Part 1: Parts Cannon!! Can it be saved? 95 Jeep Wrangler 4.0
Part 2: Frustrating Diagnosis! It LIVES AGAIN! Jeep Wrangler 4.0
Part 3: Old Jeeps Die HARD! Thermostatic Switch and Water Pump! 95 Wrangler 4.0
Part 4: Razor Sharp Gears!! NOT Good! Project Jeep 1995 Wrangler 4.0
Part 5: Smallest Shaft Ever! FRIED Flywheel! | Project JEEP! 1995 Wrangler YJ
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Customer States: Engine barely runs and has a severe lack of power. It also has the occasional no start or long cranking before it starts. So far I've found vacuum leaks, clogged ports, antifreeze leaks from the water pump and the electric fan is damaged. I had the fuel pump, filter, spark plugs, ignition wires, and a distributor cap and rotor. It also has a new coolant temp sensor, O2 sensor, MAP, intake temp, IAC and throttle position sensor replaced. The ECM / PCM has been replaced too. See part one.
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Hello everybody! Good day to you! Welcome back! It is after hours, it's dark outside, it's a little late, and I'm gonna get a little bit of Headway done on uh project cheat last episode we put the trans back in, got the clutch installed, but we have no exhaust and if you remember from earlier, we have a huge exhaust leak going on right up around that uh manifold or something like that. So what we're going to do is we're gonna let this thing down. We're gonna pull the intake manifold and the exhaust manifold off because they share ports on this same side of the cylinder head. They're both bolted onto the left side, not one on one side, one on the other side.

I Think that was actually the demise of the four liter straight six. Anyway, I Digress: Let's go ahead and let this thing down and we're gonna re-pop an easy Jeep hood and go ahead and start pulling those manifolds off because we have a surprise in a box. so stay tuned. This is going to be a very good video opening.

Z Hood Sitting pretty low now. this should be easy to work on. Hopping in the Jeep Hood these are decorative and they block the way of the hood. Release must be removed.

It's a Jeep thing. Okay, so here's what we're doing here: Intake Plumbing Coming off Everything connected to this intake manifold is coming off. wiring, harnesses, fuel lines, you name it. Etc We're gonna pull the bolts out here.

Here here, here, here, here here and here. and another set along the bottom. and then this intake comes out and then that exhaust manifold comes out. No doubt this thing is a Do or Die situation.

Either we're gonna do it all or it's gonna die and it looks like we're doing it all. So we are. We're saving. We're saving this.

Jeep Okay, let's pull that guy off too. You know what? I Don't even think I have to remove that little one there. You just you just go over there and hang out. We'll get you later.

Let's go ahead and lose this throttle cable first. we'll start with mechanical connections and then we'll uh, we'll move on to electrical connections. Come off, slide this thing out of here and just set that aside. You can just lay it right back over there.

pull the vacuum line for the brake booster. So hanging down, we've got the O2 sensor from the exhaust. I Removed that when the trans came out. So let's just start right here and start disconnecting this harness that's going to include our fuel injectors because the harness is going to come up from the studs.

I Have the valve cover bolt to hold it on. That one's stuck. Pretty good. Let's get that guy disconnected trying to get under it with a pry driver.

We're going to work it up off of the stud that it's on. There comes one on the back, one in the middle, and then the one in the front. Those are the mounts phone. Jeep I know you've been off there before.

It's got a blue valve cover gasket so I know it's good. Come on, this is embarrassing. I Can't get the wiring harness to come up there. We go.
Let's see what. we got. one injector back in there. Let's get you out of there.

So that's three injectors, four injectors, and five injectors. Last one, there's a map sensor connector and there's one more. what is that back there? I Think that's the temp probe for the ECM Let's disconnect that too. I Don't know what that is.

Do you guys know Jeep people, what is that thing back there? Yeah, there's a Idol air control motor I'm gonna click that throttle position, intake temp right here and that's for the downstream. Oh no no no no, it's Downstream and that's for the crankshaft position sensor. very high. uh failure part that will cause a no crank on your Jeep backing line now.

I can just take this wiring harness and lay it off to the side. I'll bungee it if necessary. You stay over there. We don't need you right now.

