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My exhaust manifold has cracked on my 1998 jeep wrangler (2.5L 4 cyl.). It is cracked about 1-2 inches above the exhaust pipe connection under the heat shield. I cannot find anywhere there is a bind in the exhaust system and all the bolts are torqued to spec. The manifold is fairly new (l3ss than 6 mths) any suggestions why it would crack?

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Check your local junk yards can do nothing but replace

Posted on Jan 28, 2011

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How to replace exhaust donut on 99 wrangler


This is pretty straight forward, you need to locate the exhaust manifold and follow it down to where it connect to the exhaust pipe, there three bolts on the joint and you take those out. Then see if you can separate the pipe from the manifold. If you cannot separate them then you need to get under the jeep and loosen the holders for the exhaust pipe. When you can separate the joint, take the old doughnut out and put in the new one. Make sure that you get it tight and that you tighten the bolts evenly. Don't over tighten one side.

Feb 18, 2015 | 1999 Jeep Wrangler

1 Answer

I need to replace the exhaust manifold on a 1995 Jeep Wrangler with a 4.0L HO engine. What are the torque specs for the bolts and is there a specific pattern?


Don't have a sendable diagram so here it is in words: Beginning with the bottom row, tighten the center bolt to the right of cylinder #4, then the one just to the left of cyl #3. Then the one directly above at the center of both. Continue by tightening the bolt to the left of cyl#2, then to the right of cyl#5 then the one to the front, left of cyl #1, then the remaining lower bolt to the right of cyl#6. Move to the top row, tightening the ont to the right of cyl #2, then the front, above cyl #1, then the rear ones, above cyl #5, then the far back one above cyl 6. Torque is supposed to be 24 foot lbs except bolts 6 and 7 but I've found it makes no difference. What I've found to be important though is to re check torque after running it up to operating temp and permitting it to completely cool down. Also, never tear it down while it's still hot. That promotes warping.

May 03, 2011 | Jeep Wrangler Cars & Trucks

1 Answer

My jeep is making a really loud sound like an exhaust leak it's coming from the front end of the engine can anyone help


I would have the exhaust manifold inspected, a lot of times it cracks where the pipes connect. I am assuming you have a 4.0L. Then you would just need to change the manifold to fix the problem.
Thank you,
Lee

Feb 13, 2011 | 1992 Jeep Wrangler

1 Answer

My 1999 Jeep Wrangler keeps cracking the exhaust manifold. Is there a fix ?


The best fix is to install the two piece OEM manifold from the later model (2000's) wranglers. There are also manifolds with accordian type flex joints for sale on line that will last MUCH longer than the one piece OEM manifolds.

Oct 22, 2010 | 1999 Jeep Wrangler

1 Answer

Oxygen sensor bank 1 how do i fix it


That engine is a straight six cylinder so follow the exhaust pipe from the engine exhaust manifold to the first sensor you see threaded into that pipe, that would be the bank 1 sensor 1 O2 sensor.

Tell us news.

Jul 09, 2010 | 1997 Jeep Wrangler

2 Answers

How to replace exhaust manifold gasket 1989 jeep wrangler 4.2


I also have an '89 Wrangler with a 4.2 liter inline six. I'm afraid that the spark plugs aren't on the same side as the manifolds. Mine is being a pain in the *** for me. The intake is lining up fine but the exhaust is off by about 1/4 of an inch in the way of a bolt. Was hoping for some solutions, left disappointed.

Apr 26, 2010 | 1989 Jeep Wrangler

1 Answer

2003 oil pan removal


4.0L Engine To Remove:
  1. Disconnect negative battery cable.
  2. Lift the vehicle.
  3. Drain the engine oil.
  4. Remove or disconnect the following:
    • Exhaust pipe from exhaust manifold.
    • Exhaust hanger at the catalytic converter and lower the pipe.
    • Starter motor.
    • Flywheel/torque converter housing access cover.
    • Oil level sensor (if equipped).
  5. Place a pole jack under vibration dampener with a piece of wood between dampener and jack.
  6. Remove or disconnect the following:
    • Engine mount through bolts and raise engine for clearance to remove pan.
    • Transmission cooler lines (if equipped).
    • Oxygen sensor harness from oil pan mounting studs.
    • Oil pan bolts and studs.
    • Oil pan and gasket.
To Install:
  1. Clean the gasket mating surfaces.
  2. Apply Mopar® Silicone Adhesive Sealant or equivalent onto the cylinder block in four location as shown.
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  1. Attach the pan gasket to the oil pan with Hi-tack or equivalent (2003-2005 vheicles).
  2. Use 1 ½ x ¼ inch bolts to fabricate alignment dowels. Cut off the head of the bolts and cut a slot into the top of the dowels (2006 vehicles).
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  1. Install two dowels into the timing case cover (2006 vehicles).
  2. Install two dowels into the cylinder block (2006 vehicles).
  3. Place the gasket over the dowels and onto the cylinder block and timing case cover (2006 vehicles).
  4. Position the oil pan.
  5. Install the 1/4 inch oil pan bolts. Tighten to 84 in-lb (9.5 Nm).
  6. Install the 5/16 inch oil pan bolts. Tighten to 132 in-lb (15 Nm).
  7. Remove the dowels.
  8. Install the remaining 1/4 inch oil pan bolts. Tighten to 84 in-lb (9.5 Nm) (2006 vehicles).
  9. Lower the engine onto the engine mounts.
  10. Install the through bolts and tighten the nuts.
  11. Remove jack stand and remove the piece of wood.
  12. Install the flywheel and torque converter access cover.
  13. Install starter motor.
  14. Connect the exhaust pipe to the hanger and to exhaust manifold.
  15. Install the transmission oil cooling lines (if equipped).
  16. Install the oxygen sensor wiring supports to the oil pan mounting studs.
  17. Install the drain plug into the oil pan. Tighten to 25 ft-lb (34 Nm).
  18. Lower the vehicle.
  19. Connect negative battery cable.
  20. Fill the oil pan with oil. WARNING
    Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing.
  21. Start the engine and inspect for leaks.

Jun 06, 2009 | 2003 Jeep Wrangler

1 Answer

1998 Jeep Wrangler 2.5 liter motor timing specs?


you could have vacumm problems making it seem like the timing is off, but the other guys are right on the timing!!!! it could be throw-body problems, like crack manifold problems. This year has thhis type of problem sometime. Try spraying WD-40 around the vacuum hoses, & manifold to see if the motor changes rpm????

Feb 09, 2009 | 1998 Jeep Wrangler

1 Answer

Jeep engine swap 2000>1997 4.0


engine controls are likely different... Make sure that you retain all old stuff and know where it hooks up. It's easier to change any different sensors etc before you install into vehicle. make sure that accessories on front of engine are the same, and that exhaust exit on pipe is located in the same place. Exhaust manifolds like to crack where pipes are joined together. make sure they are OK before using manifold. Base engine assembly is identical so there shouldn't be any major problems. If new engine has over 150k on it, you may want to change timing chain before using it. (its not mandatory, but you would be surpriseed how many engines, I've seen with fairly worn out chains at that mileage)
Good Luck

Jan 11, 2009 | 2000 Jeep Wrangler

3 Answers

Exhaust Manifold


Not familar with the jeeps, does the EGR tube run into the mainfold its self?

Oct 22, 2008 | 1997 Jeep Tj

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