TJ 4.0 engine removal

[matkal]

I'm in the process of removing the engine from my '04 TJ with auto trans and I was wondering if it's easier to remove the downtube(Y pipe?) from the manifold (Edit: Should I remove the intake and exhaust manifolds regardless? ) or unbolt the intake and exhaust manifolds from the head to pull the engine, leaving the manifolds attatched to the downpipe? I tried removing one of the exhaust flange bolts and didn't have any success but admittedly I didn't try all that hard as it was the last "let's take one more thing off" at the end of the day. Any other tips? One good thing, one of the PO's used regular bolts, not reverse torx, on the tranny. Also, what are the recommended mounting points for the cherry picker?

 

[pagrey]

I'd remove the exhaust from the manifold and leave the manifolds on. There is so much room on a TJ I'd pull the other stuff when the block is out. I think that's what the FSM says too. FSM also says, "attach a lifting device to the engine." Just don't use a valve cover bolt, you might have to experiment to find a pair that balance it enough for you.

 

[acct21]

Those aluminum intakes don’t like to get beat around. Would pull the intake and use intake bolts for lift points on that side.

 

[matkal]

Thank you guys for the advice. I took the intake off which gave better access to the exhaust manifold and downpipe. I decided to use an electric reciprocating wrench, aka Sawzall on the flange bolts. Three were easy but I couldn’t get to the front most bolt, which just so happens to be the easiest to get to from the bottom, so I figured out a combination of extensions and a universal (3/8 as my 1/2 impact stuff wouldn’t fit) and eventually got it with the impact. Since most of the exhhaust manifold bolts were loose I took it off as well.

Sawzall 3, impact 1