Replacing the Jeep Wrangler 4 cylinder TJ Exhaust Manifold

Replacing the Jeep Wrangler 4 cylinder TJ Exhaust Manifold - Part 2

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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 2. The manifold is already removed (see Part 1). This part goes over cleaning the engine, test fitting the replacement manifold, and getting everything installed. I’ve marked the various steps as chapters in the video if you want to skip around. 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 1: • 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
Parts (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)
Tools (some links are Amazon Affiliate links):
• Center punch: amzn.to/3soju66
• Sockets (10mm, 15mm, 1/2", 9/16”, 5/16”)
• Ratchets and Extensions
• 9/16” wrench
• 3/8-16 tap for engine block holes
• 8E External Torx socket: amzn.to/3e1QGbc
• Angle Grinder
• Drill, possibly right-angle drill and drill bits - especially if you have to drill out a snapped bolt
• Wire brush
• Fine grit sandpaper
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)
Wasp Nest (2:25)
Removing Mounting Stud (2:36)
Cleaning the Head (2:46)
Removing Exhaust Manifold Heat Shield (3:29)
Modifying the Exhaust Manifold (3:58)
Test Fits (6:12)
Installing Exhaust Manifold (8:10)
Installing Intake Manifold (10:42)
Connecting Fuel Line (14:35)
Connecting Vacuum Lines (15:19)
Connecting Electrical Connectors (15:44)
Installing Power Steering Pump (18:38)
Installing Throttle Cable (19:52)
Installing Accessory Belt (22:17)
Connecting Exhaust Pipe (23:41)
Closeout Steps (25:57)
Crank It Up! (28:24)
Parts and Tools Summary (29:05)
Final Thoughts (31:59)
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.
Music:
Call to Adventure - Comedy by Kevin MacLeod is licensed under a Creative Commons Attribution 4.0 license. creativecommons.org/licenses/...
Source: incompetech.com/music/royalty-...
Artist: incompetech.com/

Пікірлер: 28

@CarbonsDIYGarage Жыл бұрын

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

@Kav705 Жыл бұрын

That you for these videos man, finding vids for the 2.5 is almost impossible and this was a tremendous help

@CarbonsDIYGarage Жыл бұрын

I’m glad it helped and thanks for watching, Brian. It’s definitely one of the reasons I’ve been making them - trying to help others out with the 2.5L. If you haven’t already, also take a look at @ForceBuilt. And sometimes you can find YJ videos that sometimes help, at least with the earlier year TJs.

@user-bt2kw3ej6v 8 ай бұрын

Thank you very much for making this very professional video. I Definitely learned about the dry fitting it before the actual installation. GOD bless you. Keep up the good work.

@CarbonsDIYGarage 8 ай бұрын

Thanks for the feedback, Robert. I'm glad it was helpful! Thanks for watching.

@SeriouslyAwesome Жыл бұрын

Easily the most thorough exhaust manifold repair and youtube video. Thanks for the hard work. It was pretty daunting the first time I replaced mine on my '99. I learned a few things about where those extra parts go in the Dorman kit. I've messed with mine at least 6 times in the past 6 years. 3 different manifolds (2 cracked and current one is leaky). Keep an eye on those bolts backing out (a wobble socket helps so you wouldn't have to dismantle anything). I've never put locktight on them because I know it messes with the torque specs. Because my Jeep is so clean from all the work I've put in, I think if I hustled I could swap one out in an hour now. Most of the battle is the cleaning and a bunch of what you removed can just be put aside. If it's not cracked, how much do you want for that old OEM manifold? I'm tired of the aftermarket ones and would be willing to risk it if you still have it.

@CarbonsDIYGarage Жыл бұрын

Man, 6 times in 6 years - something I'd rather not be that proficient with! I definitely agree on checking those bolts and their torque - simple way to help ensure the gasket doesn't start failing. Unfortunately I gave up trying to rehome the old exhaust manifold and gave it away as scrap.

@SeriouslyAwesome Жыл бұрын

@@CarbonsDIYGarage nightmare. Always something new with them. I bought an OEM MOPAR manifold from a RockAuto closeout last week for ~$175 hoping I'd get a factory version. I'm extremely disappointed. It's just like the aftermarket ones stamped CHINA and a heat shield riveted on. I paid a premium for that. The only difference I could tell was the iron was narrower around the bolt holes like the original. After a bit of deliberation, I'm just going to return it and try to fix my current manifold leaks (small ones at basically at every seal imaginable) and use a new gasket.