Okay, down on the front of the manifold, there's uh, some fuel lines. Those are fuel lines. Yeah, and then a little bracket that holds those on. I'm just going to pull that bracket off the manifold, leave the fuel lines where they are unpicked.

It will just disconnect the lines up here at the fuel rail. Easy to do. Push it in, push that little clip back. That's gonna release the clip inside of the of the line there and it should just come right off.

Can't get a good bite on that one. Stop it. Jeep Hmm, there's one number two. We'll just set those aside All right.

Now's the Moment of Truth where we find out if we're gonna remove these bolts or if they're gonna break off. I'm hoping that they just, uh, they come out nicely. Let's find out that's tight. You're getting a lot of flex out of this extension.

Did it turned? Yep. Okay, yeah. I'm not gonna hit these with power tools. at least not to break them loose if it's gonna break I Want to feel it? Yeah, these are the easy ones.

These are the ones we can see. There's a several of them underneath of the intake. Those are going to be hard to get on. Clicks all right.

That one turned. It's good. I'll do that one by hand and just reach in there and take it off my fingers at the end. That's going to come out just fine.

Dude, you know it's occurring to me that even when I get this nut off, I'm gonna have to slide this manifold out all the way to here. and I don't think it's going to clear this bracket for this power steering pump. so I'm gonna have to take this off, uh for a second time. I already had it removed once when I did the water pump, but uh I did not realize I was going to be pulling this intake off and this exhaust.

So there's going to be a duplication of my efforts. Here is what it is. Okay, there's the nut. There's our washer.

We don't lose these. They're not a flat washer. They're uh, like a concave or a convex type of washer. all right down.

Looking under the intake, there's should be another bolt right? I think that's it right there. Yeah, there's one. Let's see if that one's gonna come out. It's covered in dirt, feels like but I'll feel it.
Okay I gotta purchase on it with my socket here. Let's see if she's gonna come loose. Yes, yeah, yeah, she's coming out. It's good.

foreign here. it comes. Okay, there's another one. There's three down.

Okay, so there's there's a couple at the bottom that are in the middle right here that I couldn't even reach from up top. So we're gonna raise this up later and I'll try to get to them from the bottom. So I moved on to the okay next one that I could get my hands on. Looks like that one came loose and switch out two power tools to expedite the process.

That one should be out there. it is. Uh, stayed in my Fastener There we go. Let's get that next one.

I left the top ones in because it's going to be hard to, uh, get to all the bottom bolts. so I don't want the weight being distributed onto those bottom. Fasteners I think that's all I can get from here I don't want all the weight to be distributed onto the bottom passengers while we're trying to work them loose. so I left a couple of the toppings in I Think we'll leave this one in and that one there I'll go ahead and pull this one out next because that's easy to get to.

That one's kind of rusty. it's coming out. Can I reach that one while I'm doing this? Sure. I'm on the very back fastener I got the washer I didn't get the bolt there.

All right. Let's lift this up and uh, let's go to work on those bottom bolts and then we'll come back up here, pull the remaining top bolts out and then the intake and the exhaust should come off simultaneously. all right back up in the air. Let me see if we can't see that bolt look way way back there.

that's the that's the menacing one. I can't get to it from the outside because there's a there's pipes in the way. So I gotta go in from up front here and try to get this with a rationing wrench. All right, let's uh, let's see if I can get in there on this.

I'm gonna try it or I'm gonna try to reach from the back I can see a little better and I need to press on it. Hang on let me get in there if I reach around the exhaust I can get two hands on on the tool and everything I think I got a bite. Yeah, that's a good purchase. Okay, yeah, it's gonna come out.

You can kind of work it by hand. now it's coming out by hand. sorry if my hand is in your way, but I got it there. It is one and there's another one.

y'all can't even see that one. It's like way behind it. Let me pull that one out and then we'll go back up top. stand by dirt.

Yeah now you can see that little bugger. It's uh, it's buried. Oh branch is slipping I can see it dirt. it's gross Jeep dirt.

oh that one wants to slip off. can't have that and I can't send it because if I slip it, it's over. I'm just gonna rock this on the wiggle. a wrench and see if it doesn't uh, get a better purchase there.
We go here. That little snap that was the uh, the bolt Breaking Free I'm stuck. come off wrench. Pry bar.

