Changing intake manifold and exhaust manifold Gaskets

Cards89YJ · 12-05-2009, 09:07 PM

I am needing to replace my intake manifold gasket and my exhaust manifold gasket. I have the 258 I6 with the stock exhaust manifold and stock intake manifold. Can someone give me detailed instruction with illustrations/pics. I want to make sure I do this correctly. I also have the stock computer controlled Carter 2BBL Carb.

CTJeepin · 12-05-2009, 09:29 PM

I have the same setup and did this about a month ago. I had to replace my exhaust manifold so I ended up removing everything but you don't have to if you're just replacing the gaskets. Remove all bolts from the intake and exhaust manifolds. The one's underneath are tricky but a flex-socket will work...just be patient. Make sure all surfaces are clean and debris free. This process will be much easier for you if you also unbolt the exhaust flange where the manifold meets the downpipe. This will allow much more movement of the manifolds and allow you to get the gaskets in place much easier.

Once you have everything unbolted and pulled away from the head, put the silver exhaust manifold gasket on first (against the head). This will stay in place once you line it up with the two studs that stick out of the head. Then place the blue or gray intake manifold gasket over the exhaust manifold gasket. I found that there is much debate on the forum as to whether or not two gaskets overlaying each other is necessary. When I did it, I called three Jeep dealers here in CT and all three service departments confirmed that this setup is designed to use BOTH gaskets that come in the kit.

Once both gaskets are in place, line everything back up and get all of the bolts caught but not tightened. To avoid leaks, it's very important to follow the bolt and torque pattern for this manifold. Just do a search on the forum and you'll find the diagram. I ended up replacing the studs on the far right and far left of the manifold because the nut was fused to the stud and it came out in one piece. They were dirt cheap and I got them from NAPA. Sorry that I don't have any pics but this should do the trick. Good luck.

**4.7stroker** · 12-05-2009, 11:22 PM

The felpro gasket I used only had one gasket that functioned as both the intake and exhaust gasket.

Dwayne

SteveJcoYJ · 12-05-2009, 11:45 PM

Quote:

Originally Posted by 4.7stroker

The felpro gasket I used only had one gasket that functioned as both the intake and exhaust gasket.

Dwayne

thats what i've always seen

ugmo · 12-06-2009, 12:31 PM

If you plan on wrenching the jeep and keeping it for some time, then you need a shop manual even if it is a basic one like chilton or haynes from a parts store .

**firefighter315** · 12-07-2009, 12:37 PM

I had to change the gasket on my '94 2.5L due to a broken stud near the fire wall. I also used the Feldpro single gasket that covered both the manifold and intake. Just be sure to follow the torque sequence exactly. I made it through with both a Chilton's and Haynes, but have since gotten a FSM and there is no comparison...

**jbolty** · 12-07-2009, 12:53 PM

the haynes book I have covers a bunch of years and has the wrong picture for the manifold. Here's the one for the 4.2

GreggVA · 10-05-2010, 06:51 PM

Quote:

Originally Posted by jbolty

the haynes book I have covers a bunch of years and has the wrong picture for the manifold. Here's the one for the 4.2

I can't find the torque specs for the intake manual. Do you have the correct one for the intake as well? Like you said, silly Haynes manual does not have the correct diagram in it.

Douglas S. · 10-05-2010, 07:07 PM

Quote:

Originally Posted by GreggVA

I can't find the torque specs for the intake manual. Do you have the correct one for the intake as well? Like you said, silly Haynes manual does not have the correct diagram in it.

That picture includes the intake.

wrongler87 · 10-05-2010, 08:12 PM

glad i found this, im doing mine this weekend....

GreggVA · 10-06-2010, 07:24 AM

Quote:

Originally Posted by Douglas S.

That picture includes the intake.

Sorry, maybe I was not clear. The picture shows the intake manifold but the sequence (#9) does not list the torque for the intake manifold. I am looking for the torque specifications for the intake manifold.

**jbolty** · 10-06-2010, 07:49 AM

Quote:

Originally Posted by GreggVA

Sorry, maybe I was not clear. The picture shows the intake manifold but the sequence (#9) does not list the torque for the intake manifold. I am looking for the torque specifications for the intake manifold.

the intake and the exhuast manifolds are held on with the same bolts. Or are we missing something?

Tompatt · 10-06-2010, 12:28 PM

read through this if it isnt on that post?

http://www.jeepforum.com/forum/f12/yj-torque-specifications-587412/

banderson25 · 10-06-2010, 12:48 PM

The intake and exhaust manifolds do share some of the same bolts but after you remove all 8 from the intake manifold there are more.

I have a cracked exhaust manifold and started the tear down part of the project last night. I only took a few pics cause my camera battery was dead when i got started and needed to charge. I will have my laptop out with me in the garage tonight posting on this thread if thats ok. I may throw in a few videos of the tricky parts.

I have chilton manual but does anyone know of an online source or intractive dvd for auto repair?

banderson25 · 10-06-2010, 12:49 PM

mine is a 89 4.2L by the way