My 97 TJ 2.5 has a cracked exhaust manifold. I just removed the driverside fender to replace it and figure now is the time to change the manifold. Do I also have to remove the intake manifold to do this? I have been sptaying the bolts with PBlaster. Is there a good write up or video that you guys suggest reading to help with this job. Thanks for any help
Exhaust manifold removal
- Thread starter woody367
- Start date
As long as it is a Mopar fitment should be fine, do yourself a favor and use a Felpro full intake/exhaust gasket and most auto parts stores carry inexpensive replacement manifold hardware kits for the 4.0 which has everything you need for the 2.5 (not normally avail for the 2.5)
If it is not a Mopar manifold measure the thickness of the flange next to the shared bolt for the intake manifold to confirm the flange thickness closely matches. Many aftermarket manifolds have a casting that is to thick to get the proper seating of the shared bolts.
From what I've seen, it may be far easier to remove the fender to gain access to the area. You'd have to remove everything on the fender, but the fender itself is only held on by a few bolts
Keep in mind that you have to take your time and not rush reinstalling the intake manifold. If you rush it you're likely to have extremely high engine rpms, if not at redline, due to it leaking air from not having been seated properly.
You don't need to remov the fender itself. Removing the lining between the fram and the fender will give you access to the lower bolt near the front. There is a hole in the back of the shock tower that allows access to one of the bokts via a long extension.
After install is complete start the engine, use a spray bottle with water, spray around the intake gasket between the block and manifold, if you have any change in rpm than you have a leak. I also suggest checking torque on all the bolts after a few complete hot/cold cycles on the engine. Its not uncommon for the bolts to loosen up a little after a few cycles.
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