Well, more like a Pride driver. kind of a screwdriver, but kind of a pry bar. It's actually a door trim tool for removing panel clips. Worked on the wiring harness connectors too.

and uh, ratcheting wrenches. There's a there's our Bolt okay looking right and up a little bit. That's our final bolt on the bottom here. see right there.

I Could have gotten this one when I had the trans out, but then you guys wouldn't see. Come on nut. Oh I slipped. Good.

That means it's more inclined to slip next time around. Uh-huh Yeah, that's gonna work. Oh man, it's stuck now. I Hammered it on and got it nice and stuck.

Oh well. at least it's uh, it's broken loose and after this and I will win. No seriously, we're done. I'm off.

Thank you joke. Over all right real quick. Oh, it's kind of tight. it's a that's a little rougher than the others were.

oh well. got it. and one more nut and uh, and it's a little washer thing. Okay, that's all the bolts for the bottom.

Go ahead and get out of here and let this down and get the remaining upper bolts and uh, and that power steering pump and bracket again coming down Jeep all the way down. So to where we were was on this side of this manifold but on the bottom side. so we have all the bolts on the bottom removed. Now we just have one there one there and potentially and probably this, uh, power steering pump bracket.

We do have to get this one because this one is bolted into that manifold. See that I Forgot about that one. Oh, and there's another one. Okay, yeah, pump has to come back off.

You know we're uh. we're just gonna go ahead and skip this part because, uh, you guys saw it a couple weeks ago. So we're just gonna move on through this rather quickly. Like, All right, I Think it's almost all the way off.

we've got I think one more. Bolt Let's get this pump all the way off of here. This this is the last ball holding it on. There's no sense in leaving it just dangling all willy-nilly like.

Pump removal nearly complete. Come on There we go. Okay, one more bolt right there and then this intake will be free. Or rather, the uh bracket will be free of the intake.

and then I can get, uh, the manifold to slide off. It's moderately obstructing the situation here. Unclick that was I launched. It might have sent it a little too hard on that one.

There we go. Hey, there's the water pump that we just replaced. You guys stay right there and don't hit the radiator please. Okay, everybody's looking good.

So far, we've got one, two more, two more bolts up top to get. okay. well. compressor.

You can't see what I'm doing now. this isn't gonna fall off. As soon as I disconnect the remaining bolts, there are some pins that, uh, foreign. There we go.
There's some pins like dowel pins similar to what the transmission had that are connecting the bottom section of this, uh, intake to the cylinder head. We just need to slide them away from or slide it off of the pins and it should come free. Should if it doesn't, we'll pry bar it. Oh there it goes.

Look at that. it is going to fall off. Okay, let me hold it. Hey I dropped my washer.

Don't go anywhere. Hang on. there's that washer. I'm gonna need that.

Okay, here comes our intake. She's coming out. Here's the manifold, not the OE It's some kind of header. Look at what else we've discovered here.

The bolts for this valve cover are are loose. That one's loose, that one's loose, and this one that one's not even in and it's loose. It's weird. it's wanting to go in sideways.

Hmm. let's go ahead and peel this gasket off of here. There's the pins that I was talking about, so that's pretty nasty. Not to Bueno don't need you, but I do need to secure these bolts wrong size.

Foreign. They don't strip. oh that one. They just had to line it up.

Clicks. We'll check the rest of them too. Yeah, that one's loose. Next, loose.

they're all loose. That one's loose loose. Let's see. how about all up, they're all loose.

Yep They're all loose. All right. You get the point. I'll finish those in a minute.

Okay, next up? we need to clean these surfaces. but I also need to protect the ports from contaminants. So stuff some towels in here and we're gonna go through with a with a cleaning wheel and polish off all this old gasket material and rust and anything else that's there that should not be there. Okay, so all the ports are plugged.

I'm gonna go grab a cleaning wheel and polish this uh, surface off real quick here. Let's uh, see how a green uh roll lock wheel does to it and if it doesn't work, we'll move on to something a little more aggressive, foreign, nice and shiny. I Think that'll do. Let's go in for its close-up Not bad.

