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

[@CarbonsDIYGarage]

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

[@Kav705]

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

[@CarbonsDIYGarage]

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.

[@RobertRenaud-r8g]

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]

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

[@SeriouslyAwesome]

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]

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]

@@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.

[@tpledger100]

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]

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

[@waden404]

Great videos sir. Thank u for this.

[@mydrums4evr]

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]

@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: kzbin.info/www/bejne/fWiQoHdod7Gflbc

[@terrencelawrence5007]

Thank you

[@CarbonsDIYGarage]

Thanks for watching, Terrence.

[@ryanbird5142]

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]

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]

@@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]

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]

@@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]

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

[@matthewkunze503]

why did your jeep not need the heat shield?

[@CarbonsDIYGarage]

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]

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

[@CarbonsDIYGarage]

@@matthewkunze503 Good luck!

[@SeriouslyAwesome]

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