Tech tip for jeep inline 4.0, 2.5 manifold replacement
The removal and replacement of the exhaust manifold or gasket could be a little less frustrating if you follow this easy tip. Getting your arms and especially the bolts in the bottom positions of the manifold is especially difficult sometimes. This little technique will help make this step and the overall experience a little less frustrating.
After you have removed the old manifolds and cleaned the surface properly install the gasket (4.0 only). Next install the exhaust manifold with the two end nuts on the studs and the top middle bolt and torque to specs. Don’t forget to attach the pipe to the manifold at this time as it is a little easier to do this from the top than it is to lay on the ground in who knows what. If you have a 2.5 now install the intake gasket. Next you can install the lower manifold studs in the lower rear positions with the washers. Only turn them in ¾ or 1 turn and pull the washers towards the head of the bolts. Now angle the intake into position past the washers and onto the alignment pins. Make sure the you get the intake manifold to sit flush on the head and positioned on the alignment pins before tightening any bolts.
This trick will alleviate the step of getting the bolts started in the hardest areas to reach allowing you to only have to get the socket to slide on the preinstalled bolts. Hope this tip help make your next experience a non wrench throwing one.