I Don't see any gasket material left. no sealant, no rust. We're good to go. nice.

So I uh I kind of dropped the ball a little bit and I didn't even show you guys what it was that. uh we were gonna install on this. we were pricing Parts Found the OE equivalents where uh oh good. The compressor's done, it's on.

The OE equivalent was the same price as a it's this manifold so we got this chromium. it might be stainless. We got this exhaust header. shiny, very shiny.

It came with gaskets which is good. So let's go ahead and get this gasket fitted onto the head. then we'll move on in, get this header installed and then we can move our intake back in, You know, let's go ahead and clean this off a little bit. Get all the micro dirts and debris inside.
None of it's going into the intake ports because they're blocked off build up here. Foreign? Okay, make sure nothing's in here. I'm spraying from the bottom of the port. Ouch.

So if there is debris right here on the face of it, it'll blow out. Not in. If I blow it here, it'll blow in. But if I blow it from here, it will blow out next.

Oh got it. That exhaust valve is open. That exhaust valve is not last one. that intake valve is open.

All right. Let's get the gasket on. Okay, gasket coming in says right here on the axle gasket manifold side. So this is the side pointing away from the cylinder head.

Put it over the stud and there's our little pins. Voila, All right. Six into one exhaust manifold slash header coming in. Again, we'll line it up with the studs that are sticking out there.

We go all right, that's in position. So before we install that intake, I Kind of want to clean it up so it's nice and shiny. I've already hit the sealing surface with a little green wheel but this is nasty and caked and I'd like to make it clean so we're going to hit this with the brake Clean Pressure Washer: Yeah, it's gonna be fun. Check this out.

Foreign pressure washer. All right. Foreign. All right.

Coming in with the intake, let's go ahead and get this guy slid into its position and then we can, uh, start to uh, get a couple bolts installed in this thing. ah, losing fuel. Yeah, the only thing that aligns it are those two uh, dowel pins which I'm having a hard time aligning here. It's gotta wiggle it around until it goes in it.

It'll go better. Please, please go in. I Can't even see negative. Hmm.

Are you gonna fit? What is this all right? Yeah. I've got one. Okay, the front one's in. so let's go ahead and get uh one of these bolts on that'll hold that front side on its pin and then I can reach back and try to line up that back side.

Come on, come on, come on. day. a couple more turns just to seal the deal here. that's good in the back pin.

That one's aligned good since that back one's in it created some more space in this front bolt that I just installed so we'll just oh, it came out. so I'll just crank this one down a little bit harder. Stay: You're making a liar out of me. No, I'm not gonna do that.

Yeah, it said yeah, we are gonna do that. Okay, hang on. let's uh. let's try this again.

that goes there and then I'll put this bolt in that should, uh, should, hold it. Come on thread, please hurry up. I'm getting some muscle fatigue. Okay, that's in.

Let's tighten that down some just to make sure that it's aligned with that alignment dowel. Yeah, no, it's not. It's not aligned. I can see down the Gap right here.

it's at an angle. It's not aligned at all. Let's try this again. I Just took the front one loose.

There it is. Now it's oh. it came out again. Come on, stop it.
Something tells me I'm doing this wrong. Hang on we're gonna stop. I know I'm doing this wrong. I'm doing this the hard way.

I'm opponent is intake back out. hang on I hate to uh do my job twice. but I do love my job. Let's go ahead and take this guy back out.

I don't like What's Happening Here The Forest tells me I've made an error I need to remedy that right now. Come out and take first things first. The bolt that goes right here doesn't do anything except for hold the manifold on the exhaust manifold. It does not contact the intake manifold so I can put that in right now.

and that's going to help to align the exhaust manifold and hold it in its position. And the same thing holds true for those nuts in the rear uh and the one up in the front. So I'm just going to go ahead and tighten those all down right now too. mm-hmm How about that back one clicks I Can tighten all these up again later, but I'm gonna get them very snug for now.

This is where they all go now. this one is Dual Purpose that one's Dual, Purpose that one's Dual, Purpose, etc etc. But these ones. these are only for the exhaust, so let's tighten those down right now.

that way that exhaust isn't flopping around. Okay, let's let's try this manifold thing again. see if I get a better result. At the very least, it'll be easier later than to uh to do those bolts because I've already gotten them foreign.

stay as it falls. Yeah, that's what you call I Run it. Let's get this one in that's easy to reach. My hand is starting to hurt the right hand.

