыл бұрын

Thanks, Steve! It was certainly a beast, but felt good after listening to the before and after. Man, sorry to hear about JJ. TDSR’s in the shop now with “yeah, that rear end needs work; we’ll get back to you when we figure out all it needs.” Previous Owner just keeps giving, amiright?

@ForceBuilt 3 жыл бұрын

@@CarbonsDIYGarage Indeed you are right lol. I think my previous owner used to live in Texas lol!

@jamesmonahan9408 3 ай бұрын

This will work for a 2000 Wrangler SE 2.5l? My gasket or manifold just went out. Gotta say your videos have been a huge help!!

@CarbonsDIYGarage 3 ай бұрын

Glad the videos are helpful, James! Since yours and mine are both 2.5L, the general process should be about the same. Be really careful with getting the right parts, though. The 2000 has a different service manual from the 1997 - 1999 models and I think there are quite a number of part differences. I don't know if there is or isn't in the area of the intake/exhaust manifold but definitely look into the service manual and parts list for the 2000 model year to make sure you get the correct parts. Good luck!

@jamesmonahan9408 3 ай бұрын

@@CarbonsDIYGarage I have a Haynes manual but it is very vague on some things. Mine should be in it but it seems like it isn't. Thanks so much for the heads-up. This is my weekend project. Ugh.

@zipzip5807 2 жыл бұрын

Hey Carbon, has how is your Fel Pro gasket holding up? Any new exhaust leaks yet?

@CarbonsDIYGarage 2 жыл бұрын

Gasket is holding great, no issues and no new exhaust leaks. A month or so afterwards I checked the torque on the manifold bolts (all were good) and I keep checking them every few months. All holding well. The 2.5L has a distinctive sound and every time I watch a video of someone else's 2.5L it's great to hear that those 2.5's sound just like mine now. Thanks for watching.

@chuckgroskopf3260 Жыл бұрын

Thank you great job. Chuck Groskopf Twain Harte ca.

@CarbonsDIYGarage Жыл бұрын

Thanks! And thanks for watching, Chuck.

@josiahellis6388 Жыл бұрын

So you made the mistake of taking the pump off and disconnecting the battery but didn’t inform us until after we also did that?

@CarbonsDIYGarage Жыл бұрын

Josiah, you're absolutely right - if I had to do the video over again, I'd put a big note on there that even though the service manual has it do it in that order, and I recorded it in order of following the instructions, viewers shouldn't do it that way or else they'll be in the same 'gotcha' that I uncovered. I updated the video description to highlight it (though I'm not sure anyone actually reads those). Thanks for watching and thanks for the constructive feedback!

@Manandmachine772 3 жыл бұрын

I am replacing my manifold gasket on my 2000 TJ 2.5 . It had a leaking gasket on the intake causing my high idle. The question I have to ask is if any of your manifold bolts or nuts were loose. All of mine were loose and did not take much effort to loosen. Just wondering if this is a problem on the 2.5 or just a improper installation. Thanks

@CarbonsDIYGarage 3 жыл бұрын

Thanks for watching, Carl! From what I saw on other videos and in my own experience, I think this is a common problem - at least with the 2.5L, if not the TJ in general. The bolts on mine when I made this video were all loose or barely snug. But I don't know if that was to blame on Previous Owner or not. It likely contributed to the gasket ending up in as bad of shape as it was. As a better data point, it's only been a couple of months after I made this video. I checked the bolts and a couple were a little loose. I don't know if the factory torque value is too low or what it is. I'm really reluctant to use thread locker on them because you really want them to come out if you have to remove them. I've added a reminder in my vehicle maintenance app to check the bolts every few months, at least for now, because it seems like the vibrate loose pretty readily. As for the nuts - they weren't loose. In fact one nut wouldn't come loose and it ended up being the stud unthreading from the block.

@Manandmachine772 3 жыл бұрын

Oh good, one of my studs is missing completely. Threads look good thank goodness. I need to chase all the threads before going back together too. I was having the same thinking as you about the locktite on the bolts just not really excited about having to add checking bolts as a maintenance procedure. Thanks for the information

@CarbonsDIYGarage 3 жыл бұрын

@@Manandmachine772 The daunting prospect of having to extract broken bolts or studs really had me worried so despite the other issues, I was still happy that I didn’t need to use those tools! There aren’t a whole lot of videos that I found on the 2.5L manifold. If you think of it, let us know what you decide to do regarding loctite and how things look in a few months.