@waden404 Жыл бұрын

Great videos sir. Thank u for this.

@tpledger100 2 жыл бұрын

different length sockets and extensions as well a a u joint got all the bolts torqued this video has been extremely helpful Thanks for posting

@CarbonsDIYGarage 2 жыл бұрын

Thanks for watching and I'm glad it was helpful!

@terrencelawrence5007 10 ай бұрын

Thank you

@CarbonsDIYGarage 10 ай бұрын

Thanks for watching, Terrence.

@mydrums4evr 3 жыл бұрын

Great video boss...one suggestion to check leaks? on cold engine plug that vacuum just like you did mix soap and water on a spray bottle and spray it from exhaust all the way to the muffler...that’s how I found all the leaks on my Jeep I have bubbles all over the exhaust and a few on the catalytic...I’m just waiting on my exhaust manifold to install it, I guess might have to do some grinding too..but thanks for the video.

@CarbonsDIYGarage 3 жыл бұрын

@mydrums4evr Thanks for watching and the comment! You're totally right. I mentioned it around 28:45 in this video but was pretty wiped when I got to this point in recording. I should have taken video of it but without all that vacuum air going out the manifold, the "after" test had enough pressure for one of the panels on the muffler to actually start flapping. (sigh) I plan to just replace the whole exhaust. Down and exhaust pipes look like crap and probably leak. I'm sure the cat is bad or near death, too. More video fodder, for sure. If you haven't seen it - check out my soap and bubbles video on the old exhaust manifold for a laugh: kzfaq.info/get/bejne/fZ1doqdjp7LQj4k.html

@ryanbird5142 Жыл бұрын

So here's a question. Do you think using a gasket sealer of some kind might help seating the intake manifold? I'm not getting the high revs, but there is still an obvious leak at the intake, because when i spray gum cutter the engine sputters at the top of the manifold. I hate to take cast iron and grind on it given its hard nature and brittleness. I'm fairly certain they make gasket sealant that would fit the bill in this application and make my life easier rather than grind, take off reseat, test only to find out i still have a leak. I'm assuming the biggest risk is sealant getting into the valve somehow.

@CarbonsDIYGarage Жыл бұрын

Hmmm… Well, first I’ll reference the disclaimer in the video description (I’m not a professional). In my research on the job/topic, I can’t recall anyone using a sealant material in addition to replacing the gasket. It would have to stand up to some pretty high heat. The replacement gasket itself should do the same thing in sealing any minor divots or imperfections. I guess maybe I’d try a high quality gasket before a sealant and see if that does the trick. I can’t say directly that a sealant will do harm, though, since I just don’t know. Maybe others will comment with different/better thoughts. Thanks for watching, Ryan, and good luck with solving your leak.

@ryanbird5142 Жыл бұрын

@@CarbonsDIYGarage No worries. Nah i know we arent mechanics, i may end up getting a better gasket and trying to use the current one as a sacrificial that i cut to match the intake holes only. At least then it will be material designed for that use case instead of something thats likely just going to disintegrate and make its way into the sealed system.

@ryanbird5142 Жыл бұрын

Ironically a quick search shows thats actually a fairly common method for replacement when folks put on custom headers - so little chance of breaking anything

@CarbonsDIYGarage Жыл бұрын

@@ryanbird5142 Interesting. I never thought to search along those lines but makes sense now. I’d be interested to know which route you choose and how it goes.

@ryanbird5142 Жыл бұрын

@@CarbonsDIYGarage Im off to grab a second gasket, ill let you know how that goes

@matthewkunze503 Жыл бұрын

why did your jeep not need the heat shield?

@CarbonsDIYGarage Жыл бұрын

A couple of reasons. First, the original manifold didn't have one. Second, it's pretty much impossible to install the manifold with the heat shield in place. It's been 22 months since I installed it and have had zero issues.

@matthewkunze503 Жыл бұрын

@@CarbonsDIYGarage Thank you! Doing this on my YJ soon

@CarbonsDIYGarage Жыл бұрын

@@matthewkunze503 Good luck!

@SeriouslyAwesome Жыл бұрын

the heat shield is pointless and makes it a nightmare to put on. If it comes loose then it will rattle like you have some serious problems. It also makes it harder to find cracks if you get one. As Carbon mentioned, there wasn't one on the OEM