I'm holding this up almost there. did I Get it? Yeah, Got it. Okay, let's raise this up and see how it looks from the bottom. Make sure that this thing is sitting flush and then we'll put some of the bolts in for the bottom of the intake manifold.

Moving. Moving. All right. So far, so good.

All those pins are aligned and everything's coming together. The bottom of the manifold is mating well with its gasket. Three clicks. Yeah, she's going together.

This is good. Same story here. On the back side, the pin is coming into place, aligning the manifold and I'm just running these bolts down there. create the clamping.

Force Let's go back to that front one. I'm going back and forth between the front and the Rears to make sure that it seats evenly. Okay, bolts going in are always harder than bolts coming out unless they break off. So I skip past the installation of the bottom manifold bolts.

we're on our way back down. I'm gonna get the top ones uh, installed next. Okay, one more up here that I've got I think two more in the back that I need to need to put in and that will secure secure this unit. both units good and tight en up that one.

it was just finger tight earlier. Now it's uh, all the way tight. Two more. and uh, yeah.
before we get going on this subject. I I Don't agree with how they've done this either. I I Think that uh, maybe one manifold on one side and one on the other side would have been better, but that's just what the engine nerds at. Uh Chrysler Jeep Dodge Ram Everyone decided to do back in 1990.

something. actually they designed this before the 90s. but anyway. I digress: two more bolts this one back here down right there so we can slap our harness back on and we're good to go.

Oh, not exactly, there's there's a lot more work to do on this thing I don't even have my uh my differential yet I've ordered it. Kind of got myself into some trouble on that one. I'll tell you about that later. Save that for another episode of Project G Onna Yeah I can't use two hands here.

I'm holding myself up with one arm I'm on the wheel well or on the fender reaching in contact. Oh yeah. All right. Manifold quickages times two.

All right. let's sling this uh, wiring harness back in into place. We'll get it. Uh, we'll get everything reconnected again.

Pretty simple harness injectors sensors. Just plug them in one at a time, going down the line. Let's get that one in. there is number four, number five, number six.

And then there's that goofy little guy that goes in the back. that temp sensor. can't forget that I think that's the one that the ECM uses for coolant temp or a cylinder head temp. All right, that's on map sensor reconnected.

that one's important. Turn that guy back to our throttle body connectors. intake temp again. Where'd this one go? Um I lost one.

Oh yeah, yeah, that's crankshenser. Let me get that. I Remember now that crank sensor wave in the back. It won't run without that click ventilation.

Okay, and I can pull the fuel lines back up and plug those in next. Actually, no, I won't I'll save that for uh after I put this power steering bracket back on. However, I think I am going to go ahead and call it a night. uh I've still got I mean there's a decent amount of work left to doing this thing.

not too much. it's safe and secure and I can put these little odds and ends together later on. I think for uh for right now I'm gonna go ahead and close it out like I said it's getting late there. So that being said, as always, like fake you for watching this video.

Hope you enjoyed this video. If you did, please feel free to let me know about that by tapping that like button down below. If you did not enjoy this video then um well gonna find something else to watch because it's the best I could do. But no all jokes aside I really do hope you enjoyed the show.

Uh, stay tuned for the next episode of Project G I think what? I'm gonna pick up is gonna be this pump and then I've got the rest of the exhaust to put on another surprise inside of another box somewhere else around here and by the time we're done with that I should have the differential here and then we can move back down below, go to the rear axle, finish rebuilding that and then fingers crossed you can ship Project Jeep back to its owner, so until the next time again. Thank you guys for watching and most importantly, do not forget to have yourselves a great day! See you guys later into Project Jeep.

97 thoughts on “Exhausting! project jeep yj 4.0 wrangler”
  1. Avataaar/Circle Created with python_avatars Daniel Clark says:

    The old inline 6 cylinder engines were around for a long time and were some of the most reliable engines you can find. The car makers got rid of them because of the length of the engine in favor of the V6 engine. The intake and exhaust manifold were put together to help heat up the intake and make the fuel burn more efficiently. And they had problems with cracked exhaust manifolds because of expansion and contractions in the cast iron. Still really reliable engines though. Good job Ray.