@Manandmachine772 3 жыл бұрын

Hello just a update regarding my manifold gasket replacement. No problem with broken bolts or the stud that was missing. Chased threads and cleaned the head and installed a new stud with no problem. Then I realized that the 2 dowel pins were missing when I took the manifold off. If these were missing how important are they in keeps everything in line and tight. Tried looking online for them no luck as of yet and hopefully they are available from the dealer. Thanks for your help

@CarbonsDIYGarage 3 жыл бұрын

@@Manandmachine772 Oh wow! Well, really glad no broken bolts. The dowel pins weren’t in the block or the intake manifold? That’s so weird. I would think they’re pretty important to get the alignment right. If I remember right, there aren’t any through holes on the intake manifold for bolts to help with the alignment. Sorry I don’t have a better answer. Maybe you can find an intake manifold at a junk yard that has the towels in it that you can remove? Good luck!

@reedcarpenter2994 Жыл бұрын

Can you share a link to the replacement bolt set that you bought? I have the exact Jeep as yours. Thanks

@CarbonsDIYGarage Жыл бұрын

You bet, Reed. The info’s in the description of video 2, but I’ll add it to the info for this video too. But here’s the info: Beveled washers (4): amzn.to/3mbXyYk Bolt Kit: amzn.to/3q9xBto Good luck and thanks for watching.

@reedcarpenter2994 Жыл бұрын

@@CarbonsDIYGarage thanks !! Awesome video. The washers say they are only for the tj through the 99 year. They said they won’t fit the 2000 tj , at least that is what Amazon says. Do you think that the bolts would fit a different manifold? I already ordered a different manifold before watching.

@CarbonsDIYGarage Жыл бұрын

@@reedcarpenter2994 My TJ parts lists is for teh 1997 - 1999 TJ. I found the parts list for the 2000 TJ and it does show different part numbers for the bolts, studs, and beveled washers. Good catch on that! Here's a link to the 2000 TJ parts list, if you don't have it: archive.org/details/2000jeepwranglertjpartsmanualrevisedocr328pages Scroll down and you can find the download option. Page 137 of the PDF for the 2.5L TJ. I hope that helps.

@reedcarpenter2994 Жыл бұрын

@@CarbonsDIYGarage it appears the studs on Amazon that you included the link for matches up, just the beveled washers don’t match. Can you confirm the studs that you included match the 2000 Jeep? Also I didn’t see you change those on the video, was it easy to change? And do you recommend changing those?

@CarbonsDIYGarage Жыл бұрын

@@reedcarpenter2994 Looking at the Questions on the Amazon page for the washers, sounds like these washers will work on the '00 as well. The description pare of the Amazon page for the bolt kit says it'll work on the '00 as well. Not sure if you meant the washers or the studs when you asked about seeing me change "those." Washers I didn't really specifically get, but you can see a new one/bolt on the front most exhaust manifold bolt location here: kzfaq.info/get/bejne/q7d7qrKrpruaY4k.html If you meant the studs, those are easy to change AS LONG as you can get the old ones out. If you can't get them out, don't snap them off trying. Clean the threads and just reuse them. As long as they're in good condition and you torque things properly, I would think they'd be fine to reuse. You can certainly reuse the washers if you need to (I may have reused one, actually, since I think I lost one of the new ones). Hope that helps. Keep in my mind disclaimer regarding not being a professional jeep mechanic.

@waden404 Жыл бұрын

Did u just say FOD? Well hello shipmate (im assuming.) F/A 18 ordnance myself.

@CarbonsDIYGarage Жыл бұрын

LOL - not Navy (though I did try but my vision kept me out), but definitely aerospace sector. I didn't even notice that "work" seeped out into the video, good catch. Ordnance - man that's certainly no easy work!

@423gamble Жыл бұрын

O no honey. Yeah they relieve pressure themselves. You could have just pulled the rail off

@clarke97kidd 2 жыл бұрын

why exactly didnt you do the step of disconnecting fuel pump relay before taking off power steering pump smh lol

@CarbonsDIYGarage 2 жыл бұрын

As described at 8:41, I was following the service manual and doing it in the order written, which was clearly not correct. That's what led me going back and doing it the right way, as described at 10:21.