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Unread 01-17-2008, 08:44 AM   #1
moerod
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2002 TJ Wrangler 
 
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Cracked Intake Manifold Causing Squeal?

So here we go. I'm $450 into this squeal and i just found out that i have a crack in the intake manifold and the sound is coming from directly beneath it along the front. Mechanic is quoting me about $1000 to replace the manifold.

What sucks is that what i spent $450 dollars on other things i could have done myself for about $150. Replace the belt, tensioner, pullley, and clean and replace gasket at throttle body (all things that the mechanic did trying to find the squeal, after doing all this he finally uses his mechanic stethescope and hears the noise directly below the crack in the manifold.)

this is the post i originally had for the squeal

http://www.jeepforum.com/forum/f9/high-pitched-squeal-engine-504848/

how hard of a job is this, could i do it myself with some mechanical knowledge and expirience.

Where can i get the manifold for cheap

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Unread 01-17-2008, 08:47 AM   #2
bigj1974
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1000 is WAY too much for a manifold. find another mechanic.

try the one at the top left of the page. a few here seem to have it and it work for them.
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Unread 01-17-2008, 08:59 AM   #3
moerod
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Quote:
Originally Posted by bigj1974
1000 is WAY too much for a manifold. find another mechanic.

try the one at the top left of the page. a few here seem to have it and it work for them.

thats with parts and labor. i can't seem to find the intake manifold anywhere, just the exhaust manifold
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Unread 01-17-2008, 09:46 AM   #4
bigj1974
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sorry, we usually talk exhaust manifolds, here, and just glossed over "intake".

I think I need to take a remedial reading course....
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Unread 01-17-2008, 09:51 AM   #5
moerod
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Help, Anyone Ever Have To Replace Thier Intake Manifold, Can't Find One Anywhere Online. How Hard Is It To Replace If You Have.
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Unread 01-17-2008, 10:04 AM   #6
Jerky bump
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Don't be intimidated if you are handy, have an array of good tools and a whole weekend. Read a good manual and decide for yourself if you can handle it. I did one before (I forget what motor) biggest worry is getting the whole thing flat-(it may require machining) and being able to hold the thing in the air- it's best to have a shop crane to help.
Have you tried a recycler for one? Sometimes you can grab the whole thing-swap them out.
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Unread 01-17-2008, 10:26 AM   #7
jeepmudgirl
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hmm...i wonder if mine is cracked then. i have the same issue of the high pitched whistling. i changed the gasket in my tb and that did nothing. my mechanic said it was probably the gasket in from my intake manifold. i have not had mine replaced yet....don't have the cash for it yet.
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Unread 01-17-2008, 10:40 AM   #8
tj120
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thats nuts! i could probably change your whole engine for $1000. to bad my garage is way over in western pa. if he has to use a scope to hear it how can he see the crack. is it obvious or just guessing? maybe its just the gasket. that intake is easy to change, all the wire conections are shaped different so you cant put them back wrong and theres only 4 vacume lines that i see. thats good money for about 2 hours work for a good mechanic!
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Unread 01-17-2008, 10:43 AM   #9
tj120
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i forgot to mention that this could be checked in about 2 min with a vacume gage. if its running the correct amount of vacume then theres no leak. these run about 20 or $30 at a parts store. if you wanna try that let me know and ill explain it better its very easy.
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Unread 01-17-2008, 10:45 AM   #10
wazilian
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i can't help you find a replacement intake manifold, but here is a link to replace the exhaust manifold. in this write-up you have to take off the intake manifold to do the exhaust manifold. i did this for the exhaust back in july, and i had no problems, and i'm an idiot so you should have no problem. like what was just said, take your time and have a whole weekend if you need to.

http://dailydriventj.com/mfr.shtml

btw, put a bit of oil on those o-rings if you do take the fuel rail off, putting those fuel injectors back in will be easier if those o-rings have some lube.


Travis
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And there's a frame under there too...I've seen it
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Unread 01-17-2008, 10:49 AM   #11
wazilian
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tj120,

i would be interested in hearing what you have to say on that vacuum gauge and where i may be able to pick one up. i am always looking for ways to find vacuum leaks easier.


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And there's a frame under there too...I've seen it
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Unread 01-17-2008, 11:22 AM   #12
Heyduke
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Instead of buying a new manifold, or finding one at a junkyard. Take yours to a machine shop and have it fixed. Then all you'll need is a gasket set, the time to do it and money for the machine work. A good shop would charge you maybe a hundred bucks to weld and machine your cracked manifold. A haines manual will give you the info for removing and replacing an intake. You can do it.....
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Unread 01-17-2008, 11:43 AM   #13
moerod
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so if i take it out and have it welded and machined what excatly does machining the manifold mean. i seen that coment several times.
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Unread 01-17-2008, 11:50 AM   #14
Heyduke
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They will grind a notch along the crack, a V if you will. Lay a bead, or beads of weld into the crack, effectively closing the crack. Afterwards they will have to take any weld off that doesn't need to be there. Flattening the sealing surfaces and making your manifold brandy new. You would be the only one that knows you had a welded manifold.
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Unread 01-17-2008, 11:58 AM   #15
Jerky bump
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Quote:
Originally Posted by moerod
so if i take it out and have it welded and machined what excatly does machining the manifold mean. i seen that coment several times.
If you get a replacement intake manifold only, it may have to be "matched" to the exhaust manifold. The mounting surface has to be flat where it bolts up to the head-or it may crack when you tighten it on. Cast iron cracks really easy. If you do the job yourself a good straightedge and feeler gauges will tell you if it's close enough.
The "pair" have to align also (port wise). If you have to pry parts into alignment, you may get lucky- but you can expect trouble later. It's not a good place for a "close enough" attitude. That's why I suggested gettting a swap out. Anyway,take your time and make sure it's right.
Some people may try to tell you you have to have the head machined also-this probably was never necessary on any engine getting new manifolds. At least never on any I ever worked on.
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