  2. Avataaar/Circle Created with python_avatars Daddyoh says:

    Ray, How did those Freeze plugs look that had rust on them?

  3. Avataaar/Circle Created with python_avatars nelson glass says:

    South main auto repair in honor of you did the brake clean prompt…

  4. Avataaar/Circle Created with python_avatars Belinda Harkless says:

    love project jeep!

  5. Avataaar/Circle Created with python_avatars Warren Tinsley says:

    …..turns off video….buys stock in Brakleen….

  6. Avataaar/Circle Created with python_avatars Happy John says:

    It is a good thing this gentleman is skinny. What contortions a fellow has to go through!

  7. Avataaar/Circle Created with python_avatars Mark P says:

    I think AMC designed that engine… And Chrysler kept it around because it was pretty reliable… Not 100% sure but pretty sure that is an AMC design…

  8. Avataaar/Circle Created with python_avatars Kevin McClure says:

    Who makes those extra stubby ratcheting wrenches you use? Those things are the bomb!

  9. Avataaar/Circle Created with python_avatars Steve Wolf says:

    When did the gaskets go on?

  10. Avataaar/Circle Created with python_avatars Brice Graham says:

    Lol that's funny, you said the "enginerds."

  11. Avataaar/Circle Created with python_avatars Brice Graham says:

    Did I hear Day N Nite in the background? If so I didn't know you were a Kid Cudi fan

  12. Avataaar/Circle Created with python_avatars Richard Alexander says:


  13. Avataaar/Circle Created with python_avatars julian revuelta says:

    Merry Christmas to you and yours Ray

  14. Avataaar/Circle Created with python_avatars herb tender says:

    I'm an old wrench turner I worked as a mechanic 60 years , Ray works his way through problems that keeps us , me entertained, click. Thank you for your time and patience learning some new technology to everyone watching click,click.

  15. Avataaar/Circle Created with python_avatars Neal Fenster says:

    The washer looks like a Belleville washer. A spring washer to maintain pressure if the nut comes loose.

  16. Avataaar/Circle Created with python_avatars Russell Styles says:

    I see no reason you could not have put in a few of the exhaust bolts (nuts) in before putting in the intake manifold. edit – yep. Watched farther.

  17. I don't know if others have mentioned this, but the 4.O in-line six can trace it's lineage back to American Motors, who designed it's predecessor, the 232 CID straight six in 1966 (approx.) (The 4.0 is, in its core, a very old-school engine, full of 1960's Detroit technology.) At that time, pushrod six cylinder engines rare, if ever, had a crossflow cylinder head because the pushrods took up too much space where the ports would be fitted if it was a crossflow head.

    I find that putting in studs on the bottom set of bolt holes for the manifold helps immensely in aligning and tightening that assembly. It is especially useful if that engine is installed in an XJ, MJ, or ZJ Jeep, where access to the lower bolts is much harder than on a YJ or TJ.

  18. Avataaar/Circle Created with python_avatars mike a says:

    Door Trim Tool. I found one on the side of the road about 10 years ago. It is the handiest tool in my tool box. I don't know how I ever got along without one.

  19. Avataaar/Circle Created with python_avatars DSM-6 says:

    These kinds of vehicles are what drives dolly innovation. LOL Some external wheels to clear your lift.

