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Unread 02-11-2013, 08:56 PM   #1
Armycherokee
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Exhaust manifold help

Ok so I have a cracked exhaust manifold haha of course. And I have a new one with new gasket and I have a couple of questions.
First off how hard is it to replace the exhaust manifold I have been spraying wd40 on all the bolts to maybe help ease them out without breaking them will this help?
Second one is will I notice any improvements in performance and gas mileage I know it's a jeep but 10 mpg kinda sucks with only a 3in lift and 31 in tall tires.
And is there anything I should watch for or be careful for while I undertake this and I have 4 days to do this job will this be enough time? I know what I need to do I just don't want to tell my wife one thing and turn out to take longer or cost more money

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Unread 02-11-2013, 09:44 PM   #2
MJR
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It's actually quite an easy job baring rusted/seized bolts or a broken stud in the back of the head. Take your time, better to take a bit more apart than short cut it and break something. Best tools a flex head long handle 3/8" ratchet, 3/8in dr 10" wobble extension (manifold bolts) , 3/8"in dr 20" extension (down pipe nuts), and universal joint with the needed socket. Just take out the air filter box and aux fan for extra room.

http://www.sears.com/craftsman-20-in...4&blockType=G4
http://www.sears.com/4-pc-wobble-ext...p-00944284000P
http://www.sears.com/craftsman-3-8-i...p-00944815000P
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Unread 02-12-2013, 11:18 AM   #3
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I found that it has been easier to cut the bolts on the lower collector joint than to try and get them off. Only done 2 of these, but both times saw an increase in MPG. Not great, but I went from 8 to 14.
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Unread 02-12-2013, 11:37 AM   #4
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Well, 10mpg is definitely not what you should be getting, unless you are crazy heavy on the go-pedal. IMHO, unless the "crack" is more of a big break, that would be unlikely to explain all of your MPG issues.

I have not done the manifold yet, but it is on my list and so I've read a lot of writeups on it. What I'd planned to do, and you might want to do, too, is a "dry run." Print out your favorite writeup (yes, read a BUNCH first), take your tools, go out there and more or less pretend you are doing the job without actually doing it. Check to make sure you can manipulate all necessary things with the tools you have. Chances are you'll discover something you need to get - anywhere from a coat hanger to hold a part out of the way, to a specific type of wrench. If you don't understand how to perform a step once you are looking at the vehicle, this gives you time to get on here and ask somebody about it. All of this done ahead of time will do two things: Give you a better idea of just how big a job it is to YOU, and speed it up when you actually start it.

An as for the original question on bolt removal, I'm gonna suggest this:
-- Soak the bolts/etc with PB Blaster for days ahead of time, spraying every day or even 2x a day. WD40 isnt nearly as good as PBB.
-- Get a pocket torch or flex-head torch to heat stuck bolts with. You do not want to break off a bolt in your block. Of course, you don't want to set your wiring or hoses on fire either, so use carefully. Patience, PBB, and heat will get nearly any bolt moving without breaking.
-- Don't use an impact gun, even if you can get it to the bolt - see above about patience & breaking bolts.

IIRC, there's a really good writeup on this over at NAXJA.
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Unread 02-12-2013, 05:32 PM   #5
Armycherokee
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Thank you for your answers it is cracked so bad on cold mornings it sounds as if it has a miss fire but after driving for a few mins it will smooth out so I'm guessing that the manifold is getting warm and expands to fill some of the cracks
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Unread 02-14-2013, 08:35 AM   #6
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Sound like it.
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Unread 02-14-2013, 10:30 PM   #7
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make certain you get on the alignment dowels. I ended up setting the manifold on top of the dowel not in the hole and caught my jeep on fire on startup. other than that its not too hard of a job.. Have fire extinguisher handy BEFORE startup.
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Unread 02-15-2013, 08:59 AM   #8
MJR
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make certain you get on the alignment dowels. I ended up setting the manifold on top of the dowel not in the hole and caught my jeep on fire on startup. other than that its not too hard of a job.. Have fire extinguisher handy BEFORE startup.
Ouch! Not only that but I've seen people not have it on the dowels and tighten the bolts down breaking a chunk off the intake manifold.
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Unread 02-15-2013, 01:14 PM   #9
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Originally Posted by MJR View Post
Ouch! Not only that but I've seen people not have it on the dowels and tighten the bolts down breaking a chunk off the intake manifold.
X2

I take a round file to the opening in the manifold for the dowels.
This gives you more wiggle room and less chances of hanging up on the dowel and crackingthe manifold.
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Unread 02-15-2013, 01:40 PM   #10
buildin1XJ
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Forget the WD-40 it is not a penetrating oil go get a can of PB Blaster. WD 40 was actually designed for the Navy as a water dispersant hence the WD and 40 being the 40th attempt of its design. While it may have some lubricating properties. Most of the manifold bolts I have removed were actually not very tight with the exception of the 2 down pipe bolts.
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Unread 02-16-2013, 05:23 PM   #11
Armycherokee
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Well In about a hour and a half I was able to get my exhaust manifold out and well I now know why it was so bad

image-3041963895.jpg



image-3001262441.jpg
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Unread 02-16-2013, 07:46 PM   #12
Armycherokee
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image-3940752619.jpg

Here it is with everything out

image-1399671759.jpg

Here's a better pic of the old cracked manifold and here's another

image-4239631791.jpg
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Unread 02-17-2013, 12:29 PM   #13
Armycherokee
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I need some help ASAP I can't get my power steering pump and bracket on if I put both bolts into the water pump I can't get the top bolt in on the intake. I have been trying with the bracket for the pump on top on the bracket to hold the pump but it isn't working. Any advice would be great
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Unread 02-17-2013, 04:46 PM   #14
MJR
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Originally Posted by Armycherokee View Post
I need some help ASAP I can't get my power steering pump and bracket on if I put both bolts into the water pump I can't get the top bolt in on the intake. I have been trying with the bracket for the pump on top on the bracket to hold the pump but it isn't working. Any advice would be great
Did you take the intake manifold off before this started happening? Reason i ask is what if the intake isn't installed on the locating dowels to the cylinder head. It would be angled upward and the bracket wouldn't line up. Usually best to take the pump off the bracket before remounting the bracket.
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Unread 02-17-2013, 08:47 PM   #15
Armycherokee
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It is on the dowels but not much I used a punch to see if the intake manifold was on them it was and I have all the bolts in but it doesn't seem like it mattered so I need to take all it all apart and try again any tricks on how to get the intake manifold all the way on the dowel pins?
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