  20. Avataaar/Circle Created with python_avatars S N. says:

    Great video project! Love to see old Jeeps get some love. As for the 4.0L, AMC designed and went to production in 26 months. Just in time to be released in September of 1986 fo rthe '87 model year, much to the chagrin of Chrysler execs. Even though Chrysler execs had the purchase of AMC in the bag, prior to their actual takeover in January '87, they decreed the AMC 258 shall not be installed into the XJ platform even under the cries of customers demanding better power with a six. But AMC got around the order with the 4.0L borrowing some of the design cues from the 258. The XJ/MJ was designed for a V6, hence the short hood design but the absolute dog of GM, the 2.8L was what they could get by the 1984 debut instead of anything else. Fast forward to 5 million 4.0L engines made and more stringent upcoming emissions standards for 2007. Chrysler would not spend money to make it emissions compliant and thus the '06 model year was the last. They chose instead to install an engine from the minivan line into the new plastic JK Wrangler until their own Pentastar design was available.
    For those not in-the-know, you can use the 258 crank and rods with the stock 4.0L pistons and come out with a 4.5L with no other mods required. In terms of intake manifolds, both 'Log" and "Horseshoe" flow fairly equally despite the myth about the "Horseshoe" style intake being "a lot" better. In terms of the "best" head? The 7120 (lacking provision for the block's head locating dowel pins) or the 0630 (with the dowel pin locator holes) are the best flowing factory heads. Both heads will work on all 4.0L blocks. Only the raising roof of the exhaust port increases flow and in the case of the infamous 0331 smog head casting, was raised but over all made with a smaller cross-section to control emissions and still keep the engine legal without an EGR (which was deleted from the '91 and later using the Chrysler SBEC-II ECU).

  21. Avataaar/Circle Created with python_avatars Keith Malmberg says:

    You can do the exhaust with out removing the intake. It makes most of the work harder and unseen.
    I did it on a 92 YJ with the 2.5l 4 banger and a 2000 XJ with the 4l 6.
    Both because I did a cold deep water crossing with a really hot exhaust and cracked the cast bit.

  22. Avataaar/Circle Created with python_avatars Hola! Ryan Hedges says:

    Love all your videos mate.

  23. Avataaar/Circle Created with python_avatars Edward Mcloughlin says:

    Most likely wrong, but one or two of the freeze plugs looked like they were ready to fail?

  24. Avataaar/Circle Created with python_avatars Ian Hood says:

    Would wrapping the exhaust help mitigate issues that having the manifolds on the same side prevent?

  25. Avataaar/Circle Created with python_avatars Oral Pierce says:

    Hi Ray keep up the good work and love your show. I have a 87 yj thinking of electric fan upgrade. Want to know what all needs to be done. Do I have to upgrade the charging system and everything to make it work

  26. Avataaar/Circle Created with python_avatars Phương Ma says:

    Ray that intake and exhaust closed to each other is to heat up in cold starting, they design that way like old carburetor electric choke

  27. Avataaar/Circle Created with python_avatars dhldriver says:

    Super clean shiney shine shine!

  28. Avataaar/Circle Created with python_avatars Noob of noobs says:

    The rectangle ports are the intake toe round ports are the exhaust you said the opposite

  29. Avataaar/Circle Created with python_avatars Aaron Parriette says:

    What brand is the 1/4" ratchet you are using? I'm always on the lookout for a long handle 1/4" and I can never find one.

  30. Avataaar/Circle Created with python_avatars Saienide says:

    I've found a reason for me

    To change who I used to be

    A reason to start over new

    And the reason is you

  31. Avataaar/Circle Created with python_avatars Shade Tree Mech says:

    Hey, Ray, looks like you left your socket on that rear most nut on the exhaust manifold.

  32. Avataaar/Circle Created with python_avatars Gee F says:

    And the owner of this Jeep is : R a y ! 😂😂

  33. Avataaar/Circle Created with python_avatars Eldon Howard says:


  34. Avataaar/Circle Created with python_avatars Brett McLaughlin says:

    The 4 liter straight 6 engine was great other than being a real gas guzzler, it had amazing power and torque, something that the 2015 V6 in my Rubicon unlimited doesn't have. From my experience the Straight 6 was the best engine Jeep had other than perhaps the 390ci V8 American Motors engine that came by special order back in the 1970's.( If my memory is correct)

  35. Avataaar/Circle Created with python_avatars JJHoover70 says:

    would've looked into replacing the freeze plugs

  36. Avataaar/Circle Created with python_avatars S Fnnll says:

    Sometimes I miss my '70 Grand Prix with 400 cu in V8. A few bolts and hoses, the radiator and fan were out and I could stand on the ground in the engine compartment changing the timing belt and gears, or whatever was needed in there. I think all cars then were required to have a hidden secret bolt on the water pump.

    Working through an 82 Z28, an 88 and 94 Ford Explorers, 2007 Honda Accord kept getting tighter and tighter. Plus the thrill of buying all new metrics. Went through the same tool additions at work when we switched from Boeing to Airbus.
    Finally a 2022 RAV 4 Hybrid with the bells and whistles, and I can spot the oil filler, air filters, and fuse box.;
    I'm waiting for you to dig into one of them before I dare to start ripping and tearing.

    Love your channel, don't let the trolls grab ya from under the interweb basement stair bridges where they hide from their moms and pass judgement.

    After 40 years aviation tech on USMC F-4s, De Havilland Herons,; Cessnas, to Boeings, 737- 200,300,400; 727-100,-200 757; 767; 777; Fokkers, Japaneese YS-11's, McDonnel Douglas DC9, DC10 We've learned to adapt. go by the book when that part should be there, but eng decided it would be harder to get to hidden elsewhere. (It fits perfect on the drawing).
    Occasionally we find the golden part that most of the entire Aircraft is built around, and we gotta change it .Keep pulling stuff loose 'till it falls off. Fun times with commercial aviation.

    You have YOURSELF a great day, and we'll be waiting for the next gravity drop. If the members haven't worn it out yet.


  37. Avataaar/Circle Created with python_avatars Leonard Mattos says:

    I have been watching this guy since he started posting, I learn something new every time! Thank you and please keep us all enthralled and entertained.

  38. Avataaar/Circle Created with python_avatars Cody Blanchard says:

    Next investment should be a top side creeper

  39. Avataaar/Circle Created with python_avatars T MANN says:

    You would save a shitload in Brakeleen if you had a parts washer.

  40. Avataaar/Circle Created with python_avatars Al Pha says:

    I thought this is a cooking channel ,,smokem if you brought em.

  41. Avataaar/Circle Created with python_avatars Howard Benally says:

    Hi ray remember you’re Business will succeed with you’re wife help try not stay late remember you have awesome families and as always you and your families be safe 🇺🇸🇺🇸

  42. Avataaar/Circle Created with python_avatars Robert Montgomery says:

    Rusty ? 😂 Only a Floridian would call those rust free bolts “rusty”.

  43. Avataaar/Circle Created with python_avatars Daniel Ventura says:

    I would not run an intake manifold over the exhaust manifold without a heat shield of some sort.

  44. Avataaar/Circle Created with python_avatars Raziels_fate says:

    "jeep dirt" careful how much of that you lose…. could be all that's holding it together haha!

  45. Avataaar/Circle Created with python_avatars Neil duncan says:

    If only jeep updated the head to be a crossflow with port fuel injection…..I think the 4.0 is abetter engine than current V6's less power yes…but more durable and easier to work on

  46. Avataaar/Circle Created with python_avatars Chris says:

    Ray, you are entertaining and awesome to watch. I work for myself, I hate to tell you this but when you work for yourself there is no after hours. It's just a longer day than usual. 😜
    When I went to work for myself I told my old boss if I work as hard for myself as I do for you I can't help but succeed. I did and it's obvious that you will too. Congratulations on being your own Boss.
    You are literally doing everything on this Jeep, are you sure it's not yours?

  47. Avataaar/Circle Created with python_avatars Zyxalis says:

    I had a 1987 wrangler in high school back in 05. Took me a month of nights and weekends to do that clutch in MA in Feb with no garage.
    It was hell.

    Also you Florida guys got it made with no salt on the roads. Wrenching on northern cars is something else entirely. Every bolt would have fought you on that job.

  48. Avataaar/Circle Created with python_avatars Flies2FLL says:

    My understanding is that the hot tip on these 4.0's was to install the fuel injection from a GM 4.3 liter V6.

  49. Avataaar/Circle Created with python_avatars Russell Trupia says:

    Hi Ray just wanted to tell you how much I enjoy your channel,awesome job👍👍

  50. Avataaar/Circle Created with python_avatars Mark Wolfe says:

    The 4.0 got a tubular header from the factory on the YJ and XJ, they always crack where the pipes come together, that was an OEM header you pulled off.

  51. Avataaar/Circle Created with python_avatars Andy Tate says:

    Bloody ads are getting worse. Every 5 minutes is a little ridiculous